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Adhesives t for Space
p|44
machinedesign.com
JULY 18, 2013
A FRESH LOOK AT
SERVOPNEUMATICS
p. 50
HOW OIL-FILM
BEARINGS FAIL p. 62
WHERE TO USE
FLEXIBLE SHAFTS p. 70
In Space, No One Can Hear You
OUTGAS
BY ENGINEERS FOR ENGINEERS
A PENTON PUBLICATION
G S
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FEATURES
44 EPOXIES AND ADHESIVES FIT FOR SPACE
Adhesives and epoxies used on spacecraft must withstand the harsh environment without outgassing.
50 SERVOACTUATORS THAT RUN ON AIR
Servopneumatic drives offer precise motion control with higher ef ciency than traditional pneumatics and better durability and power density than electromechanical actuators.
56 MORE INDUSTRIAL SENSORS GO WIRELESS
New industrial wireless sensors can put out signals that carry for miles, greatly boosting their role in recon guring production lines.
62 DETECT BEARING FAILURE
Identify and correct two common culprits of oil- lm bearing failure.
70 GET TO KNOW FLEXIBLE ROTARY SHAFTS
Engineers choose exible rotary shafts over rigid shafts for budget and weight-conscious system designs.
DEPARTMENTS
4 ON MACHINEDESIGN.COM 10 LETTERS 14 WHATS INSIDE
Disc Spring Makes Right-Angle Drill a Reality
ON THE COVER: Spacecraft
like this one must use adhesives
approved for space.
Lightweight Vacuum Pump Fits in Your Hand
92 DATA FILES
94 CLASSIFIEDS
94 AD INDEX
96 PUZZLES, MYTHS, AND CURIOSITIES
NEWS
16 NEWS
Software Lets Lighter Spacecraft Carry Heavier Loads
38 COMPANIES IN THE NEWS
COLUMNS
6 EDITORIAL
The Upside of Pesticides
12 INTERVIEW
Does Offshore Manufacturing Still Make Sense?
43 COMMENTARY
Will The 3D Printing Revolution Kill Engineering Jobs?
76 GOLDENSE ON R&D-
PRODUCT DEVELOPMENT
The Maker Movement Spurs Corporate Innovation and Entrepreneurship
PRODUCTS
78 PRODUCT SPOTLIGHT
Actuators,Controls & Drives
82 NEW PRODUCTS
2 07.18.13 MACHINE DESIGN
Printed in U.S.A., Copyright 2013. Penton Media, Inc. All rights reserved. MACHINE DESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January, February,
April, June, July, August, and October by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212.
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44
62
70
50
In This IssueJULY 18, 2013 | VOLUME 85, ISSUE 9
the #1 value in automation
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with COMMUNICATIONS
The fi rst Ethernet port is a real bargain since it comes embedded on the H2-DM1E CPU ($399)
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ENGINEERING TV
BUILD YOUR OWN 3DSCANNERThe Intel International Science and Engineering Fair is the worlds largest precollege science competition. This year in Phoe-nix, the event let more than 1,500 high-school students from more than 70 countries display their independent research. See how one student built a 3D scanner with a combination of parts, including some from a Lego Mindstorms kit. It uses a camera and tracking laser to generate a 3D model with a resolution under 0.17 mm. View the episode at www.engineeringtv.com/
FASTENER APPSpecialty fastener manufacturer PennEngineering has launched its PEMSpec app, letting engineers quickly access the companys product database via most mobile devices. Users can fi nd catalogs, data sheets, and application info, and view CAD drawings and animations. Find it at www.pemnet.com.
AUTOMATION AND SAFETY SITESOmron Automation and Safety has launched new Web sites for the U. S., Canada, and Latin America all accessible through www.omron247.com. Content includes datasheets, brochures, tech notes, and manuals; product-selection tables; CAD drawings; and an Expert Area with application examples and access to additional information.
LED MICROSITECooper Crouse-Hinds, a division of Eaton, has a new microsite (www.follow-the-leder.com) covering light-emitting diode (LED) technology. Content discusses LED life, lumen output, and overall effi ciency. A cost calculator on the site lets users compare overall costs, and maintenance savings, versus traditional lights.
EDITORS WEB PICKS
FREE WEBCASTS
NEW DEVELOPMENTS IN CONFORMAL COATINGSJULY 18, 2013, 2:00 P.M. ETConformal coatings have long been used to protect electronic, automotive, aerospace, and medical devices from their environments, as well as provide thermal and electrical insulation and a host of other benefi ts. But a drawback has been the inability to fully protect small, complex devices. Parylene, an ultrathin, inert, transparent coating, meets this challenge. It offers excellent dielectric and barrier properties, extreme chemical inertness, and is biocompatible. This Webinar, sponsored by Specialty Coating Systems, will discuss Parylenes unique properties, including antimicrobial capabilities; explain how it is applied to parts; and offer examples of successful applications. Learn more and register at http://tinyurl.com/or86cqp.
ADVANCED MATERIALS FOR THE AUTOMOTIVE INDUSTRYJULY 25, 2013, 2:00 P. M. ETThe automotive industry is always on the lookout for innova-tive material suppliers and converters who can engineer and manufacture fi lms, adhesives, and insulation products. This Webinar, sponsored by 3M, Fabrico, and Light Fabrica-tion, will discuss the latest advances in automotive materi-als, including: buzz, squeak, and rattle (BSR) tapes and acoustical insulation; acrylic foam tape for attaching fenders, dashboards, and linings; thermal isolation materials; and surface-protection fi lms. It will also include tips on selecting and converting these materials to ensure that the fi nal product meets performance, cost, and production effi ciency require-ments. Learn more and register at http://tinyurl.com/qjsyk5t.
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4 07.18.13 MACHINE DESIGN
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Editorial
LELAND TESCHLER | Editor
One summer when I was growing up on our family dairy farm, we
had a number of cows deliver twin calves. Thats unusual. A herd
the size of ours might see one or two sets of twins in a year.
As it happened, my father had treated his feed corn with a
commercial herbicide that was a derivative of Agent Orange, a defoliant used at
the time in the Vietnam War. Agent Orange had been linked to birth defects in
Vietnamese children. And twin births are a form of birth defect in cows. Putting
two and two together, my father switched herbicides. As I recall, we only had one
set of twins next year.
In Vietnam, the military sprayed defoliating chemicals at an average concentra-
tion of 13 times the recommended USDA application rate. Similarly, I now suspect
our calving experience arose because we inadvertently overapplied the chemical.
I recalled this story when I realized that 6LOHQW6SULQJWKHERRNFUHGLWHGZLWK
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But Carson also made a number of other pronouncements that have turned out to
be wrong. It is worth reviewing a few of them for lessons learned.
Carson was big on preserving natural habitats. Perhaps the biggest hole in her
argument that critics have pointed out over the years is that pesticides and herbi-
cides play a part in preserving natural habitats by reducing the amount of land and
other resources necessary to grow crops. They are key, for example, in no-till farm-
ing. No-till eliminates erosion and loss of soil nutrients from wind and water action
that comes from running tractors through fields numerous times to kill weeds.
