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November 22, 2012A Penton Media Publication

Tune in toEngineeringTV.com

Reengineering the

SNOWMOBILE page 34

HANDLING EMIWITH INDUSTRIAL

FIBER OPTICS,page 38

ENERGYEFFICIENTCASTINGS,

page 42

BETTER HEATSINKS WITH

MULTIPHYSICS,page 45

APPLIANCE WIREGETS A ROLEIN MACHINE

BUILDING,page 48
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FEATURES

CAD/CAM/CAE/FEA

Its no secret thatcarmakers are undera lot of pressure to reducethe number, size, and weight ofengine components for better fueleconomy. In one case, we were t asked with

designinga smallerand more-efficientheatsink to thermally regulate the electroniccomponents in Toyota hybrid vehicles.Instead of using typical analytical designmethods and trial-and-errorphysical prototyping, wefirst used mul-tiphysicssoftwareto designand testpossible prototypes.

Hot under the hoodToyota hybrid vehicles have sophisticated electrical systems in

whichmany powerdiodesandpowersemiconductorssuch asin-sulated-gatebipolartransistors handlepowerconversion andotherapplications. These components are standard planar silicon devicesmeasuringafewcentimetersoneachside.Thedevicesmountonalu-minumheatsinks, orcold plates,withchannelsin whichawater-and-

How Toyota designed

a small, efficient heat

sink to cool electronic

components in its

future hybrid vehicles

Authoredby:

Ercan(Eric)DedePrincipal ScientistToyota Research Institute ofNorth AmericaAnnArbor, Mich.

Editedby Leslie [email protected],Tw itter@LeslieGordon

KeyPoints: Engineersdesignedasmallerandmore -efficientheatsink tothermally regulatethe

electroniccomponents infutureToyotahybridvehicles.

Numericsimulations generatedanoptimalcoolingchannel topology with fluidstreamlinesinbranching channels.

Thed ual configurationprototypeprovidedhigher-performancecooling inanultracompactpackage.

Resources:Toyota Research Institute ofNorth America,http://tinyurl.com/8kdkq3r

MULTIPHYSICS SOFTWARE builds a

better heat sink

Theseisometric

viewsshowthederivedhierarchical

microchannelcoldplatewithoutajetplate(top)

andwithajetplateshowntransparentforclarity(bottom).

NOVEMBER22, 2012 MACHINE DESIGN.com 45

ELECTRICAL/ELECTRONIC TECHNOLOGY GUIDE

High-endAWM-style cablesaremaking a comebackinmachinewiringprovidingover20yearsofreliableperformance.

AWMandNFPAcomplianceOnecompany successfully navigating the shoals oftherecent

NFPA-79 revisions is KronesInc., Franklin,W is., amanufacturerandintegrator ofp ackagingl ines forfoodandbeveragecompa-nies.Thecompanys engineering teamrecently foundthatcom-plia ntAWM usagedoes requireabitofextraeffortcomparedto

thea utomaticcompliance foundwith UL-listedMTW.Wheneveryou mustimplementchanges becauseo fanelec-

trical-codechange, theresdefinitely anengineering-labor factor,says Mike Nelson, the Krones engineer chargedw ith NFPA-79

compliance.So m e of that engineering labor w ent into researching spe-

cific AWM products tos ee whether they meet the c o mpliancerestrictions . E venp roperj acketl abeling doesnt answer every

compliance question regarding AWM.Y ou cant tell whether aproductcomplies justby looking attheca ble,says Nelson. And

evenmoreen gineeringl aborwenttoNFPA-79s documentationrequirements.

Inall, Nelsonestimates thatKrones has spentmorethan150engineering man-hours complyingw ith there quirements relat-edtoAWM use. Andthatfigurerepresents justthe work doneto formulatea compliancestrategy.I tdoes notincludet hetechnicaldocumentationanddrawing changes neededtoincorporatethewireinto each andevery machine.

If you find electrical safety standards confusing, youre not alone. Manymachine builders recently grappled with an ambiguous round of changes toNFPA-79.Thisisthe National Fire Protection Association codethat outlineselectrical standards for industrial machinery that protects operators, equip-ment, and facilities from fire and electrical hazards. NFPA-79 is cited exten-sively in the National Electrical Code (NEC) that governs the electrical wiringofindustrialmachines.

Thestandardcuts abroadswath acrossthe industrialmachinerylandscape.Itappliestoa comprehensiverangeofmachines everythingfrom machinetoolsandinjection-moldingpressesto testingmachinesandpackaginglines. Itencompasses all ofa machines electrical andelectronicelements operatingat600Vor less.Thismeansthata vastmajorityofmachinepower,control,and

lightingcircuitsfallunder thescope ofNFPA-79.Machinebuilders compliedwiththe dictatesofNFPA-79 foryears. Butear-lier this year the standard underwent revisions that make it more difficult tospecifycompliantelectricalcabling.

AppliancewireOKdThe key change to NFPA-79 for 2012 involves the ability to use appliance

wiringmaterial(AWM),whichhadbeenbannedsince2007.AWMcanbeaneconomicalwiringchoice comparedtohigher-performingUL-listed machine-toolwire(MTW). Butthere wereseveralsound reasonsbehindthe AWMban.

Forone, somecontractorswereusing AWMincorrectlyaspart ofthe build-inginfrastructure.The NECdoes notrecognizeAWMfor thistype ofuse.

Also,notallAWMproductsarecreatedequalwhenitcomestothequalityof their insulation layer. The insulation thickness of low-quality commoditycablingvariedsuchthat thewire, whilemeetingits electricalinsulationrequire-ments,wasnot sufficientlyflameresistantforuse inindustrialmachines.

Its important to stress that not all AWM suffers from these quality issues.Lappandotherreputablecable manufacturerscanand doproduceAWM prod-ucts whose insulation wall thickness is both consistent and adequate for thevoltage ratingofthe cable. High-quality AWM can pass the specified verticalflametests(FT1)andcansafelybeusedinindustrialmachines.Keepinmind,however, that AWM lacks the extra layers of PVC-nylon insulation found in

Appliance wire

is back, but

regulations may

limit its use.

Authoredby:

RickOrsiniSeniorproductmanagerLappUSAFlorhamPark,N.J.

Editedby [email protected]

Keypoints:NFPA-79outlines electricals tandardsforindustrialmachinery to protectoperators,equipment, and facilitiesfrom fireandelectricalhazards.

Bannedin200 7, AWMmaynow beusedinmachinewiring, restrictionsp ermitting.

Newpermissions mayletMTWp roducts thatcarrya ULTC-ERlistingslash installationcosts,evenoverAWM.

