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RS# 111
 May 20, 2010
A Penton Media Publication
Tune in to EngineeringTV.com

WHERE ADHESIVES EXCEL

WITH PLASTICS, page 54

TUBING THAT DOESN’T CHOKE

HYDRAULIC SYSTEMS, page 60

CONNECTORS ARE CRITICAL

IN PORTABLE MEDICAL GEAR,
page 66

PIEZOMOTORS FOR COMPACT

MOTION SYSTEMS, page 72

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RS# 102
 VOLUME 82
ISSUE 9
MAY 20, 2010

INDY 500

DeltaWing Racing Cars

IndyCar 2012 DeltaWing is taking a radical approach on many fronts. In addition to being supported by key IRL
teams rather than an established chassis builder, DeltaWing has pledged an open-source design pro-
cess. Anyone can access the car’s specs and CAD drawings, and anyone can submit original design
ideas.
The concept has produced a radical design, including a 160-lb, 2.0-liter, 300-hp, four-cylinder, turbo-
charged engine, that is projected to weigh 1,030 lb with a driver and cost around $600,000. The engine

the
race is on
and transmission are nonstressed members of the chassis, so the car can accommodate different pow-
ertrains. DeltaWing is pushing for IRL to restrict fuel-delivery rate to the engines and leave other engine
specs up to teams.
The smaller powerplant and mass are made possible in part by bodywork that nearly encloses both
sets of wheels. Distance between front wheels is 24 in. while in back it is 70 in. Cutting the drag of open
wheels, narrowing the track, and beefing up the front fairing, let DeltaWing cut the drag coefficient 60%
to 0.24. Replacing the rear wing with a vertical fin keeps the car stable in turns but doesn’t add drag
on straightaways. And the absence of front and rear wings makes the car less sensitive to “dirty” air
when following closely and leaves a cleaner wake.
Safety, better efficiency, Simulation and full-size wind-tunnel testing confirm that 80% of the aerodynamic downforce acts
on the rear of the car, which also supports 72.5% of the mass. This aero and mass balance give better
and more-exciting racing traction to the 12.5-in.-wide rear tires during acceleration without adding weight. Stability is also en-
hanced by a six-speed, driver-controlled differential with full torque vectoring and active stagger that
are revving up the chassis eliminates the need for different diameters on the inner and outer tires on oval tracks.

FEATURES
Bodywork in front of the front wheels and behind the engine absorbs crash energy to further pro-
tect the driver. Tegris polypropylene composite from Milliken & Co., Spartanburg, S.C., will add impact
designs competing to run at and intrusion resistance without adding weight to DeltaWing’s prototype. Compared to glass and
IndyCar events in 2012. carbon-fiber composites, Tegris resists two to five times the impact energy, has comparable
stiffness, and is easier to manufacture and recycle.

54 Engineering tricks
make parts stick Auto racing is about more than getting cars to go as fast as possible. Premier groups
like the Indy Racing League (IRL) also want to keep drivers safe, fans engaged, and
technology relevant to real-world consumer applications. They also want more
teams competing.
To that end, IRL’s IndyCar chassis is getting a refresh. Officials are hoping to
The field’s two relative newcomers are BAT Engineering, Indianapolis, led
by principals with experience at Lola and other race-car constructors such as
Reynard and March, and DeltaWing Racing Cars, Indianapolis, featuring the
technical head of Target Chip Ganassi Racing which took the IndyCar champi-
onship in 2008 and 2009.

Durable, low-cost, low-surface- choose a chassis and engine platform for the 2012 season by June 1 of this year.
Early this year, IRL President Brian Barnhart outlined what the organization
is looking for in a new car, and designers were quick to respond. Five firms have
entered the competition for the 2012 chassis, including current chassis construc-
Car criteria
IRL clearly set out its expectations for the new car in February. The new
chassis must meet current safety standards, but winning designs need to pro-
tor Dallara, Parma, Italy, and LeMans and ChampCar designer Lola, Huntingdon, pose additional ways to prevent crashes and make them less dangerous for driv-

energy plastics are widely used, 44

Cambridgeshire, U.K. Swift Engineering, San Clemente, Calif., a seasoned design
firm, notably of the current Formula Nippon design, is also developing an entry.