But perhaps most interesting is Carsons claim that man-made carcinogens caused
a majority of cancers and that cancer could eventually strike one in every four
Americans. So you would expect to see cancer rates trending upward if synthetic
pesticides were a cause. But once figures are adjusted for our aging population, cli-
nicians say this hasnt happened. In fact, cancer death rates for nonsmokers up to
69years old declined from the 1950s onward.
Epidemiologists have estimated that no more than 5% of all cancer deaths are due
to pollution and that most cancer deaths arise from tobacco and diet. Moreover,
research has also shown that 99.99% of carcinogens we ingest are natural, manufac-
tured by plants to defend against pests.
Still, you have to give Rachel Carson credit for raising sensitivities to environ-
mental issues. If her predictions about cancer rates sound overly dire, it is helpful to
know that she was dying from breast cancer when she was writing her book. That
kind of reality has a tendency to color ones outlook on things.
The upside of pesticides
07.18.13 MACHINE DESIGN
Sense-ability.
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EDITORIAL
EDITOR IN CHIEF: LELAND TESCHLER [email protected] EDITOR: KENNETH J. KORANE [email protected] EDITORS: ELISABETH EITEL [email protected] J. MRAZ [email protected] EDITOR: LINDSEY FRICK [email protected] PRODUCTION MANAGER: DENISE GRECO [email protected] DIRECTOR: RANDALL L. RUBENKING [email protected]
INDUSTRY COVERAGE:
AUTOMOTIVE, PACKAGING, MEDICAL STEPHEN J. MRAZCAD/CAM, MANUFACTURING ELISABETH EITEL, LINDSEY FRICKFASTENING & JOINING, MATERIALS LINDSEY FRICKFLUID POWER KENNETH J. KORANEMECHANICAL ELISABETH EITEL, LINDSEY FRICK, KENNETH J. KORANE
ART DEPARTMENT
CREATIVE DIRECTOR: DIMITRIOS BASTAS [email protected] DESIGN DIRECTOR: ANTHONY VITOLO [email protected]
PRODUCTION
GROUP PRODUCTION DIRECTOR: CAREY SWEETEN [email protected] COORDINATOR: COURTNEY DENISON [email protected]
AUDIENCE MARKETING
AUDIENCE MARKETING MANAGER: BRENDA ROODE [email protected] DEVELOPEMENT MANAGER: DEBBIE BRADY [email protected]
ONLINE
ONLINE SALES & MARKETING MANAGER: VIRGINIA GOULDING [email protected] SERVICES COORDINATOR: JOANN MARTIN [email protected]
SALES & MARKETING
BRAND DIRECTOR: PAUL MILNAMOW T|312.840.8462 [email protected]
REGIONAL SALES REPRESENTATIVESAZ, CA, ID, OR, NV, UT, WA, BRITISH COLUMBIA: PAUL MILNAMOW, [email protected] T|312.840.8462 F|913.514.3957AL, AR, FL, GA, KS, LA, NM, MS, MO, OK, TX: FRANNY SINGLETON [email protected] T|678.947.8563 F|913.514.6884CO, IA, S. IN, KY MN MT, NE, ND, S. OH, SD, TN, WI, WV, WY: PAUL MILNAMOW [email protected] T|312.840.8462 F|913.514.3957IL: MELINDA HURLEY [email protected] T|847.784.9825 F|913.514.6625N. IN, N. OH, MI, NY, PA, Ontario: BILL RODMAN [email protected] T|216.931.9636 F|913.514.6841DE, DC, MD, NJ, NC, SC, VA: BRANDY BISSELL [email protected] T|919.773.1875 F|913.514.6357CT, ME, NH, MA, RI, VT, QUEBEC: LIZ STOTT, [email protected] T|857.636.9737 F|913.514.6914
INTERNATIONAL SALES REPRESENTATIVESInternational Sales Director: MIKE HANCOCK, [email protected] T|011.44.1372.824284 F|011.44.1372.824322UNITED KINGDOM, SCANDINAVIA, FRANCE, SPAIN, PORTUGAL: STUART PAYNE [email protected] T|+44 0)1932 564999 F|+44 0)1932 564998Belgium, Netherlands, Luxemburg: RODRIC LEERLING [email protected] T|011.31.229.841882 M|31.683.232625Germany, Austria, and Switzerland: CHRISTIAN HOELSCHER, [email protected] T|011.49.89.95002778 F|011.49.89.95002779Italy: CESARE CASIRAGHI Casiraghi Pubblicit Estera T|011.390.31.261407 F|011.390.31.261380Tokyo, 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 BAUMANNGROUP DIRECTOR OF EDITORIAL CONTENT: NANCY FRIEDRICHGROUP DIRECTOR OF OPERATIONS: CHRISTINA CAVANOGROUP DIRECTOR OF MARKETING: JANE COOPERRESEARCH MANAGER: JULIE RITCHIEMARKETING & EVENTS SPECIALIST: ADRIAN PIAZZAMARKETING COMMUNICATIONS SPECIALIST: CYNTHIA RODRIGUEZ
PENTON MEDIA INC.
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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
JULY | 2013
07.18.13 MACHINE DESIGN8
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PRINTING GUNS
I agree with Mr. Teschlers blog entry
that regulating 3D printers is a knee-
jerk reaction and is counterproductive
(Good night! Now They Want to Reg-
ulate 3D Printers!! May 13, From the
Editors Desk). However, given the cost
and relative lack of expertise needed to
run a 3D printer (especially compared
to a lathe or CNC), then it is easy to see
why 3D printers would be the manu-
facturing method of choice for making
something like a plastic gun. But if we
cant get background checks on people
who have guns, how are we going to
get background checks on people who
have access to equipment which could
conceivably make guns?
Name withheld
Its amusing that the solution to this
so-called problem is yet another law
which either wont work or will be
poorly enforced. It would help if they
would take the time to find out how
items are really manufactured before
they start talking and expose their
ignorance. That 3D gun you see takes
a full day to print for a single shot.
This low-power weapon threatens the
world? Get serious.
Jerry M
While they are at it, how about register-
ing knives. Knives kill more people in
the U. S. than firearms. Oh, dont forget
clubs, too, and things that can be used
as clubs like tree branches. Better regis-
ter trees, too, just to be safe.
Greg E.
Apparently these folks arent familiar
with lost-wax casting, modern ma-
chining, or any of the sintering tech-
nologies that let you make stainless-
steel products at low temperatures.
Most guns can be made today in a
garage with a couple of gas ovens and
a few hours work with some plaster
of Paris. Cheap weapons might even
be made like belt buckles with rubber
spin casting. So why worry about some
guy with a 3D imaging set up? The
engine lathe coupled with a five-axis
CNC mill is a much more productive
way to make guns.
At the shop where I used to work,
the machinists had access to machines
after working hours. They turned out
about five automatic rifles and shot-
guns a week, cherry-wood handles,
hand-engraved silver and brass trigger
housings magnificent. And show
me where that is illegal in most states?
It is just a great way to make some
beautiful machines by turning idle
time into cash.