Resources:LappUSA,www.lappusa.com

NFPA79Standard, bit.ly/Rbblbv

ULWireandcable flammabilitytesting, bit.ly/TxHTv2

Fora whitepaperontheNFPA79 electricalcode,s canthis codeor goto: http://machinedesign.com/whitepaper/understanding-the-electrical-code-to-be-compliant-0501

NFPArestrictions.Inthe caseofextremely largemachinessuch as bottling lines, machine builders and installationcontractors can spend dozens of engineering hours andthousands of dollars complying with the documentationrequirements.

These documentation needs, while not insurmount-able,mustbefactoredintothecostofwiringthemachine.Insomecases,theaddeddocumentationcostscanerodetheminorprice advantagesofsomeAWMcables.

One way around the concern of documentation is tofavor listed MTW. Because it inherently complies withNFPA-79, MTW cabling alleviates the documentation

requirement and eliminates any residual confusion overwhetheragivenAWMproductisapprovedandproperlylabeled.MTW alsohas ahost oftechnicaladvantagesthatderivefrom itssuperior flexibilityandresistanceto flame,

MTW.Thisextrainsulationallows sometypesof MTWtopassflametests(FT4)morerigorousthanthoseforeventhebest AWM.

Reversing the AWM ban reflected the realities of theglobalmachinery marketplaceinwhich AWMremainsawidely used cabling choice. The restrictions imposed bythe new NFPA standard attempts to negate the potentialdrawbacksofAWM.

Thefirst restrictionstatesthatthe AWMmustbe iden-tified as suitable for the application at hand and must beusedin accordancewith themachine-manufacturersin-structions.Otherrestrictions detailcableconstruction in-

cludingminimumconductorcount, flameresistance,andwallthickness.CompliantAWMcable mustcarry ajacketprintlegendthatspellsouttheAWMstylenumber,volt-age,temperaturerating,andflame rating.

The reversal on AWMusage also requires moredocumentation. For ex-a mple, ma n uf a cturersmust provide field-instal-lation information relatedto the AWM wire witheach machines technicaldocumentation.

EasycomplianceGiven all the cable runs

onandaroundtodayscom-plex industrial machines,the n eed to documen tAWM usage for each andevery machine representsthe most onerous of all the

Exposed cableruns for fast installationAnother change in the 2012 NFPA-

79 standard allows exposed cable runs

along the structureo fthee quipmentor

inthema chinechassis. As long as thee x-posed cables closely follow the surfaceandstructural member s ofthema chine,

thein stallationdoe s notrequirecond uit,

raceways, orany special hardware.Thanks

toreductions ininstalla tiontimea ndla-

bor, exposedcabler uns canreducecosts

dramatically compared to traditional in-stallationmet hods that need conduit orspecial mountingh ardware.

Certain UL-listedcables meetexposed

run(-ER) specifications,which providea n

additional l evel of protectionfor thesetypes ofapplications.C ables meeting-ER

requirements are subjected to the samecrush and impact tests as armored -typeormetal-clad(MC) cables, thatlets cablesleavet hema chinearea andenteracabletray withoutconduit.

Keep inmind, though, thatnotall UL-listed cables meet NFPA requirements,

especially lower-priced commodity and

rigidproducts.

Safety standard gives

APPLIANCE WIREa new lease on life

AKronestechniciandocumentstheuseofAWMincompliancewithNFPA-79.

NOVEMBER 22, 2012MACHINE DESIGN.com48 NOVEMBER 22, 2012 MACHINE DESIGN.com 49

Access our Reader ServiceWeb site to quickly find andrequest information on the

products and services foundin the pages ofMACHINEDESIGN.www.machinedesign.com/rsc

VOLUME 84ISSUE 18

NOVEMBER22, 2012

45

Multiphysicssoftware builds abetter heat sink

Toyota used multiphysics

software to build a betterheat sinkfor itsfuture

hybrid vehicles.

Safety standard givesappliance wire a new leaseon lifeAppliance wiringmaterial, banned

in 2007, isnowbackin service owing

to the realitiesoftodaysglobalmachine marketplace.But, itsusecomeswithrestrictions.

48

Rethinking thesnowmobileTechnology borrowed from

motorcycles, snowmobiles,

mountain bikes, and snowboardsleadsto a lighter, more-nimble

Personal SnowVehicle.

Better economics for

industrial fiber opticsPlastic optic fiber isa better option

than copper wiringfor applications

plagued by electrical noise.

Casting with quartzThe castingofsynthetic-quartz-

composite mixturesto tolerance useslessenergy than castingiron.

34

42

38

NOVEMBER22, 2012MACHINE DESIGN.com2
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://tinyurl.com/8kdkq3rmailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.lappusa.com/http://www.lappusa.com/http://machinedesign/http://machinedesign/http://machinedesign/http://machinedesign/http://machinedesign/http://machinedesign/http://machinedesign/http://machinedesign/http://machinedesign/http://machinedesign/http://machinedesign/http://www.machinedesign.com/rschttp://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://www.machinedesign.com/rschttp://machinedesign/http://www.lappusa.com/mailto:[email protected]://tinyurl.com/8kdkq3rmailto:[email protected]


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... with 1-ft. cable and4-wire locking connector

SureStep stepping systems providesimpleandaccuratecontrol of positionandspeedwhereopen-loop control andcostareconsiderations.

Pulses (or"step" and"direction" signals) fromDo-morePLCs, DirectLOGIC PLCs, orotherindexersandmotioncontrollers are"translated" by themicrostepping driveintoprecisemovementof thestepping motorshaft. TheSureStep stepping motorsuse2-phasetechnology with 200full steps perrevolutionor1.8 perfull step.

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ON THE COVERAn SR-85SnowRunner

from Sierra Snow

EDITORIALSillinessat 40 below

EDITORIAL STAFF

LETTERS

SCANNING FOR IDEASSpindle drive moveswithaccuracyFilter vent equalizespressure inside and out

REPORTERS NOTEBOOK

LOOKING BACK

COMMENTARYWhatsupwithmodel-based engineering?

ORR ON ENGINEERINGThe deathofe-mail?

SOFTWARE REVIEWSolidWorks2013 makes3Dmodelingeasier

PRODUCT SPOTLIGHT

Adhesives& fastenersPRODUCTS

DATA FILES

BUSINESS INDEX

AD INDEX

BUSINESS STAFF

BACKTALK

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ED

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Whats new onlinemachinedesign.com

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Oil-cleanliness bookletMore than 75% ofall hydraulicsproblemscan be linked to

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www.zero-max.com 800.533.1731

2010 ZERO-MAX

Our ServoClass couplings have been recently redesignedto enable your actuator to go even faster and achievethe positional accuracy that will take your designs

to the next level. Our couplings will do all thiswith low bearing loads.

3 New sizes now available.

Now, size, select and see the rightServoClass coupling solution for yourapplication with Zero-Max 3D CAD files.

Check our FAST deliveries.