MACHINE Design.com MAY 20, 2010

ers, crew, and spectators.
“It is often said about the 3S of racing — safety, strength, and speed — that

MAY 20, 2010 MACHINE Design.com 45

but engineers must take special

IndyCar 2012: The race is on
care to ensure strong and lasting
adhesive bonds. 44 Race officials are close to choosing
which of five proposed chassis will be
60 Sizing tube lines for
efficient hydraulics
racing at Indy in 2012.

The right size tubing limits fluid-

friction losses that cause pressure MOTORS & DRIVES TECH GUIDE

drop, heat generation and, in

the case of suction lines, pump- Medical-device
damaging cavitation. makers warm up
Connecting with
to piezomotors
66 portable medical devices
Piezoceramic
motors and actuators
avoid several problems
that beset ordinary

Engineers designing connectors motors in medical uses.

Piezomotors
for portable medical equipment
A miniature
streamline medical-
must take into account device performance
Piezoelectric motors and actuators have many advantages
piezo-linear
over conventional electromagnetic (EM) motors for med- motor mounted
ical equipment. Current medical applications for piezoelec- on the left side
tric devices include ultrasonic emitters, artificial fertiliza- of the circuit
tion, medical nanomicroliter pumps, micromonitoring, board can reach

mechanical, electrical, and surgery devices, and MRI-compatible robots. They are
particularly useful for pick-n-place systems as used for
microdose dispensing, cell penetration and cell imaging in
cytopathology, and medical material handling.
velocities of
200 mm/sec.
The right side of
the board holds Fewer mechanical parts to
the motor-drive

safety concerns. Piezoelectric actuators

A piezoelectric (or just piezo) actuator is a solid-state de-
electronics.

vice that uses the change in shape of a piezoelectric material when an electric
field is applied to create motion. A piezoelectric-ceramic element produces
wear out and service as well
mechanical energy in response to electrical signals, and conversely, is capable of
producing electrical signals in response to mechanical stimulus.
The use of piezoelectric materials dates back to 1881 when Pierre and
Jacques Curie observed that quartz crystals generated an electric field when
stressed along a primary axis. The term piezoelectric derives from the Greek
as positioning with higher
word “piezein,” meaning to squeeze or press, relating to the electricity that re-
sults from pressure applied to a quartz crystal.
Piezoelectric ceramics consist of ferroelectric materials and quartz. Piezo-
ceramic elements typically start as high-purity powders of piezo materials such
as PZT (plumbum, zirconate, titanate) that are pressed to shape, fired, elec-
accuracy, it’s no wonder
troded, and polarized. Polarization uses high electric fields to align the material

72 MACHINE Design.com MAY 20, 2010

these little piezo devices
are fast becoming medical-
Ladies and 72 device manufacturers’
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RS# 103
 ON THE COVER
BAT Engineering’s proposed
2012 Indy-car design.

DEPARTMENTS READER SERVICES

Letters to the editor: Please

8 EDITORIAL include your name, address,
The formula for innovation and daytime phone number.
Letters may be edited for brevity
10 EDITORIAL STAFF and to focus on essential points.
12 LETTERS Mail: Letters, MACHINE DESIGN,
18 SCANNING FOR IDEAS 1300 E. 9th St., Cleveland, OH
Using electricity to keep hydraulic and lubricating fluids clean 44114-1503, Fax: 216-621-8469
Medium-pressure ball valve for long-term service E-mail, Editorial:
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Online forums: To comment
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40 BERKE ON SAFETY engineering topics, go to http://
Investigating farm accidents community.machinedesign.com/
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isn’t just child’s play
log in.
42 WORLDS’ SMARTEST Questions about articles:
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STAFF WHAT’S THIS?
When you see a code like this, take Editorial reprints: Contact
95 BACKTALK a photo of it with your smart phone Joel Kirk, 216-931-9324,
(iPhone 3G-S gives best results) and, joel.kirk@penton.com or
using software from www.neoreader.
com, you will be connected to relevant visit pentonreprints.com
content on machinedesign.com List rentals: Marie Briganti,
877-796-6947,
mbriganti@meritdirect.com
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on ebm-papst EC technology, visit www.ebmpapst.us