Name withheld
It just goes to show how technologi-
cally ignorant some of our legislators
are. Firearms are just a special type
of useful machines created by human
ingenuity and creativity. The knowl-
edge about making firearms is already
out and no amount of regulation on 3D
printers can put it back into the realm
of elite craftsmen.
Chuck Peters
CNC SHORTAGE? REALLY?
Being in my late 40s and having just
graduated from an accredited CNC col-
lege program, I have been trying to en-
ter the workforce as a CNC machinist.
So its bittersweet reading what some
in your audience have written about
not being able to find CNC machinists.
Even your editorial on November 17
advised Wall Streeters to pursue CNC
machinist or welding jobs.
Well, your readers and employers
are not asking for just CNC machinists
they are asking for CNC machinists
with three-years experience. Unfortu-
nately, having a diploma for CNC ma-
chining doesnt qualify as experience.
In my case, living in Houston and
looking as far as California and North
Carolina (and all states in between)
hasnt landed me a machinist job in
almost five months. The headhunters
and companies I speak with tell me
they get plenty of applicants but with-
out the experience that they need.
This tells me that there is a huge
problem with the mindset of most
employers: They think only of the
short term. This creates the perceived
shortage of both machinists and en-
gineers. Finally, anyone talking about
shortages in the workforce should
ask themselves: If we hire candidates
and give them on-the-job-training for
three to six months, will we still need
to be looking for applicants seven
months from now?
Name withheld by request
AND THE WINNERS ARE
John Meyer was the first reader to cal-
culate and send in the correct answer to
the June 13th pyramid puzzle -- 4.76in.
And Edward Grivna was the first
to identify the gadget in the June
issue. It was one of the balls dropped in
Times Square to usher in the new year.
Congratulations to both.
Letters
WHEN 3D PRINTERS
AREOUTLAWED
Readers were not outraged over Leland Teschlers
blog entry about using 3D printers to make guns.
The idea of trying to regulate those 3D printers,
however, caused several readers to question our
lawmakers intelligence and sincerity.
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: [email protected]
10 07.18.13 MACHINE DESIGN
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Interview
MICHAEL BLOOM | President
Sinotech Portland, Oreg.
With all the talk today about reshoring and
the resurgence in American manufactur-
ing, one might think offshore manufactur-
ing is dead. Michael Bloom is certified by
the U. S. Small Business Administration and by the National
Assn. of Small Business International Trade Educators as
a global trade professional and has been working with clients
worldwide for more than 20 years. He offers some opinions on
offshoring issues.
Is sourcing and manufacturing in Asia for the North Ameri-
can market still a viable option for U. S. companies?
There are still many good reasons for North American
OEMs to source and manufacture in Asia. However, more
careful cost-benefit analysis is required now than before. For
many U. S. companies, manufacturing offshore incurs risks
related to the extended supply chain, quality issues, shipping
costs, duties, currency revaluations, and delays in time to
market. Many firms, therefore, set a benchmark for minimum
cost savings typically from 15% on up before accepting
the risks. This is achievable in some but not all cases, as cost
savings available several years ago may have disappeared in
todays offshore manufacturing environment.
What are the advantages of manufacturing in Asia?
The chief advantages are lower production and capital costs
and greater manufacturing capacity. While labor rates and the
cost of social safety nets are steadily increasing in Asian facto-
ries, total labor costs are still below those in the U. S.
U. S. factories may face difficult expansion decisions if
demand for their goods approaches in-house production
capacity. When choosing between building new plants here
and offshoring to existing Asian factories, offshoring pres-
ents a lower risk. Also, as a domestic factorys aging machines
near end of life, it may be attractive to contract some manu-
facturing to an Asian factory that has already retooled with
modern equipment.
What types of products are best suited for this?
Generally, products with high labor content are best suited
for Asian sourcing. For example, its not practical to fabricate
extrusions in Asia because simple extrusion dies are inexpen-
sive, even in the U. S., and the cost of the extruded material
is likely to be the same worldwide. However, take the same
extrusion and cut, machine, heat treat, and paint it, and youve
Does Offshore Manufacturing Still Make Sense?
got a viable project for Asian outsourcing.
There is a sweet spot for offshoring projects. Products in the
design and development stage are best kept close to home, as it
helps ensure more-effective collaboration among engineering,
manufacturing, and management. On the other hand, projects
with high tooling expenses, such as molds for complex cast-
ings or progressive stamping dies, can offer considerable sav-
ings. For small-to-midsized production runs, less-expensive
tooling from offshore manufacturers may be the only way
to achieve cost targets when amortizing tooling over a small
number of parts.
Whats the best approach to sourcing from Asia?
The best approach to successful sourcing from Asia is to
enlist the assistance of a knowledgeable organization with
boots on the ground in Asia. This assistance must be from
a company that knows local business practices and business
culture, and maintains good relations with capable factories.
Its personnel must also be well versed in manufacturing pro-
cesses and engineering. Finding a partner company with all of
these skill sets is quite a challenge.
Unfortunately, U. S. and state governments do not offer a
lot of support they aid exporters, not importers. One place
for help is foreign organizations whose purpose is to encour-
age trade with their own country. Groups like the Hong Kong
Trade Development Council can be quite helpful.
Consider attending foreign trade shows. And approach the
contacts you and your associates may have in the country of
interest. Though likely not the person qualified to represent
you, at least they can point you in the right direction and with
a higher level of confidence in the referral. Use caution search-
ing for suppliers on Web sites like www.alibaba.com, as you
never know what or who you are getting. Of course, you can
use the services of a company like Sinotech that already has
sourcing infrastructure on the ground.
The biggest pitfall we see is choosing the wrong factory in
the first place. If you select the wrong factory, a project is likely
to fail regardless of any assistance you may later provide. Try-
ing to locate a suitable factory from arms length is a recipe for
disaster. Even with a good sourcing partner, be prepared to
visit the factory and conduct your own audit before making a
decision. Look for a partner who understands quality systems
and has processes in place to protect your interests.
12 07.18.13 MACHINE DESIGN
Whats Inside
ENGINEERS AT DeWalt
Power Tools and
Accessories, Baltimore (www.
dewalt.com), were tasked with
designing a high-power, right-angle drill that
was lightweight, compact, and portable. The drill
would need a mechanical clutch to limit maximum
torque output to 70lb-ft. Without it, the drill could transmit
up to 175-lb-ft torque directly to the technician operating the
tool. The DeWalt team quickly determined that the clutching thrust
needed in the space available would require a disc spring. Compared
to conventional coil springs, disc springs offer higher load capacities in less
space. Just as importantly, the drills life and performance relied on the disc-
spring design.
DeWalt eventually turned to Spirol International Corp., Danielson, Conn. (www.
spirol.com), for a custom spring since a standard spring would not do the job. The custom
spring had nonstandard dimensions and material, and required a secondary operation to
increase cycle life.
When the drill was built and tested, the disc spring helped it achieve a working life far in
excess of the design requirement.
Disc Spring Makes Right-Angle Drill a Reality
Pressure plate
Cam plate
SpacerClutch shaft
Clutch pinion
Clutch gear
Nuts
Disc spring
Hardened balls
Lightweight Vacuum Pump Fits in Your HandTHE LIGHTWEIGHT piCHIP vacuum
pump from Piab USA Inc., Hingham,
Mass. (www.piab.com), is flexible enough to
surface mount quickly on a variety of materials.