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Ourcoupling

RS# 105
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11/70

EDITORIAL

Sillinessat 40 below

Manyyearsagoaco llegeclassmateofmineto ldafunnystoryabouthis summerjob testingcommunicationsgearforadefensecontractor.Hespenthistimealternatelyfreezing theradios to40C and heatingthemto85C,whileoperatingthemtomakesuretheydworkattheseextremetemperatures.

Troublewas,mostoftheradioswou ldntpassthistest.Tofixthe problem, the contractorhad togothrougharedesign,whichtookmorethanamonth,puttingtheprojectbehindschedule.Oncethe electronicshadbeenfixed,mybuddydrewalotofover-timerunningradiosintemperaturechambers,tryingtocatchup.Infact,the pacewas so hecticthatnobodybotheredtochecktheradiosatroomtemperature.

Youmaybeabletoguesswhathappened.Itwas onlyasthingssloweddownthatQAdiscoveredthe revampedradiosoftensput-teredoutwhenoperatinginambienttemperatures.

Withthatsituationinmind,I was amusedatataletoldinthememoirsofformerGeneral MotorsCorp.ViceChairmanBobLutztoillustratesomeofthe whackydesignpracticesheencoun-teredwhenhejoined GMin2001.Hediscoveredthe ashtrayofanewCadillac STS hadalot ofspringpressure.Whenopened,itshotout asthoughlaunchedfromacannon,and oncedep loyed,was toughtopushinwithjust onefinger.Thiswas incontrasttothe ashtrayonanAcura,whichglidedopenandtookasingleef-

fortless pushtoclose.Lutzfiguredthe ashtraydesigninthe Cadillachadtobeamis-

take,sohewas flabbergastedwhenaseniorinterior-trimengineersaiditoperatedthatwayonpurpose.Thereason: Soitcouldmeetan internal GM standardthatdictatedashtrayshadto functionafteranightspentat40F.

Lutzsaysloopysituationslike the Cadillacashtraywerenotatall uncommoninthosedays.TheyarosebecauseGMhad ahabitofengineeringitsvehiclesforextremesituations.Thatwas anobleidea,but it cameat theexpenseofalienatingthousands ofGMownersonadailybasis.

Youmightwonderwhathappenedto the40Fashtrayspec.Lutzsayshis teameventuallyeliminateditand 90% oftheothersacredbutsillyengineeringdosanddontsthathad somehowbe-comeembeddedinGMculture.Healsoopinedthatthe existenceofthesedisconnected-from-the-real-worldpracticeswas atesti-monytoaculturethatwas inwardlyfocusedinpursuitofitsowngoals,withthe customerleft outofthe equation.

I wouldputitalittledifferentlythanLutzdid.Bothinthe caseofthebadradiosandwiththeashtrays thatoperatedsuperblyonlyat40C,the designershad lostsightofthe trade-offstheyweremaking.Thereis alessonherefor anyengineerwhodliketoavoidhavingsomethingtheydesignedbe thebuttofjokes,orwhodoesntwanttheirworktowindupasahumorousincidentinsomeoneelsesmemoir.

Leland Teschler, Editor

RS# 106

NOVEMBER22, 2012
mailto:[email protected]://www.spirol.com/http://spirol.com/s/md-latch/


12/70

Actuatorlinehas all the precision you need and wont keep you waiting

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13/70

MITRPAKPower Transmission Products

38 River Road, Uxbridge, MA 01569Tel: 508-278-2422 Fax: 800-346-0018 800-648-7725

www.mitrpak.com

Does your gear drive mesh properly? Not all do.MITRPAK drives are precision made. You can feel the difference.

MITRPAK features include: Stainless steel shafts Double-shielded ball bearings Factory optimized gear mesh Hardened spiral Adjustable locknuts in place of Completely sealed

bevel gears spacers and retaining rings Lubricated for life

U.S. and metric right angle, three-way, and counter-rotating gear drives in stock andguaranteed to ship in 24 hours.

For complete specifications and CAD files, log ontowww.mitrpak.com

, or calltoll free, 800-648-7725.

EDITORIAL STAFF

1300 E. 9th St. Cleveland, OH 44114-1503

EDITOR

Leland E. [email protected]

MANAGING EDITORKenneth J. Korane

[email protected]

SENIOR EDITORSLeslie Gordon

[email protected]

Stephen J. [email protected]

ASSOCIATE EDITORSLindsey Frick

[email protected] J. Repas, Jr.

[email protected]

INDUSTRY COVERAGE:

AUTOMOTIVE, PACKAGING,

MEDICALStephen J. Mraz

CAD/CAM, MANUFACTURINGLeslie Gordon

ELECTRICAL, ELECTRONICSRobert J. Repas, Jr.

FASTENING & JOINING,

MATERIALSLindsey Frick

FLUID POWER

Kenneth J. Korane

MECHANICAL

Lindsey FrickKenneth J. Korane

EDITORIAL PRODUCTIONDenise Greco

Editorial Production Manager

Randall L. RubenkingArt Director

RS# 108

RS# 109

NOVEMBER 22, 2012MACHINEDESIGN.com10
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14/70

Ideal for todays compact electronicsmicro

TM

382R

2012

www.pemnet.com

70 YEARSOF EXCELLENCE

1942-2012

Locating pins Standoffs/spacers

Surface mountnuts/spacers

Inserts for plastics Low profile head screws

fasteners

RS# 110
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15/70

LETTERS

ized tests without the enormousbudgets of public schools and inspite of (or perhaps because of)most parents lacking educationdegrees.

Not all home-schooling parentsare in it just to get their children agood education. Some parents aremore interested in religious indoc-trination and some appear to beducking the responsibility of get-ting their kids to school every day.I became a home-schooling parentwhen I saw that children in manyoverseas schools, especially in Asia,

were about two years ahead ofAmerican kids in math by 4th grade.I figured that my children were go-ing to have to compete with thosekids when they grew up, so I tookon the rather large responsibility ofteaching them at home. I rememberasking a public-school teacher whythey didnt assign more homework.

The response was that the parentswould complain.

Funding ever more assistantsand fewer students per school isnot going to fix the problems ofpublic education. Plus, it ignorestwo extremely serious problems:

The lack of parental involvement,which would change if all parentspaid part of the cost out of pocket;and the cultural sense of entitle-ment that everyone deserves aneasy, effortless life courtesy of thegovernment.

When the government subsi-dizes something we get more of

it. Subsidizing idleness, teenagemotherhood, and recreational de-grees that dont lead to produc-

Anyone for ethics?Unfortunately, ethics went out thewindow in the U. S. many years ago

with the advent of our instant so-ciety (Where Did Ethics Go? Sept.6). Everyone wants everything theycan possibly need and dream ofwithout waiting or working for it,all at the expense of others.

This problem is more prevalenthere in the U. S. than in Europe,Asia, or the Caribbean countries.It is most likely the fault of parentswho let others raise their kids andadvertising wonks.

And it doesnt matter what theprofession is, it is all about greed.