The engineer’s choice

RS# 104
What’s new online machinedesign.com
NEW VIDEOS
Regenerative drives
Engineers from B&R Industrial Automation talk about regenerative-drive
technology and how it relates to sustainable machine design. The discussion
includes active front ends, power factors, cooling options, and servomotor
considerations, as well as advice on where these drives are best applied.
New tutorials and
Compact-rail technology podcasts on
Most linear bearings must have perfectly parallel rails to run smoothly without Learn Web site
excessive friction or binding, but aligning the rails can be time consuming. An
expert from Rollon Corp. discusses linear-bearing alignment and demonstrates
Learn more about PLCs and other
a new design that reduces the need for highly accurate setups. View these at the
industrial control products with
Videos section of http://machinedesign.com.
several new videos and podcasts
on AutomationDirect’s free self-
service learning site, http://learn.
WEIGHTWATCHER PROTOTYPES automationdirect.com.
Rapid prototyping large models usually means heavy
parts. Solid Concepts has developed a new polymer The Click PLC Series now spans
for a stereolithography process called ID-Light, and it 14 videos, starting with “What is
lets designers build thin layers on an internal lattice. In a PLC?” and progressing through
some cases, it cuts part weight by nearly 90%. See more a hardware overview and system
at http://engineeringtv.com. configuration tips, installing the
FREE programming software,
and creating a simple program.
Other PLC topics include simple
DirectLogic PLC programming
examples and the basics of
Ethernet communications.
Win a trip to Napa! available at www.rittal-corp.com/
Bishop-Wisecarver celebrates its software, helps users select and size Other new videos include a
60th anniversary and is searching for industrial-enclosure coolers for the two-part series on universal
the most-creative application for its best performance and efficiency. signal conditioners. HMI,
DualVee linear-guide wheels. One It determines cooling capacity and drives/motors, motion control,
winner will receive a trip for two to recommends the best cooler, based and sensor overviews are also
San Francisco, Napa Valley, or Lake on factors such as size, ambient available.
Tahoe. All it takes to enter is a 60-sec temperature, humidity, and heat
video, and the deadline is June 15. loss from installed electrical A new podcast presents
EDITOR’S WEB PICKS

For more details, visit http://bwc.com. components. an interview by industry

Innovation tour hits the road
Wago Corp.’s Innovation in
Automation Tour has two vehicles
patterned after trade-show booths
carrying automation, interconnect,
and electronic products across North
America. Each stop features new
products, pick-and-play displays,
interactive demos, and product
samples, along with specialists who
can address specific application
needs. View the schedule or
request a stop at www.wago.us/
innovationtour.htm.
Enclosure sizing software
Rittal’s Therm 6.0 enclosure climate-
control specification software,
High-density flex circuits
Minco’s new brochure and 20-
page test report on high-density
interconnect flex circuits are
available for download at www.
minco.com. The circuits reportedly
save up to 40% of the space and
weight of traditional flex circuits.
expert Dan Hebert with Jeff
Payne, AutomationDirect’s
Programmable Controller
product manager. Hear a
discussion of commercial off-
the-shelf technologies and their
adoption into industrial-control
products.
Visit http://learn.
automationdirect.com to watch
these and other tutorials on a
range of industry topics.