Its compressed-air and vacuum ports are on the
same side, making it easy to add to machines or
instruments. And, if adjustments are needed due to
process changes, the piCHIP can be quickly modified
to double the output for faster response. The small
pump makes little noise, so it is well suited to clean-room
operations and the medical and electronics industries.
The pump is made of polyamide with the interface to
the compressed air, vacuum, and exhaust channels on the
housings open side. Nitrile seals are standard but Viton
alternatives will be available soon for challenging chemical
applications. The exhaust can be routed directly from the
pump or through a sealed (central) plug.
With a choice of three different types of coax
vacuum cartridges to suit specific needs,
the piCHIP can handle vacuum levels from 22.2 to
27.2-in. Hg with almost a 2:1 ratio of vacuum flow to air
consumption. Coax cartridges are also up to twice as fast
as other cartridges and provide three times the flow of a
conventional ejector with the same air consumption. This
lets the piCHIP provide a consistent vacuum even at low
or fluctuating feed pressures (14.5 to 87 psi).
Edited by Stephen J. Mraz
Polyamide
housing
Coax
cartridge
Exhaust
plugs
Gasket
14 07.18.13 MACHINE DESIGN
Revolutionary Liquidmetal Alloy delivers precision, strength, and nish that far exceeds MIM, at a cost less than CNC. Based upon breakthrough technologies developed at Caltech and NASA, Liquidmetal Alloy is a revolutionary amorphous metal that offers an unmatched combination of strength, elasticity, and corrosion-resistance. It can be injection-molded, and because it experiences virtually no shrinkage as it cools, it delivers nearest-to-net shapes in just one step. Take the challenge. Talk to a Liquidmetal Technologies expert about how this breakthrough technology can work for your application.
250% 0.2%.002
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16 07.18.13 MACHINE DESIGN
Software lets
LIGHTER SPACECRAFT carry heavier loads
Researchers at NASAs Ames Research Center,
Moffett Field, Calif., are developing a Com-
mon Bus spacecraft made of stackable octagonal
rings and off-the-shelf parts to form small landers,
orbiters, or rovers. The squat octagons measure
14-in. tall and 46-in. across, with matching bolt pat-
terns around their ends for quick assembly. When
stacked, they form the crafts body and serve as a
monocoque structure a shell that supports loads.
To customize the rings composite and metal make-
ups, engineers use HyperSizer structure-optimization
software from Collier Research Corp., Newport
News, Va. It calculates failure modes and logs data
to predict how material choices, construction types,
and input loads will affect a designs ability to with-
stand its environment. It makes trade-off studies
to find permutations that best balance design goals
using a material-property database with information
from literature and empirical tests.
NASA engineers recently used HyperSizer to design
the first Common Bus craft, the Lunar Atmosphere
Dust Environment Explorer, or LADEE. It is sched-
uled to launch this year, orbit the Moon, and analyze
lunar dust. Two of LADEEs four modules contain
propulsion systems. The other two carry avionics,
communications gear, and experiments. The vehicle
is clad in solar panels.
Once the team arrived at a
working design, HyperSizer
sharpened LADEEs finite-
element model to profile about
500,000 shell elements subject
to nearly 100 global loads. For
each element, the software
checked about 20 failure modes
and interactions, including core
shear, flatwise tension, face
dimpling, and local buckling.
HyperSizer also verified metal
interfaces and brackets. In all,
the software calculated 1bil-
lion structural margins and
organized the data into detailed
illustrations of critical loads and
failure modes.
Before HyperSizer, NASA
The NASA Ames Lunar Atmosphere Dust and Environment Explorer (LADEE), a Common Bus space-
craft, is built as a stack of modules. Soon, larger versions of this satellite could perform modest
robotic tasks such as meeting up with asteroids or investigating the lunar atmosphere. Common
Bus craft go from design to launch in less than two years and cost as little as $50 million, about
one-tenth the price of conventional unmanned spacecraft.
Photo: NASA/Ames
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NASA engineers used
ProEngineerCAD with
Windchi l l and Minx,
ProMechanica, Patran,
Nastran, and HyperSizer
to design LADEE. Here,
HyperSizer shows the
crafts primary struc-
ture and components.
HyperSizer performs
ex tens ive t rade-o f f
studies, determines
suitable materials, and
calculates safety mar-
gins at all design stages
from preliminary layout
to flight certification.
engineers manually analyzed such
data, or hired analysts to write
code to do so. Usually, this result-
ed in complicated designs being
simplified. Then analysts applied
stresses and strains to critical
areas and thickened any resulting
overstressed areas, often missing
strength-to-weight goals.
Thanks in part to HyperSizer
optimization, LADEEs body is a
tailored blend of materials. Most
of its panels are lightweight T300
carbon-epoxy composite with a
Tencate RS-3C resin. T300s high
specific strength and low thermal
distortion ensure the pointing
accuracies of observational instru-
ments. The propulsion housing is
stiff M55J, a carbon-cyanate fiber
composite that prevents vibra-
tions at natural frequencies.
A heat-rejecting radiator relies
on an aluminum-faced panel
while bonded-aluminum inserts
serve as interface sections and are
shaped for thermal survivability.
Most brackets are sheet metal or
Red areas are metal features
controlled by isotropic failure
criteria. Green are compos-
ite structures controlled by
composite criteria. Blue indi-
cates elements governed by
panel-shear criteria for both
metallic and composite pan-
el sections. Even during fab-
rication, HyperSizer helped
engineers assess the impact
of fabrication imperfections.
Modules can be customized
for specific craft during fab-
rication with equipment-
attachment inserts and trims
to decks and walls to make
room for internal equipment.
Specifying AC gear motors
ference is in overall axial length. In heli-
cal gear units, the gears mesh through
rolling friction for low losses in mechani-
cal efficiency (at less than 2% per stage).
Three main types of right-angle
gearing exist. Worm gears are least
efficient. Spiral bevel and hypoid gears
are the most efficient with less than
2% mechanical efficiency loss per
stage. Spiroid gearing is fairly efficient
at low ratios, but at high gear ratios,
efficiency drops to that of a worm gear.
HOW DO I SIZE AND CONFIGURE
AC GEAR MOTORS FOR
EFFICIENCY?
Higher efficiency is the most important
feature of new motor designs. Maximize
your investment and efficiency by
combining NEMA Premium motors
with highly efficient gearing that can
deliver high ratios with fewer stages.
Use free simulation and configuration
tools to get the most suitable gear
motor. An undersized gear motor
accelerates part failure and provides
inadequate driving force or power,
but oversized ac gear motors are
costlier and waste energy.
To allow the use of a smaller motor
option. Theyre more compact and
mount directly to machine assemblies,
often with quick-lock tapered bushings.
HOW DO GEAR MOTORS
AFFECT THE CONFIGURATION OF
AUTOMATION EQUIPMENT?