Randy Scott

I have worked in the engineeringfield for more than 40 years. I amnow in business for myself as aforensic mechanical engineer do-ing accident reconstruction for at-torneys and insurance companies.Part of my job involves testifyingin court on civil and criminal caseswhere I have been amazed at what

some engineers will say under oathto prove a case for their clients.Sometimes they testify to accidentscenarios that violate the laws ofphysics. Some engineers testifyingare registered professional engi-neers and are theoretically boundto follow the Engineers Code ofEthics. But they dont. How canthey look in the mirror and notcringe at what they see?

Why do people try to beat thesystem? Do they really think theeasy way is the best way? Its prettysimple, and somewhat trite, buthonesty is always the best policy.

Harold A. Schwartz

Smaller can be better

Yes, small sample sizes have moreoutliers, but there is more to thestory (Bad Math for Fixing BadMath Scores, Aug. 23).

Home schooling represents the

smallest of schools, and home-schooled kids have average scoresin the 88th percentile on standard-

tive jobs erases the work ethic thatmade this country great.

Karl Oberstramm

Get off of my cloud

Im concerned over privacy in thecloud. I am no expert on this topic,

just someone who has seen Face-book, Google,and other e-mailproviders data mine everythingthat passes through their hands.Supposedly no personally identi-fying data is ever mined, but how

many pieces of a jigsaw puzzlehave to be present before the fi-nal piece can easily be deduced?Its already frightening how muchGoogle knows and what adver-tising clout they have attained. Iuse Google as an example, but thesame principle applies to similaronline organizations and to gov-ernments. If I have heard correctly,the U. S. government, for example,is building an ambitious project torecord everything in the U. S. thatgoes on in the Internet. So am Iright to be downright frightened ofstoring my employers engineeringinformation in the cloud, where Iwill have no real control over whomight see it?

David Rensle

Running NASA Apple-style

By your example, Steve Jobs letthe project run off the rails and

then chewed out the develop-ment team after developmenthad reached a crisis (If Steve Jobs

Ethics are dead?

A couple of readers bemoan the lackof ethics in practically every facetof American life. Others debatewhether Steve Jobs managementstyle would work at NASA.Andone reader wonders about ourprivacy and cloud computing.

NOVEMBER 22, 2012MACHINE DESIGN.com12
http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/


16/70

RS# 111
http://www.nbcorporation.com/


17/70

TM

in the Spring when I found thatthe float valve on my lawnmowerrusted, even after draining it for thewinter.

Fortunately, I found a station thatsells ethanol-free gas. These can befound atwww.puregas.org . AndWashington state now lets marinestations sell only ethanol-free gas.

The real surprise came whenI started using ethanol-free gasin my car and truck. The truck (a2005 F 150) was getting 13 mpgaround town and the spark plugswere black. In Feb. of this year,I started using ethanol-free gasin the truck. Within two tanks, itwas getting 14.5 mpg, and thenew plugs are running tan. Sincethen, the mileage has been 14.5to 15 mpg, which is an 11 to 15%improvement.

This might be an isolated case,but it seems a rigorous test needsto be done.

Erik A. Larsen

Had Run the Mars Rover Project,Sept. 20). Only then did he takecorrective action.

The NASA results might have

been the same with Steve Jobs pres-ent. It depends on how much mi-cromanaging (or project oversight)Jobs was capable of. NASA made itsdecisions and lived with the conse-quences. Managers there thoughtthey had managed the risks.

It takes proactive checks to pre-vent projects from running off therails. Even Steve Jobs didnt do that.

I think your analogy is faulty.Stephen McDonald

A wise manager taught me early inmy career that if you fire everyonewho makes a mistake you are soonleft with only those folks who arenot doing anything at all.

David Leahy

I agree with whoever said SteveJobs was the last American busi-

nessman who knew what he wasdoing, so I doubt he would haveany interest in landing an SUV onMars. But if he did, hed have the

right people in the right places atthe right times.You dont keep underachieving

employees on your payroll. Getrid of the people who do it wrongand promote/hire those who do itright. The replacements automati-cally learn from their predecessorsmistakes. Or they, too, become pre-decessors.

Frank Blankenship

Curing those ethanol bluesMy problem with ethanol startedout with my RV and some equip-ment I store for winter. The 10%ethanol/gas blend attracts water inthe atmosphere. This fact was ham-mered home as I pumped 2 gallonsof water from my 200-gallon fueltank on my boat. It was also evident

LETTERS

RS# 112NOVEMBER 22, 2012MACHINE DESIGN.com14
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18/70

TRANSVERSE

VIBRATION COMPARISON

25

20

15

10

5

0

CLAMP

(LBF-

THOUSANDS)

0 50 100 150 200 250

time(SECONDS)

HUCK 360

OTHER VIBRATION-

RESISTANT

NUT DESIGNS

SOLUTION:

HUCK 360

BOLT NUT

BOLT NUT

PROBLEM:

CONVENTIONAL THREAD

TRANSVERSE

VIBRATION

Anatomy of the

HUCK 360

Once vibration begins,

clamp load quickly

decays with nuts and

bolts, while it holds

constant with the Huck 360.

Nogap exists.

Threads are locked

preventing any

movement.

Gap between the threads allows

for transverse movement.

RS# 113
http://afsindustrial.com/huck360


19/70

SCANNINGFOR IDEASEdited by Stephen J. Mraz

For a white paper ongearhead constructionand use, scan thiscode or go to: http://machinedesign.com/

whitepaper/gearhead-construction-and-use-0911

Spindle drive moveswith accuracy

Requestfreeinformationvi

aour

ReaderServiceWebsiteat

www.machinedesign.com

/rsc

The BS22-1.5 spindle drive fromMICROMO,Clearwater, Fla. (www.micromo.com), a member ofthe Faulhaber Group,uses ballscrews to generate highly accuratelinear motion. The stainless-steeldrive is accurate to within 5 mor less over its entire length oftravel. The motor connects to the

ball screw through a backlash-freecoupling that is part of the ballscrew.

The screw is 126.5-mm long,and the standard stroke measures94 mm. Pitch is 1.5 mm. Axial loadcapacities are to 519 N (dynamic)and 475 N (static). The devicecan handle input speeds up to5,000 rpm and still maintain itsaccuracy.

RS# 401

Motor

Motor flange

Clutch housing

with duplex ballbearings

Spindle thread

Spindle nut with

fastening screwthread

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20/70

COMMUNITY:element14.com

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PHONE: 1.800.463.9275

LEARN MORE:newark.com/together

HOW MAY WE HELP YOU TODAY?

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SCANNINGFOR IDEAS

Filter vent equalizes pressure inside and outElectronic enclosures are often sealed againstwater and contaminants, but this can lead topressure differentials between the interior andexterior that cause problems. For example,lower pressure inside the enclosure can pullwater and air in, damage the seals, and wreakhavoc on the electronics. To prevent this prob-lem, engineers at W.L. Gore & Associates Inc.,Elton, Md.(www.gore.com/protectivevents ),developed a protective vent, the PolyVent D3,that lets air pass in and out, but keeps water,dust, insects, and debris from getting in.