6 MACHINE Design.com MAY 20, 2010

RS# 105
 EDITORIAL

The formula for

innovation
With U.S. unemployment still hovering above 9%, there is a lot of hand
wringing about innovating our way out of economic malaise. If the economy
can create enough start-up companies, so the thinking goes, the benefits will
be enough to swamp out poor policy decisions by politicians who created the
economic mess in the first place.
Alas, no one really knows the formula for mass-producing start-up compa-
nies. Efforts aimed at recreating cradles of innovation like Silicon Valley have
generally produced mediocre results.
So it is useful to analyze parts of the world where start-ups do, in fact, flour-
ish. The country that probably holds first-place honors in this area is Israel,
which has the highest density of start-ups in the world, 3,850 at the most recent
count, one for every 1,844 Israelis.
It is fair to ask what kind of environment breeds these sorts of figures. And
that is what Dan Senor and Saul Singer did in a recent book called Start Up Na-
tion. One thing that becomes immediately clear from their research is that most
countries would have a difficult time duplicating Israel’s prowess at minting
start-ups.
But perhaps the biggest point in Israel’s favor for nurturing start-ups is the
fact that most of its citizens serve in its military, in various capacities, well into
their 30s. For one thing, pervasive military service breeds healthy questioning
of orders regardless of who gives them. One reason: In civilian life, a lieutenant
might well report to one of his sergeants. And Israel’s size (it is a bit larger than the
state of New Jersey) oftentimes forces its residents to pick up multiple skills. Their
jack-of-all-trades mode of agile thinking works well in many start-up settings.
There is one area in particular where the U.S. could learn something from
the factors driving Israel’s start-up mentality. In Israel, a person’s academic past
is often less important than his or her military past, say Senor and Singer. Elite
forces are trained in finding cross-disciplinary solutions to specific military
problems. The same knowledge and experience is ideal, they say, for creating
new companies.
That isn’t to say the U.S. services don’t impart the same kind of training, but,
“When it comes to U.S. military resumes, Silicon Valley is illiterate,” say Senor
and Singer, who go on to remark about the waste of excellent leadership talent
coming out of Iraq and Afghanistan: “The American business world doesn’t
quite know what to do with them.”
A typical experience is that noted by one American vet who managed large
numbers of people and equipment in a war zone. After explaining all this during
a job interview, the response was, “That’s very interesting, but have you ever had
a real job?”
That kind of attitude doesn’t bode well for the 1.4 million U.S. citizens on ac-
tive duty and 800,000 reservists whose military training could help reverse the
current economic gloom.
— Leland Teschler, Editor

DON’T BE A SPOTTER — BE A QUALIFIER!

If you’ve been watching the race for the World’s
Smartest Design Engineer from the grandstands, now
is the time to rev up your engines and hit the track. It’s
fun to watch Automation Boy, NATHAN, nanotube,
and kingph lap each other . . . It’d be even more
fun to beat them!!

RS# 106
8 MACHINE Design.com MAY 20, 2010
RS# 107
 EDITORIAL STAFF
:LL\ZH[,HZ[7HJR)VV[O


Leland E. Teschler, Editor,

leland.teschler@penton.com

Kenneth J. Korane, Managing Editor,

ken.korane@penton.com

SENIOR EDITORS
Leslie Gordon,
Stephen J. Mraz

AUTOMOTIVE &
NEWS FEATURES
Stephen J. Mraz,
stephen.mraz@penton.com

CAD/CAM

We’re Molding This Leslie Gordon,

leslie.gordon@penton.com

ELECTRICAL, ELECTRONICS
One Just for You Robert J. Repas, Jr.,
robert.repas@penton.com

FASTENING, JOINING
As the industry’s largest supplier of product protection, Caplugs offers Jessica Shapiro,
the widest array of sizes and styles to fit your application. Using the jessica.shapiro@penton.com
latest advances in injection molding, vinyl dip molding and extrusion, FLUID POWER
we have the technology and expertise to provide the right standard Kenneth J. Korane,
part or customized solution. ken.korane@penton.com

Whether it’s unique in shape, size, thickness, material or color needed MANUFACTURING
Leslie Gordon,
for your application, or a secondary operation to punch, slice, cut, leslie.gordon@penton.com
print or engrave onto a part – we can solve your needs. Plus, we Kenneth J. Korane,
have the quick turnaround and responsive service you need in today’s ken.korane@penton.com
demanding environment. Contact Caplugs for your product solution.
MATERIALS
Jessica Shapiro,
:4 jessica.shapiro@penton.com
>L»]LNV[L]LY`[OPUNJV]LYLK
MECHANICAL
Kenneth J. Korane,
ken.korane@penton.com
Jessica Shapiro,
jessica.shapiro@penton.com