It depends. Many new designs are
moving to integral gear motors. Here,
the gearbox and motor are permanently
coupled and sold as a single unit. The
pinion gear driving the gearbox is
directly mounted to the motors drive
shaft for perfect alignment and zero
mechanical losses. Such integral designs
are shorter than designs with separate
subcomponents. Theyre also lighter,
and most suppliers can easily incorpo-
rate brakes and encoders as needed.
The more traditional option is a
gearbox with C-face adapter paired with
an ac motor and other accessories sold
separately. This modular arrangement
allows for different types of motor
frames (NEMA, servo, IEC) though
the shaft connection point is prone to
corrosion and fretting if not assembled
correctly. In addition, a two-bearing
adapter must be used to prevent axial
forces on the motor that can otherwise
cause premature failure.
WHAT KINDS OF
GEARS CAN I GET?
Typical performance
ac gear motors use
either helical or
right-angle gearboxes
in two or three stages
for ratios of 3:1 to
over 360:1.
In helical units, the
gearbox output shaft is
either inline or parallel
to the drive shaft of the
motor. Their main dif-
Gearing paired with ac motors makes high-torque applications possible. But what pitfalls should you avoid during gear motor specification? Following are common questions that arise when designers look to simplify the motor-picking process.
HOW DO I INDEPENDENTLY SHOP
FOR THE GEAR MOTOR I WANT?
The standard approach is to search
printed catalogs often a time-
consuming process that requires the
designer know exactly what he or
she wants upfront. Online catalogs
are more searchable but dont always
list features for full customization.
The newest option is configuration
wizards that ask a series of questions
and then list appropriately sized and
configured gear motors for the applica-
tion at hand. Some wizards assist in
sizing, define options, and describe
configured gear motors in plain text.
Typically they provide 2D and 3D CAD
models as well. Here, make sure you get
models with the exact geometry of the
gear motor you want to order, and not
just a model with similar part geometry.
WHAT IF I NEED TO PICK FROM
SEVERAL VARIATIONS?
Determine whether the application
may benefit from specialty setups a
gear motor with a low-weight aluminum
housing not requiring paint, for
example. Then pick the shaft type to
transmit torque from the gear motor to
the machine assembly. Solid-shaft ac
gear motors allow for additional speed
reduction via a chain or belt though this
is much less efficient than adding more
ratio inside the gearbox and external
reductions necessitate more mainte-
nance and safety guards. Hollow shaft
ac gear motors are the preferred design
Sponsored by Siemens
FREQUENTLY ASKED QUESTIONS
y
x
As the pinion gear moves inward;
More compact length (along x-axis)
As the pinion gear moves outward;
More compact height (along y-axis)
Worm gear
Spiroid gear
Spiral bevel /
Hypoid gear
A D V E R T I S E M E N T
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(and boost overall efficiency) also
consider eliminating belts and chains.
Keep in mind that gearbox efficiency
is the product of all the stages efficien-
cies. Therefore, use the least number
of gear stages possible to get the gear
ratio required for the application.
Finally, remember that driving the ac
gear motor with a variable frequency
drive can boost energy savings as well.
WHEN WILL I GET MY GEAR
MOTORS?
Standard delivery can take weeks,
but some suppliers can supply even
custom-configured gear motors in a
few days. These typically rely on local
assembly in the U.S. and large parts
inventory. Confirm that order tracking
is offered. To get gear motors repaired
or replaced quickly make sure the
supplier has a complete inventory of
spare parts stocked and standardized
designs that eliminate special parts.
Sometimes motors are discounted
if youre willing to wait, so ask the
supplier about extended delivery dates.
HOW DO I KEEP TRACK OF THE
GEAR MOTORS I BUY?
Two features speed unit identification.
One is RFID nameplates that allow
service technicians to safely scan gear
motors from a distance. The other is
smart numbers to completely identify
unique gear motor configurations down
to their mounts and colors, since
model or type numbers usually are
not sufficient. These can help plants
minimize spare-unit inventory (if a
motor design is used in more than one
place in an installation) and eliminate
guesswork when ordering exact
duplicates of a given gear motor.
For more information, visit
industry.usa.siemens.com.
Thousands of enclosures
Hundreds of sizes
Next-day shipping
machined aluminum. Larger
panel-to-panel interface
fittings consist of bonded
machined titanium. All pan-
els have aluminum honey-
comb cores.
Empty, LADEE weighs
102 lb with composite-faced
panels accounting for about
70% of the weight, aluminum-
faced panels for 5%, and met-
al inserts, fittings, and brack-
ets making up the final 25%.
Instruments add another 184
lb and the spacecraft will car-
ry about 514 lb of fuel, giving
the spacecraft an 800-lb take-
off weight.
In the past, Ames designs
have been overweight, says
Ian Fernandez, materials
and analysis lead on LADEE.
HyperSizer lets Ames be
competitive in lightweight
designs where more failure
modes and stress interac-
tions are possible and must
be checked. As budgets are
trimmed, the software could
replace several rounds of
physical tests.
News
About 1 billion safety margins were calculated
during HyperSizers stress analysis of LADEEs
primary structure. The colored legend displays
minimum margins from all failure criteria, load
cases, and elements. The software optimized
the composite and metal layers that make up
LADEEs module walls. Areas under high load and
stress are reinforced so typical wall centers
have two plies, edges have four, and corners have
six. This reduces mass and cost and modular-
ity minimizes post-cure bonding and panel join-
ing used for traditional composite-spacecraft
manufacturing.
CERTIFICATION
NORTHWIRE INC.,
OSCEOLA, Wis., has earned
Aerospace Quality Standard
AS9100 Rev C certification
and recertification to exist-
ing ISO 9001:2008 quality
standard for compliance with
the rigourous requirements
of Aerospace, Space and
Defense organizations, such
as EAR and ITAR. Northwire
designs, manufactures, and
contracts custom wire and
cable, retractiles, assemblies,
harnesses, injection molding,
overmolding, and contract
engineering.
WATLOW, ST. LOUIS, a
designer and manufacturer of
complete thermal systems,
announced its tubular flange
heater has received additional
IECEx d flameproof certifica-
tions. Its suitable for Ex d IIC:
T1-6 Gb, up to 80C (176F),
enclosure/anticondensation
heaters, and IP66.
www.rittal.us
WILL THE ARMY GET A TILTROTOR?
BELL HELICOPTER WANTS to sell the U. S.
Army 4,000 V-280 aircraft, a third-
generation tiltrotor designed using les-
sons learned from the V-22 Osprey. The
aircraft could replace both Black Hawk
and Apache helicopters in the transport/
utility and attack roles.
Bell says the V-280s speed and range
will make it more useful and efficient to the
Army. (The 280 in the planes name refer-
ences the aircrafts top speed of 280 knots.)
Unlike the V-22, The new tiltrotor has
engines and a wing that remain fixed
while the rotors and drivetrains mount
in tilting pods. This should make it safer
for troops to enter and leave the plane
through its 6-ft-wide side doors. The new
configuration will also give door gunners
a more open field of fire. And station-
ary engines should simplify certification
because theres no need to check engine
performance at a variety of operating angles. Bell also
wants to reduce the loading on the rotor disk to lower
the amount of downwash coming off the propellers.