The vent has a press-fit width of 2.5 mmand gas-flow capacity of 7 ml/min. The hous-

ing is polypropylene and contains an ePTFEmembrane. This membrane lets gases passthrough while keeping out contaminants. Thevent works in temperatures from 4 to 212F.

The vent takes up no space inside enclosuresand its low-profile exterior portion reducesthe risk of damage from technicians who ser-vice the enclosure. RS# 402

RS# 116RS# 115

Liquid andparticles kept out

Polypropylenehousing

Air and gasmolecules pass inand out throughthe membrane

ePTFE membrane

Polyester backing

http://www.gore.com/protectiveventshttp://www.gore.com/protectiveventshttp://www.gore.com/protectiveventshttp://machinedesign.com/http://machinedesign.com/http://machinedesign.com/mailto:[email protected]://www.techno-omil.com/http://servometer.com/sample-requesthttp://machinedesign.com/http://www.gore.com/protectivevents


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SimplicitysZip tie barsintegrated into

mounting brackets

sTiered structure for easy access

sEasily removable clamping bars

Better Clamping and ReducedCable/Hose SlippagesDouble rowsof large fingers

hold more zip ties

sAnti-slip ridgeson bar prevent

cable slippage

NEW ZIP TIEMOUNTINGBRACKETREVOLUTIONIZES

CABLE/HOSE CLAMPING

A Division of A&A Manufacturingwww.Gortrac.com

Email:[email protected] Free: 800-298-2066Fax: 262-786-3280

RS# 117
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REPORTERS NOTEBOOK

carries one person, the driver, who should weigh lessthan 260 lb. Though developed in the U. S., U. K., andNew Zealand, Quadskis will be built Michigan andshould be available next month. MD

The Quadski fromGibbs Sports Am-phibians Inc.,AuburnHills, Mich., can travel45 mph over landor water, and transi-tions between thetwo modes at the pushof a button. The 1,180-lb(dry) amphibian vehicle isequipped with a 1,300-cc175-hp BMWenginethat either powers therear wheels on land or aGibbs-designed and built

jet drive for speeding overthe water. On land, theQuadskis four wheels aresupported by independentcoil springs and hydraulicdampers. Once the opera-tor drives it into the water,he pushes a button andthe wheels retract within4 sec for a smoother,

more-streamlined hull. Thecomposite hull is madefrom a single-piece mold. In the water, the hull lets thecraft plane but still has the lateral grip needed for tightmaneuvers. The vehicles low center of gravity makesit stable on the road and in the water. The $40k vehicle

Amphibian jet ski hits 45 mph on land and sea

Resources:Gibbs Sports Amphibian Inc.,gibbssports.com

MACHINEDESIGNarticle on Gibbsamphibian sports car,tinyurl.com/d9mwnsm

The amphibious Quadski gets is power froma four-cylinder, water-cooled BMW engine.The engine features electronic fuel injection,

a double-overhead camshaft, and dry-sumplubrication. Engineers at Gibbs spent morethan 18 months and 75,000 engineering man-hours adapting the engine to the Quadski.
http://gibbssports.com/http://tinyurl.com/d9mwnsmhttp://tinyurl.com/d9mwnsmhttp://gibbssports.com/


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Forklift motor letseMotorcycle take the

checkered flagEngineering students at Virginia Tech Universitydesigned anelectric motorcycle that ran in the TTXGP, a series of 20-mile races.

The motorcycle, dubbed the VT Bolt, competed in the 75 class, inwhich bikes are limited to a 7.5-kW-hr battery pack. The bike tookfirst place in all three of its races, consistently hitting top speedsover 100 mph.

The VT team worked with engineers from Kollmorgen,Rad-ford, Va., the company that supplied the motor, a permanent-magnet, low-voltage AKM 74, and the controller, an ACS80XL 80VGen6. The motor was modified to accept a motorcycle sprocketand was outfitted with a custom side bearing that let it withstandhigher-than-normal loads exerted on the shaft by the chain. Themotor was also rewound to operate on the battery-packs rela-tively low voltage. The controller, usually used with motors havinga maximum of 54 hp (40 kW), was delimited to let it control mo-

tors with up to 73 hp (57.6 kW). Thislet the controller and motor betterhandle the short-duty cycles andpower demands of TTXGP races. Thecontroller was also modified to con-trol speed, torque, and regenerativebraking. The drive usually controlstraction in 4 to 5-ton fork lifts. Both

the motor and controller are sealed to IP68 levels, so they canwithstand vibrations common in race cars.

The VT Bolt won all three of its races, making it this years NorthAmerican TTX75 Cup winner. MD

Low-densitysealantcutsweight in aircraftNo materials are left be-hind in the race to reduceweight in aircraft, not evensealants. Simrit, Elgin, Ill.,the industrial sealing prod-ucts division of the Freudenbergand NOKGroupcompanies, developed a low-densitysilicone material that reduces weight by 15to 20% compared to other sealants. With aspecific gravity of less than one, the materialhas the same physical properties of tradi-tional silicone materials, but weighs less.

These low-density silicones operate attemperatures anywhere from 85 to 401F(65 to 205C), and set at a durometer ofaround 50 to 60+ Shore A. Like most sili-cones, they resist common aircraft fluids andwill work in fireproof constructions.

Simrits silicone meets SAE AerospaceMaterial Specification (AMS) 3302 and 3303.

The material is produced at Simrits Nad-cap-approved Tillsonburg, Ontario, Canada,

plant. The plant is certified to AS9100 Revi-sion C quality management, including de-sign for the aerospace industry. MD

Resources:Kollmorgen,www.kollmorgen.com

RS# 406Virginia Tech University,www.vt.edu

Resources:

Simrit, simrit.com

RS# 407

The VT Bolt is an all-electric motorbikedesigned and built bystudents at VirginiaTech University to

race in the TTXGP. Its7.5-kW-hr battery packpowers a Kollmorgenpermanent-magnetmotor, which givesthe bike a top speed inexcess of 100 mph.

NOVEMBER 22, 2012 MACHINE DESIGN.com 21
http://www.kollmorgen.com/http://www.vt.edu/http://simrit.com/http://simrit.com/http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://simrit.com/http://machinedesign.com/http://www.vt.edu/http://www.kollmorgen.com/


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Thousands of enclosures

Hundreds of sizes

Next-day shipping

REPORTERS NOTEBOOK

Navy tries turning seawater into fuel

Engineers at the U. S. NavalResearch Laboratoryare de-veloping a way to turn seawaterinto fuel. The multistep processfirst extracts CO

2and H

2from

seawater, then catalyticallyconverts the two into jet fuelin a gas-to-liquid transforma-tion. The fuel could be used foraircraft, ships, and amphibiousvehicles. Giving naval ships theability to make fuel from sea-water would eliminate the needto deploy ships and manpowerto deliver fuel to ships at sea.And a lot of Navy resources gointo delivering fuel. In 2011,for example, 15 replenishmentships loaded 600 million gal-lons of fuel onto Navy vesselsunderway.