CONTRIBUTING EDITOR
Victoria Burt, vburt@gmail.com
®
EDITORIAL PRODUCTION
Denise Greco,
Editorial Production Manager
Randall L. Rubenking, Art Director
ÜÜÜ°V>«Õ}ðVÊUÊ1-888-CAPLUGS

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RS# 108
10 MACHINE Design.com MAY 20, 2010
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RS# 109
 LETTERS
A dogfight over
light aircraft
I generally read Mr. Berke’s safety
column and find it informative.
I am an aeronautical and me -
chanical engineer and have been
looking into doing some foren-
sic-engineering work, so I’m at-
tending meetings of the National
Academy of Forensic Engineers.
However, I was disappointed
that Mr. Berke didn’t address
one of the points made by Mr.
Brian Winter in his letter to the
magazine (“Engineers and liabil-
ity,” Letters, March 18), namely,
the destruction of the American
light-aircraft industr y by law-
suits.
Safety is important, but so is
the recognition that lawsuits are
sometimes settled unfairly due
to lack of understanding by juries
and a plaintiff’s attorney’s overly
aggressive sense of justice.
%*$#4
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Does liability set
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A reader takes issue with our safety
columnist’s views on whom to blame
for the demise of the general aviation
industry.
I was professionally involved for the manufacturer was a small
as a designer and chief engineer percentage of the cost of each
in four light-aircraft companies, unit.
so I have some relevant knowl- But between 1975, when strict
edge and experience in the area. liability reform began, and 1985,
For approximately 50 years — the cost of that same airplane
from 1925 through 1975 — the soared to 10 to 20 times the cost
cost of a starter small airplane, of a Cadillac or Lincoln while the
was approximately the cost of a cost of liability insurance became
Cadillac or Lincoln car. And dur- nearly 50% or more of the selling
ing that time, the U.S. dominated price. In the same period, the to-
the manufacture and use of light tal output of the industry went
aircraft. The country built about from approximately 25,000 units
25,000 aircraf t per year from per year to under 1,000.
1965-75. And liability insurance Surely 50 years of fine prod-
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RS# 110
12 MACHINE Design.com MAY 20, 2010
 A dose of sealing solutions.

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Now accepting
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RS# 111
 LETTERS
ucts didn’t become hazardous
overnight. As Mr. Winter inferred,
many of those same aircraft, now
35 to 60 or more years old, are
still safely flying.
The same thing has happened
to the medical profession. I know
excellent doctors who are ready
to just quit rather than fight the
lawyers.
I believe in safety and safe
products, but something has to
be done. The only real produc-
tion of wealth is manufacturing,
making something of more value
from something of lesser value.
Transferring large amounts of
money to the pockets of lawyers
adds nothing to the well-being
of the country as a whole.
As I get into forensic engi-
neering, my skills will be used
to defend manufacturers where,
in my opinion, they are unfairly
targeted.
Roland Friestad
It is my general opinion that the
light-airplane industry brought
their problems onto themselves by
not putting out good, safe prod-
ucts, and that the FAA let them do
that.
Let me give you an example of
my experience. I am a licensed pi-
lot with an instrument rating, even
though my medical is not up to
date.
Many years ago I flew my wife
and another couple to another
city and back. The aircraft was a
Cessna 172. Part way into the first
leg of the flight, my seat lurched
forward and I was laying against
the yoke (steering wheel for those
of you who are not familiar with
aircraft). I was at a safe altitude
so everything was all right, even
though I was startled. We landed
and I checked out my seat but
couldn’t find a problem.
On the flight home, it happened
again. Again, I was at a safe alti-
The exact automation products you need, faster.
tude, but I was getting concerned.
When I arrived at my home airfield,
on final approach and about 100
feet off the ground, it happened a
third time. Because I had just gone
through this twice before, I was
able to properly land the aircraft
and taxi to the hangar. I asked my
friend who has been sitting behind
me what was going on. She told
me her leg was cramping on her
and she was stretching her leg out
each time my seat was released.
I checked out my seat from the
back seat and found I could reach
under the front seat and release its
locking mechanism.
When I got home, I wrote a let-
ter to Cessna and the FAA describ-
ing the events, and recommended
a steel plate be required to cover
that opening so no one could inad-
vertently release the seat-locking
mechanism. I received letters from
both Cessna and the FAA telling
me the problem that I had identi-