The V-280 will have a straight wing rather than
the Ospreys forward-swept design, a measure taken
to simplify the overall design. The wing will also be
built as a single, large component using what Bell
calls Large Cell Carbon Core technology. This should
reduce weight and cost, and let any damage to the
wing be detected immediately.
Bell has tentatively planned for two models. The
utility version would carry a crew of four and 11 pas-
sengers, while the attack version would carry guided
weapons inside the fuselage and under the wings, and
have a turreted gun under the nose. They will have a
combat range of up to 800 nautical miles and a one-
way ferry range of 2,100 nautical miles.
An artists conception of the V-280 tiltrotor shows its V-tail and nontilting wings and
engines. Only the propellers and drivetrain rotate to give the plane the ability to take-off
and land vertically.
Polishing, tensioning or counterbalancing?
One of these is precisely what you need.
When polishing, tensioning, or counterbalancing is a critical function of themachines you design, precisely controlling their performance calls for something extraordinary. Why? Because for optimum performance youre going to need very accurate force control. So, consider the Accurate Force Pneumatics cylinders from Airpot Corp. The Airpel, Airpel-Plus, and Airpel-AB are speci cally designed to provide actuation forces with extremely low friction zero friction in the AB! The result is an unmatched responsiveness to minute pressure changes, force reso-lution down to 0.5 gram, and response to pressures as low as 0.2 psi. Which all adds up to the very best cylinders you can use for your applications requiring:
Q precision polishing of read/write heads, lenses, and mirrors Q error- free deburring
Q delicate tensioning during winding, spooling, and processing of ultra- ne wire, ber optic cable, lm, textiles, and tapeQ accurate counterbalancing of z-axis
positioners in gantries, linear motors, CNC measurement heads, and other precision mechanisms. Youll nd even more advantages, including life spans ranging into hun-dreds of millions of cycles, with clean operation (no lubrication needed, ever). Plus the ability to operate over extreme tempera ture ranges. And at very high or low speeds with no change in perfor-mance even after sitting idle for years. Visit airpot.com to get your hands on a free sample. Or call us at 800-848-7681 and speak with one of our helpful design engineers to select the actuator that will work best for you. Youll see rsthand how Accurate Force Pneumatics solutions begin with Airpot.
Motion Controlled. Problem Solved.Airpot, Airpel & Airpel-AB are registered trademarks of Airpot Corp.
MADE IN USA
22 07.18.13 MACHINE DESIGN
News
SPECIAL FORCES GET SPECIAL MOTORCYCLEENGINEERS AT Zero Motorcycle,
Scotts Valley, Calif., have devel-
oped the MMX, an all-electric
motorcycle for the U. S. Defense
Dept.s Special Forces. A fleet of
bikes is currently being operation-
ally tested by the military.
The MMX is powered by the com-
panys Z-force motor, which puts
out 54 hp and 68 lb-ft of torque.
The bike also has regenerative
braking which conserves power and
extends the range. A pair of battery
packs gives the bike a 2-hr range,
and the packs can be switched out
for fresh ones in less than a min-
ute. The bike also carries a charger
which will fully recharge a battery
pack in an hour. The packs have a
safety override and reserve power,
so range can be extended if needed,
but equipment may be damaged.
The motor runs almost silently and
generates a much smaller IR signa-
ture than an internal-combustion
engine.
Modifications for the military
include a simple toggle switch
instead of a key and ignition switch
for quicker starts. The headlight
can be switched off for nighttime
operations. And there are wiring
connections for IR lighting. The
bike can also operate in up to 3 ft of
water. And many of the bikes fea-
tures and performance characteris-
tics can be adjusted remotely using
a smartphone app.
the #1 value in automation
2UGHU7RGD\6KLSV7RGD\* See our Web site for details and restrictions. Copyright 2013 AutomationDirect, Cumming, GA USA. All rights reserved.
The new ViewMarq LED message boards can display preformatted and real-time factory oor data messages sent by a PLC, PC, or other master device. The text message displays can be controlled by:
ASCII strings through the RS232 or RS485 port Modbus RTU messsages through the RS232 or RS485 port Modbus TCP messages through the Ethernet port
The Viewmarq line o ers:
v 2QHWZRDQGIRXUOLQHGLVSOD\Vv 9LHZLQJGLVWDQFHVXSWRIHHWDQG GHJUHHYLHZLQJDQJOHv 5656DQG(WKHUQHWSRUW VWDQGDUGRQDOOPRGHOVv 6FUROOLQJEOLQNLQJFDSDELOLW\v 1(0$1(0$H[WUXGHGDOXPLQXPKRXVLQJV VXLWDEOHIRUKDUVKHQYLURQPHQWV
Use the FREE Viewmarq con guration software(online download) to con gure the display; create,preview and send messages from a PC; or createASCII strings that can be transferred to PLCinstructions to control the Viewmarq.
with Viewmarq industrial displays*(7
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24 07.18.13 MACHINE DESIGN
NASA SAYS TWO of the Kepler space telescopes four gyro-
scopic reaction wheels have failed, making it inoper-
able for its mission imaging planets in other solar
systems. The reaction wheels let Kepler precisely hold
position, which is critical for the long exposures the
satellites optics need to gather clear images from out-
side our solar system.
One reaction wheel failed last year, but it was a
redundant assembly, and the satellite could function
using three wheels. But then a second wheel failed in
May, a problem not entirely unexpected, according to
NASA administrator John Grunsfeld. We have some
history with wheels by this manufacturer, that they
have a limited lifetime, he explains.
After the second failure, NASA engineers started
using onboard thrusters to keep Kepler in the right
position and orientated so the solar panels faced the
Sun. When they then tried to give control back to the
reaction wheels and halt the spinning telescope, three
wheels responded properly. But the fourth remained at
full torque, a clear sign the wheel has an internal fail-
ure. Engineers switched back to thruster control, con-
fident there will be enough fuel to last several months.
And if NASA puts the spacecraft in rest mode, it
could remain on station for several years while engi-
neers decide what to do with it.
Fortunately, Kepler has completed its planned
3.5-year mission since being launched in March of
2009. It has already found 2,165 eclipsing binary stars,
2,740 possible planets, and 132 definite planets. Many
of these newly found planets appear to be Earth-sized
and within their stars habitable zone, where water
could exist in liquid form. Plus, there is still a year-and-
a-half-worth of data still in the pipeline that scientists
have yet to examine. So Kepler will likely be respon-
sible for future planetary discoveries despite being out
of action.
NASAS PLANET-HUNTING space telescope suffers critical failure
Before it failed, Kepler would detect planets by monitoring how the
light from some distant stars varied over time as planets revolved
about them.