So far, naval researchers havedeveloped and demonstratedtechnologies for recovering CO

2

and H2from seawater using an

electrochemical acidification cell.Theyve also converted the CO

2and H

2into hydro-

carbons. The Navy estimates that once tweaked andscaled up, the processcould produce fuel for$3 to $6/gallon. MD

Resources:U.S. Naval ResearchLaboratory,nrl.navy.mil

The acidification cell used to draw CO2out of seawater fits on aportable skid. It includes a reverse osmosis unit, power supply,pump, and a CO

2recovery unit. The cell has the benefit of

producing hydrogen at its cathode as a by-product.
http://nrl.navy.mil/http://nrl.navy.mil/http://nrl.navy.mil/http://nrl.navy.mil/


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www.rittal-thesystem.com

3D printingfor charitytechfortrade,a London-based charity, revealed the

winners of its 3D4D Challenge for the best 3D print-ing technology that would improve the incomes andlivelihoods of people in developing countries.

The 3D4D Challenge finalists included: BethanyWeeks and Luke Iseman, U. S., for an off-grid 3Dprinter that recycles plastic bags into tools for localfarmers; Boris Kogan, Israel, for a small-scale, easy-to-manufacture and assemble robotic greenhouse thatwill help communities grow good food, even in themost-difficult environments; and Edmund Bell-Kingand Cornell Jackson, U. K., for solar lamps createdfrom recycled plastic Coke bottles. The lights replacethe costly and dangerous kerosene lanterns com-mon in rural India.

Other winners included Tom Fripp and SteveRoberts, U. K., for 3D printing soft-tissue prostheses;JF Brandon, Canada, for a simple, 3D-printed solar

tracker that can provide solarelectricity to communities; RoyOmbatti, Kenya, for 3D-printedshoes made from recycled plasticthat can be worn by individualswith deformed feet resulting from

jigger-fly infestation; and Suchis-mita and Jayant Pai, India, for providing young en-

trepreneurs and students access to 3D printers andmaterial based on discarded plastic bottles.

Winners each receive $1,000 and access to ex-perts who will help them develop their projects fora follow-up competition to take place at this years3D Printshow in London. The final winner will get$100,000 to further develop his or her project. MD

Softwarestrengthens

3D-printed partsResearchers at Purdue University, are workingwith Advanced Technology Labs of Adobe Inc.,San Jose, to develop a computer program thatstrengthens objects created us-ing 3D printing. Bedrich Benes,an associate professor of com-puter graphics at Purdue, saysthe software targets online userswho pay $300 to create an objectwith 3D printers, only to have itbreak along areas of high stressduring shipping.

The software strengthens objects by makingstructural elements thicker or adding struts. I talso reduces the stresses on structural elementsby hollowing-out overweight areas.

The software first uses mesh-based simula-tion to identifygrip positions, where users arelikely to grasp the object. The solver requires lesscomputing power than traditional FEA packages,which are used in high-precision work such asdesigning jet-engine turbine blades.

The software not only makes objects lighter,

it also cuts part costs by 80%, says Benes.In the future, researchers plan to write soft-

ware that will help users better understand howstructural strength is affected by 3D printedobjects layered composition. They might also ex-pand the software algorithms to include printedmodels with moving parts. MD

Resources:Advanced TechnologyLabs of Adobe Inc.,www.adobe.com/technology.html

Purdue University,www.purdue.edu

Resources:3D4D Challenge,www.3d4dchallenge.org

techfortrade,www.techfortrade.org

RS# 118
http://www.rittal-thesystem.com/http://www.adobe.com/technology.htmlhttp://www.adobe.com/technology.htmlhttp://www.purdue.edu/http://www.3d4dchallenge.org/http://www.techfortrade.org/http://www.techfortrade.org/http://www.techfortrade.org/http://www.techfortrade.org/http://www.techfortrade.org/http://www.techfortrade.org/http://www.3d4dchallenge.org/http://www.purdue.edu/http://www.adobe.com/technology.htmlhttp://www.rittal-thesystem.com/


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REPORTERS NOTEBOOK

The Scion iQ proves that small carsneednt be Spartan. For example,though the car measures just10-ft long and 5.5-ft wide, theresplenty of room for two adults inthe comfortable front seats. It wasthe perfect vehicle for driving (andparking) in and around Boston fora week.

The hatchback is powered bya 1.43-liter four-cylinder enginewith an 11.5:1 compression ratiothat cranks out 94 hp and 89 lb-ftof torque, enough to get the carin and out of traffic whether onBostons skinny downtown streetsor its many freeways. The iQ couldeven pull a U-turn on some fairlynarrow streets, thanks to its 26.4-ftturning circle (curb to curb).

The engine also gets an honest30 mpg, city or highway, with thehelp of its continuously variabletransmission. Though the fuel

tank only holds 8.5 gallons, thatsenough to cover over 255 miles.And the transmission is sealed;Toyotaclaims drivers will neverneed to replenish the transmissionfluid.

The roomy front seats comecourtesy of a few nifty design

tricks. For example, tomake more space for thefront-seat passenger,

Toyota designers leftout the glove compart-ment. To replace thatcargo space, they addeda drawer under the pas-senger seat. They alsopushed the passengerseat a tad forward for abit more legroom in theback seat. Also absent isthe spare tire. Instead,unlucky drivers must use a repairkit in case of a flat.

Steering is crisp and precise onthe front-wheel-drive iQ with the6.5-ft wheelbase and electric-assiststeering. The steering moduleis smaller than a conventionalpower-steering unit, so it takesup less room under hood. Thefront-mounted differential is also

designed for compactness becauseroom under the hood is so limited.

The short wheelbase makes the ridea bit rough over bumpy roads butthe car handles and corners well.

Those worried about safetywhen driving a small car can ap-preciate the iQs numerous safety

2012 Scion iQ Hatchback:Compact and comfortable

features. They include stabilityand traction control, antilock discbrakes with assist, and electronicbrake-force distribution. The careven carries 11 air bags, includingone that pops up between the rearseat headrests. When inflated, ithelps keep out broken glass anddebris common in collisions.

The iQ also carries a full array of

electronics: a 160-W, six-speakerstereo with HD radio and a CDplayer, Bluetooth, and a USB portfor plugging in your iPod. Thereare also power door locks, mirrors,and windows, air conditioning,keyless entry, and even a tachom-eter (an odd instrument for a car

Resources:Scion, www.scion.com/cars/iQ

http://www.scion.com/cars/iQhttp://www.scion.com/cars/iQhttp://www.scion.com/cars/iQhttp://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://www.scion.com/cars/iQ


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with CVT). As expected,cargo room is tight,3.5 ft3with the back

seats in place. But thatsenough for groceriesor a briefcase or two.Folding the back seatsflat opens up 16.7 ft3 ofstorage, which will holdeasily hold a couplesuitcases.