RESOURCES:
NASA, tinyurl.com/6a5y32
More on NASAs Kepler, tinyurl.com/d23pmak
News
W e s t b r o o k L o n d o n P a r i s F r a n k f u r t M i l a n S t o c k h o l m
Ultra Lights
With today's high cost of fuel, it's never been more important to shed aircraft weight. Fortunately, The Lee Company had plenty of runway with this challenge by making it our priority over 60 years ago. As a result, our Ultra Light products are now even smaller and lighter some weighing less than the page you're reading. And of course, they're just as reliable as ever. Lee Plugs, restrictors, valves and screens are unsurpassed in offering breadth of choice and peace of mind. No one offers more experience designing, manufacturing and ensuring zero-defect, as-promised quality. Which helps explain why we're on board every commercial and military aircraft that leaves the ground today. Call today for the latest edition of our Technical Hydraulic Handbook, and discover hundreds of ways to put your next design on a low fuel diet.
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26 07.18.13 MACHINE DESIGN
News
AMERICANS AND CHINESE WILLING TO PAY MORE FOR U. S.-MADE PRODUCTS
A RECENT REPORT prepared by Penton
Media Design Engineering and
Sourcing Group (parent company
of MACHINE DESIGN), OEM Outlook:
Marketing intelligence for OEM
suppliers, found that 8 out of 10
U. S. consumers are willing to pay
more for products labeled Made
in USA than for those made in
China. And 6 out of 10 Chinese con-
sumers are willing to pay more for
American-made products. Some of
the reasons listed by U. S. consum-
ers for paying up to 60% more for
American-made goods are qual-
ity and patriotism. Some of the
goods U. S. consumers prefer to be
American-made include apparel,
appliances, baby food, and electron-
ics. The report also says that 14%
of American companies are moving
some manufacturing back into the
States. Companies cited rising ship-
ping rates, quality problems, and the
intangible costs of having factories
so far from headquarters.
The report also looks at engineer-
ing and manufacturing trends in the
U. S., what design and engineering
equipment companies are using,
and evaluates a host of high-tech
industries and markets includ-
ing robotics, medical equipment,
motion control, and nanomaterials.
RESOURCES
For a copy of the report, e-mail
your request to Julie Ritchie at julie.
[email protected] and put OEM
Report in the subject line.
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28 07.18.13 MACHINE DESIGN
NAVY UAV SETS ENDURANCE RECORD FOR ELECTRIC DRONES
THE ION TIGER UAV recently completed a record
48-hr, 1-min flight powered by a liquid-
hydrogen-fed fuel cell. The powerplant gives
the aircraft the low noise and IR signature of a
battery-powered UAV and the efficiency of using
high-energy liquid hydrogen and fuel cells.
The plane was developed at the U. S. Navy
Research Laboratory, and the flight broke a
record set by the Ion Tiger in 2009. For that
flight, however, its fuel cell was powered by gas-
eous hydrogen stored at 5,000 psi, and it stayed
aloft for 26 hr and 2 min.
Liquid hydrogen is three times as dense
as 5,000-psi hydrogen gas, which gave the
revamped UAV more endurance. The key to using the
cryogenic hydrogen was development of a lightweight,
insulated, and vented container which could serve
as the fuel tank. To make the technology suitable for
battlefield drones, researchers will need to develop a
portable electrolyzer and compressor to pull hydrogen
out of water and refrigerate it using electricity, possibly
from solar cells or wind turbines.
RESOURCES:
U. S. Naval Research Laboratory, tinyurl.com/cqsewa5
The Naval Research Laboratory flight crew holds the record setting Ion
Tiger UAV.
News
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Mastering challenges together Rexroth makes it easy to implement automation.
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Tough application,
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30 07.18.13 MACHINE DESIGN
News
SAKER-1: Will it be the worlds fastest personal jet?
SEAN GILLETTE, A one-time Air Force pilot, is develop-
ing the Saker-1, a military-style general-aviation jet
that will have a range of 1,600 miles and a top speed of
Mach0.99, or about a mile every 6 sec. The airframe can
withstand +7/3 g, so the pilot can safely execute almost
any maneuver. Gillette and his company, Saker Aircraft
in Los Angeles, have raised almost enough funds to build
prototypes and begin securing FAA and EASA Part 2
certification. He hopes to have certification by 2018 and
start selling the Saker-1 by 2019.
The two-seat jet is powered by two Williams FJ44-4
engines with each putting out 3,600 lb of thrust. That will
be enough to let the jet climb at 12,000 fpm to an altitude of
45,000 ft. The engines are economical in that they can be
used for 5,000 hr before they must be overhauled. The jet
will carry 500 gallons of fuel, giving it a 1,600-mile range. If
the plane is outfitted with two external tanks, each carrying
100 gallons of fuel, the range increases to 2,200 miles. The
aircrafts mileage, which is 20% more than its competitors,
is due to the engines and the planes sleek shape. Between
fuel economy and reduced maintenance, the cost of owner-
ship is estimated to be about $2/mile.
The plane weighs 5,500 lb (empty), but has an
11,500-lb maximum takeoff weight. So it can carry
about 6,000 lb of fuel, crew, and cargo.
Saker insists no military training will be needed to fly
the S-1, which has a cockpit and controls designed to be
handled by any well-trained pilot. Stall speed is about
90knots, and the plane can take off and land at airports
with 1,500 ft of runway. If a potential buyer/pilot is leery
of his or her ability, or the plane itself, they can order
the optional ejection seats.
Gillette plans on building two versions, an executive S-1
for about $5 million and a military version with ejection
seats and a slightly higher top speed (Mach 1.1), for around
$6.5 million. The company is already taking orders.
GO TO MACHINEDESIGN.COM 31
ELECTRIC VEHICLE GOES FOR WORLD SPEED RECORD
DRAYSON RACING TECHNOLOGIES, U. K.,will try to set a new
FIA World Electric Land Speed Record this month
in the under 1,000-kg category. The car, a slightly
modified B12 69/EV, will be driven by Lord Drayson,
the companys cofounder and a one-time science
minister for the U. K. The attempt will take place at
RAF Elvington on the airfields 1.86-mile runway.
The current record, 175 mph, was set by Bat-
tery Box General Electric in the U. S. in 1974. This
record has not been broken in 40 years due to the
challenge of running an electric vehicle consistently
and reliably at such speeds when weighing less
than 2,200 lb. According to Drayson, It is not the
outright speed that is impressive about this record
attempt, but the engineering challenge of accelerat-
ing a 1,000-kg electric vehicle to such a high speed,
sustaining that speed over a measured mile, stop-
ping safely within a relatively short distance, then
turning round and doing it again within an hour.
The B12 69/EV was partially conceived as an
entrant in the new Formula E Series, a new race series
for electric vehicles. The racer generates over 850 hp
and can hit speeds of 200 mph or more. The batteries,
nanophosphate cells made by A123 Systems, West-
borough, Mass., power four rear-mounted, axial-flux
motors. All the motors tractive force gets channeled
through the rear wheels. There is no transmission; a
single reduction gear links the electric drives to the
driveshaft. And batteries are recharged via induction
coils in the floor of the car. These let the car recharge
when parked over a charging pad.
For the record attempt, some changes have been
made to the drivetrain and set-up of the car so that
downforce is minimized. This will give the race car
enough traction to quickly get to its top speed and
stop within the distance available.