The car is easy todrive, easier to park,comfortable, and getsgreat mileage. If Toyotaengineers designed theiQ with the same dura-bility and reliability oftheir other cars, the iQscould be around a long,long time.

The car costs about$17,500, and comes inonly one well-thoughtout trim level. There area few options: an aerokit for the exterior, andsome floor mats, cargo

nets, and a seven-colorspecial lighting kit forthe interior. You canalso get alloy wheels,some tricked out sus-pension components,and a navigation sys-tem. Stephen J. Mraz

Navigating Marswith Morse CodeCuriosity, NASAs

Martian rover, peri-odically checks to seehow much its drivewheels are slipping inloose gravel or sandby comparing the dis-tance it actually trav-els to how far it hasbeen told to move.

To do this, the roverchecks dozens ofnearby features, suchas nearby pebbles andshadows on rocks.NASA engineers haveensured Curiosity cancarry out this visualodometry even ifthere arent any distin-guishable landmarks.

NASA designersetched the MorseCode letters J-P-L (for

Jet Propulsion Laboratory) in all six wheels so that they leave a distinctive pat-tern in the sand as the rover moves. Curiositys cameras can discern the pattern

and use it for measurements. If Curiosity determines theresa significant position error from wheel slip, it recalculates thepath to its next target. This should let the rover get to targetsmore quickly and directly. MD

Resources:NASA Curiosityrover,www.nasa.gov/mission_pages/msl

Curiosity leaves a pattern of distinct lines in the tire marks itleaves behind in the Martian soil. They are actually the lettersJPL in Morse Code (J: --- P: -- L:-). They let the rover determineif its wheels are slipping in gravel or sand.

RS# 120NOVEMBER 22, 2012 MACHINE DESIGN.com 25
http://www.nasa.gov/mission_pages/mslhttp://www.nasa.gov/mission_pages/mslhttp://www.nasa.gov/mission_pages/mslhttp://www.nasa.gov/mission_pages/mslhttp://machinedesign.com/http://machinedesign.com/http://machinedesign.com/mailto:[email protected]://www.veljan.in/http://machinedesign.com/http://www.nasa.gov/mission_pages/msl


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Phone

1-888

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466

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5

16

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www.ondrivesUS.com/ShoulderScrews

.US Corp.

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REPORTERS NOTEBOOKLOOKING BACK

10 YEARS AGO 2002Cat latches:Heavy-duty compres-sion latches from Southco,Con-cordville, Pa., help Caterpillarsecure

inspection panels while meetingmore-stringent noise regs.Caterpillar's small and medium-

sized tractors and large track loaders

use a modified version of SouthcosVise Action Compression Latch.

The latch was tweaked so it installs

quickly and easily, fits flush with panels,has a folding handle for easy opening,and locks with a key.

The lockplugs pawl is fully adjust-

able and its shaft was shortened by10 mm to reduce inside protrusion. An-tivibration washers eliminate potentialloosening of the pawl during equip-ment operation.

30 YEARS AGO 1982High-angle helical gears from metalpowders: Helical gears with anglesas high as 41can now be made frommetal powders on a production basis,reports Dixon Sintaloy Inc.The gearswere previously produced from metalpowderswith anglesup toaround 30,except asexperimen-tal or spe-cialty items.However,the company claims to have perfecteda new technique that allows volumeproduction of metal-powder helical

gears with angles approaching the 45limit. The technique is applicable to allcommonly used metal-powder alloys.

50 YEARS AGO 1962Recovering big boosters in a pillow-like structure is proposed by PhilipBono and John Hayes of DouglasAircrafts Missile and Space SystemsDiv.The Roost (Reusable One-stageOrbital Space Truck) would be usedwith a 50-ft-diameter, 273-ft-long sin-gle-stage boostercapable of carryinga 160-ton payload.After separation ofthe payload, liquidhydrogen (left overfrom the launch)would inflate twoheat-resistant fabricbags, protectingthe booster witha conical structure 327 ft in diameterat the base. The blunt cone structure,

designed to withstand 1,800F, limitsreentry temperature to 1,500F. Air re-sistance should allow Roost to land atthe gentle rate of 1 mph. MD

Latch

mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://www.ondrivesus.com/ShoulderScrewshttp://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://www.ondrivesus.com/ShoulderScrewsmailto:[email protected]


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www.masterbond.com

get to thefinish line

+DFNHQVDFN 1- 86$ PDLQPDVWHUERQGFRP

Epoxy Adhesive Cures Rapidly in Thick or Thin Sections

Two Part System EP30-4

Low viscosity Excellent optical clarity Rigid bonds

RS# 121
http://www.masterbond.com/mailto:[email protected]:[email protected]://www.masterbond.com/


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REPORTERS NOTEBOOK

COMPANYNEWS

EDUCATION CENTERIn a joint effort, Agilent Technolo-gies,Santa Clara, Calif., ConciliumTechnologies,Republic of SouthAfrica, and the department of elec-trical, electronic, and computerengineering at the University ofPretoria,South Africa, have devel-

oped one of the largest electricalengineering training laboratoriesin the world.

The Agilent-Computer AidedEducation Center is an undergrad-uate laboratory with 144 worksta-tions, each fitted with an AgilentDSOX2002A digital oscilloscope

with a built-in function generator,a U3401A 41/2 digit dual-displaydigital multimeter, an E3630A triple-output dc power supply, and variousRF design and analysis softwareprograms.

CAPABILITIES EXPANDEDSil-Pro,Delano, Minn., has pur-chased 60 to 100-ton SodickPlustech thermoplastic injection-molding machines and converted a5-ton liquid-silicone rubber machineback to thermoplastics to handle in-creased demands for thermoplasticsmolding.

Sil-Pro is a contract manufacturer

specializing in molded and extrudedsilicone, thermoplastics, and full-service medical-device contractmanufacturing and assembly.

ACQUISITION

The Drives & Motion Div. of Yas-kawa America Inc.,Waukegan, Ill.,has acquired Wermac Electric Ltd.in Calgary, AB, Canada. Wermachas been an innovator in applyingvariable-speed drives and electrical

controls in the oil and gas industry.The new division, Yaskawa Wer-mac,will reside at the former Wer-mac Electric facility in Calgary, AB,and is now a division of YaskawaMotoman Canada,a subsidiary ofYaskawa America Inc. The Drives &Motion Div. manufactures industrialautomation equipment, includinginclude industrial ac drives, com-mercial HVAC drives, spindle drivesand motors, servosystems, motioncontrollers, and low-voltage indus-

trial control switches.