GO TO MACHINEDESIGN.COM
News
WHY ORGANIC SOLAR CELLS HAVE LOW EFFICIENCIES
ORGANIC PHOTOVOLTAICS HAVE several advantages over
conventional silicon-based cells. Raw materials and
manufacturing costs are lower, and they generate less
pollution during manufacturing and disposal. But they
are significantly less efficient than conventional cells
(>3% compared to about 15%). Scientists at the Argonne
National Laboratory recently discovered why they lag
behind in efficiency: Traces of the catalysts such as pal-
ladium used during manufacture trap electrical charg-
es the organic cells generate when struck by a photon.
RESOURCES:
Argonne National Laboratory, tinyurl.com/c2b7pcq
Scientists have known for some time that a simi-
lar problem plagues organic light-emitting devices,
which work like solar cells in reverse, turning electric-
ity into light. Its actually a bit surprising scientists
didnt recognize that this problem could also occur in
organic solar cells until recently, says Seth Darling, an
Argonne researcher.
Researchers discovered the trace contaminants by
using high-intensity X-rays from the labs Advanced
Photon Source.
AN AWARD
iGUS, EAST PROVIDENCE, R.I., received
two awards at this years iF product design
competition for its e-spool (a variation on
traditional cable drums) and Triflex TRLF cable
carrier. The iF design awards are sponsored by
iF International Forum Design GmbH, Hannover,
Germany.
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For heavyweight hydraulics that cover the gamut and go the distance, put Continental Hydraulics in your corner.
952. 895. 6400 | www.continentalhydraulics.com
GO TO MACHINEDESIGN.COM
News
THE METEOR
HEARD ROUND THE WORLD
THE METEOR THAT streaked over Russia last February was
heard entering the atmosphere by Georgia Institute
of Technology researchers at Lilburn, Ga., almost
6,000 miles away. They used an infrasound listening
station, one of 400 that make up the USArray in the
Eastern U. S. They heard the sound about 10 hr after
the 55-ft-diameter, 7,000-ton meteor hit the atmo-
sphere going 40,000 mph.
Researchers are sure the sound originated from the
meteor because all 400 USArray stations detected its
movement across North America. The stations mainly
record seismic activity inside the Earth, but they also
pick up ultralong-period sound waves,or infrasound,
such as that given off by the meteor as it traveled
across the Earth. The sound created by the meteor
could also be detected for the 10 hr after it entered
the atmosphere.
The meteor that arced across Russia last February is estimated
to have had the energy of 30 nuclear bombs and it injured more
than 1,500 as it passed. It also created a low-frequency sound
that could be heard 6,000 miles away.
RESOURCES:
Georgia Institute of Technology to see and hear the meteor:
tinyurl.com/bsq3dnn
ANNIVERSARY
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36 07.18.13 MACHINE DESIGN
News
U.S. NAVY PUTS FIRST LASER WEAPON ON A WARSHIP
THE U. S. Navy will deploy a fiber-
optic, solid-state, weaponized laser
onboard a ship next year, two years
ahead of schedule. The weapon is
projected to reduce munition inven-
tories, will be able to fire as long
as the ship has electric power, and
each round costs about $1/shot
(compared to hundreds of thou-
sands dollars for a missile). And
ships neednt carry propellants or
explosives for it.
The new laser weapon developed by the U. S.
Navy was first tested onboard the USS Dew-
ey, a destroyer.
At first, the laser will be used
against incoming missiles, planes,
and boats, working with the Mk 15
Phalanx close-in-weapon system
and sharing its targeting radar. But
the Navy has other plans for it as
well. For example, lasers heat up
targets so IR trackers can more eas-
ily lock onto them. Another ideas is
to have lasers dazzle or blind and
confuse pilots and the electronics on
subs, ships, and aircraft.
The laser, developed at the
Naval Sea Systems Command
Laboratory in Washington D. C.,
will be installed on the AFSB[I]
Ponce 15, the Navys first interim
afloat forward staging base. The
USS Ponce started out as an LPD
(amphibious transport dock) ship
and was originally commissioned
in 1971. Testing and development
will continue, particularly on the
lasers gimbal mount and to ensure
the laser and its optics can with-
stand the ocean environment.
RESOURCES:
Naval Sea Systems Command,
www.navy.mil
For a video of the laser in action,
tinyurl.com/a5kajvw
38 07.18.13 MACHINE DESIGN
News
standard drive, marking the first
time an ABB Drive Series has
reached that production mark.
The 1 millionth body-in-white
Jeep Wrangler JK has rolled
off the assembly line at KUKA
Toledo Production Operations
(KTPO) in Toledo, Ohio. The
company is consistently ranked
among the most-efficient body
shops in the North American auto
industry. KTPO is a wholly owned
subsidiary of KUKA Systems
North America LLC.
PERSONNEL
The Board of Directors of Spirol
International Corp., Danielson,
Conn., has elected Pam Cinami to
serve as a Director for the North
American Operational Board.
Mike Dickson has joined Piab
America, Hingham, Mass., as
Regional Director Americas.
Mr. Dickson was previously with
Kollmorgen, a Danaher company.
ACQUISITION
Autodesk Inc, San Rafael,
Calif., has acquired of Firehole
Technologies (DBA Firehole
Morrisville, N. C., for use with
their high-performance direct and
indirect LED lighting components.
MILESTONES
ABB, New Berlin, Wis., has
produced its 3 millionth ACS550
CHEMICAL-TESTING
PROTOCOL
Henkel Corp., Rocky Hill, Conn.,
is the first adhesives manufacturer
whose Loctite products meet
the stringent chemical-testing
protocol developed by Cree Inc.,
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40 07.18.13 MACHINE DESIGN
News
merger agreement to merge
MakerBot with a subsidiary of
Stratasys
Motion-systems and components
supplier Kollmorgen, Radford, Va.,
has acquired Brazilian-based MCS
Engenharia Ltda., a manufacturer
and system integrator of standard
and customized high-performance
motion controllers and
complementary motion-control
components.
COMPLIANCE
The majority of Agilent
Technologies Inc., Santa
Clara. Calif.,electronic test and
measurement products are now
designed for compliance with
RoHS, the European Unions
restrictions on the use of certain
hazardous substances in electrical
and electronic equipment.
DEVELOPMENT
Experts from TV Rheinland,
Cologne, Germany, and TV
Rheinland Photovoltaic Testing
Laboratory, Tempe, Ariz., have
developed a new solar simulator
that characterizes concentrator
photovoltaic (CPV) modules. The
simulator permits more precise
comparison measurements
because it generates and
maintains 77F (25C) under the
laboratory conditions.
DISTRIBUTION AGREEMENT
Electronic components distributor
Digi-Key Corp., Thief River
Falls, Minn., is expanding its
distribution agreement with
Honeywell Sensing and Control,
Morristown, N. J., to globally
distribute products which
include snap-action, limit,
toggle, pressure, position, speed,
pressure, torque, and airflow
switches.
Stratasys Inc., Eden Prairie,
Minn., a manufacturer of 3D
printers and materials for
prototyping and production,
and MakerBot, Brooklyn, N. Y.
a manufacturer of desktop 3D
printers, have signed a definitive
Composites), Laramie, Wyo., a
privately held software company
that specializes in design and
analysis software for composite
materials. Autodesk develops