Pecora Corp.,Harleysville, Pa., amanufacturer of weatherproofingproducts, has acquired the deck-coating product line of CarlisleCoatings and Waterproofing Inc.,Wylie, Tex.

PERSONNELBrent Ekiss, technical sales represen-tative with Fabrico,Kennesaw, Ga.,

will now pursue LED market oppor-tunities in North America. Fabricooffers design and manufacturingservices for flexible materials.

http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/mailto:[email protected]://www.smalley.com/getcataloghttp://www.smalley.com/hoopsterhttp://machinedesign.com/


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Get the Original fromAvago Technologies!

Technology You Can Trust

Avago has been making encoder modulespreviously used in US Digital kit encodersfor over 25 years. Get your US Digitalreplacement kit encoder from the originalsource... Avago Technologies.

For further information, visit us at:

www.avagotech.com/encoders

If you have been using US Digitalkit encoders in the past, then youve

been using Avago encoders all along.

RS# 123
http://www.avagotech.com/encodershttp://www.avagotech.com/encoders


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REPORTERS NOTEBOOKCOMPANY NEWS

ciples and physics behind of eachtype of motor is included as wellas applications and commerciallyavailable products with drawingsand technical data.

The piezomotor brochure can bedownloaded at: www.piezo-motor.net/pdf/PI_Brochure_Piezomo-tor_Piezo_Motor_PiezoWalk_Ultra-sonic_Actuator.pdf

EMPLOYER OF YEAR

FINALIST

Mouser Electronics Inc.,Mansfield,Tex., an electronic-component dis-tributor, which employs nearly 1,000people, is a top-five finalist to be the

2012 Texas Employer of the Year. TheTexas Workforce Commissionwillannounce the winner at its annualconference Nov. 28-30.

If chosen, it would be the sec-ond award Mouser receives at theconference the other is the LocalEmployer of Excellence Award for

Tarrant County, nominated by theWorkforce Solutions for TarrantCounty.

FREE COMPILER

Microchip Technology Inc.,Chandler, Ariz., is offering the freeMPLAB XC32++ Compiler withunlimited code generation. TheMPLAB XC32++ supports all ofMicrochips 32-bit PIC32 microcon-

trollers and lets designers developand reuse C++ projects by makingall of Microchips C language exten-sions available in an environmentthat is compliant with the majorityof C++98 and C++2003 ANSI stan-dards. The compiler also includes

Dinkumware standard C, C++, andtemplate libraries.The compiler can be downloaded

at www.microchip.com/get/10E7.MD

three types of piezomo-tors inertial motors,often referred to as stick-slip motors; ultrasonicmotors; and stepping(walk) type motors.Background informationon the operating prin-

PIEZOMOTOR

TECHNOLOGIES

A 70-page brochurefrom PI (Physik Instru-mente) Inc.,Auburn,Mass., a manufacturerof piezo-positioningequipment, covers

RS# 124


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http://www.piezo-motor.net/pdf/PI_Brochure_Piezomotor_Piezo_Motor_PiezoWalk_Ultrasonic_Actuator.pdfhttp://www.piezo-motor.net/pdf/PI_Brochure_Piezomotor_Piezo_Motor_PiezoWalk_Ultrasonic_Actuator.pdfhttp://www.piezo-motor.net/pdf/PI_Brochure_Piezomotor_Piezo_Motor_PiezoWalk_Ultrasonic_Actuator.pdfhttp://www.piezo-motor.net/pdf/PI_Brochure_Piezomotor_Piezo_Motor_PiezoWalk_Ultrasonic_Actuator.pdfhttp://www.piezo-motor.net/pdf/PI_Brochure_Piezomotor_Piezo_Motor_PiezoWalk_Ultrasonic_Actuator.pdfhttp://www.microchip.com/get/10E7http://www.microchip.com/get/10E7http://machinedesign.com/http://machinedesign.com/http://machinedesign.com/http://www.sabcable.com/http://www.sabcable.com/mailto:[email protected]:[email protected]://www.sabcable.com/http://machinedesign.com/http://www.microchip.com/get/10E7http://www.piezo-motor.net/pdf/PI_Brochure_Piezomotor_Piezo_Motor_PiezoWalk_Ultrasonic_Actuator.pdf


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COMMENTARY

Whats up with

model-based

engineering?Model-based engineering (MBE) seems to mean dif-ferent things to different people. But according to CAD

validation specialist Doug Cheney of ITI TranscenDatain Milford, Ohio(www.transcendata.com),the model-based approach repre-sents the future of product development because machines not humans will read the data and validate models. A good model-based approach drivesdesign decisions based on a companys engineering and business rules. Itshould significantly slash costs by flagging design errors early on, when theyare relatively inexpensive to fix. The main MBE tenet is that data is createdonce and directly reused by all downstream consumers.

Cheney says high-end OEMs use model-based approaches to reduce thenumber of drawings, or even do away with them all together. As industryleaders such as Daimlerand Boeinglead the way into MBE, they are pushingCAD vendors to fully support 3D annotation, an important attribute of 3Dproduct and manufacturing information (PMI). PMI conveys nongeomet-ric attributes in 3D CAD that are needed for manufacturing. It can includeGD&T, surface finish, and material specifications. Cheney also says its in-teresting that midrange packages such as SolidWorks and Solid Edge alreadysupport 3D PMI.

MBE means that OEMs and smaller companies no longer have to manuallycheck drawings but process owners should plan on using the latest tools forautomatically checking models. Hand in hand with this technology change,

its necessary to plan for model defect resolution processes during the CAD-model-creation stage. Otherwise, a companys MBE scheme will fall flat onits face, says Cheney.

So what kind of technical roadblocks do companies face in moving toa model-based enterprise? Cheney say nontechnical issues include limitedbudgets and the natural human resistance to change. Technical issues includeincomplete CAD software functionality, digital data variation, and laggingregulations.

There are several types of digital-data variation. They fall under the head-ings of Can it be manufactured? (i.e., no unrealistic features such as wallswith zero thickness); Is it equivalent? (i.e., no data loss in migration ortranslation from CAD A to CAD B); and, Is it correct and clear? (i.e., nounintentional or undocumented changes).

To manage variation in model-based enterprises, it is necessary to auto-mate the checking of data to ensure consistent structures, complete content,and realistic features. It is also critical to automate translation validation toeliminate data loss or degradation. Lastly, companies should automate ECO

validation so that no unintentional changes get through and all intentionalchanges are clearly documented.

Cheney adds that STEP is an important part of MBE. Companies can col-laborate in a few ways. They can give external suppliers access to their PLMsystems. Or, they can publish models in various visualization formats. An-other way is to share models through the latest version of STEP, AP242.

According to Cheney, some engineers predicted the death of STEP whenvisualization formats arose. But STEP has enough intrinsic value and sup-

porters in the government and large aerospace/defense OEMs that its still animportant pa

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