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RS# 112 Contact us with your application:

SENSORS | NETWORKS/FIELDBUS | RFID | CONNECTIVITY | INTRINSIC SAFETY 1-800-544-7769


 
 
www.turck.us
 Well-connected.

Newark has the best connections. All the top the connector you need for your application.
connector brands are in stock and ready to ship And you’ll find it fast.
to you today: Molex, Amphenol, Tyco Electronics, Learn more at www.newark.com/connectors
AVX, 3M, FCI and many more. So you’ll find just or contact us at 800.463.9275

A Premier Farnell Company

© 2010 Newark, a trademark of Premier Farnell Corp. All other trademarks, registered or unregistered, are the property of their respective holders. DESIGN WITH THE BEST
RS# 113
 LETTERS

fied was not actually a problem
at all.
A few years later, the FAA issued
a directive that the open space that
let a back-seat passenger release
the front seat locking mechanism
be blocked with a steel plate.
I wonder how many people were
killed by this design flaw and the
FAA called it pilot error. This was
only one problem I ran into, but
there were others that Cessna and
their suppliers should have found
and not relied on the public to be
their test laboratory.
Now it appears the light-air-
plane manufacturers have their
act together with one possible ex-
ception. I do not see any reason
for general-aviation aircraft to be
priced at $250,000 to $500,000
other than to give the companies
huge profits on the sale of each
aircraft.
You make one very good point:
Over a 50-year span, general-avi-
ation aircraft did not suddenly be-
come hazardous. They were haz-
ardous all along. — Lanny Berke
Mr. Berke:
Your experience, while extremely
serious and certainly deserving
of immediate correction by the
manufacturer, doesn’t seem to me
to warrant an across-the-board
statement that light aircraft were
“hazardous all along.” On the other
hand, flying does have inherent
hazards, but to make a blanket
condemnation of the industry be-
cause of your single case seems
pretty short-sighted.
I do know of cases of design
or manufacturing flaws that have
resulted in injury and fatalities
and they are tragic and highly
regrettable. These are far out-
numbered by deaths and injuries
caused by flying under the influ-
ence of alcohol or drugs, “shade-
tree” maintenance, and just plain
lack of judgement on the part of
pilots. Statistics bear this out.
Any such design flaws I discov-
ered while in charge of aircraft
manufacturing were corrected as
soon as possible. I was not always
popular with the front-office man-
agement and “bean counters” but
always had the full cooperation of
the FAA in any such matters.
I, too, am a licensed pilot and
owned a Cessna 172 for many
years. I never ran into the situa-
tion you describe, or any others
that I could attribute to design
deficiencies. (And Cessna was not
one of the companies for which I
worked).
The huge profits to which
you refer are only in your mind.
Any light aircraft company that
makes even a 5% profit considers
itself very fortunate.
It is obvious to me that we
must agree to disagree.
— Roland Friestad

O innovative electric systems are being used to upgrade gas spring

Our
an
and manual operations, and due to their simplicity and state of the art
de
designs, are rapidly replacing hydraulic and pneumatic systems.

LI
LINAK has a selection of reliable actuators to provide your application
th
the movement you desire.

Visit our website for our complete product range: www.linak.com

V

+(- *Ä4 2 Ä(MB ÄlÄ-NQSGÄ@MCÄ2NTSGÄ

LINAK U.S. Inc. lÄ-NQSGÄ@MCÄ2NT
NTSGÄ LDQHB@MÄ'D@CPT
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RS# 114
16 MACHINE Design.com MAY 20, 2010
[ MOTOR TRUTH #2 ]

Can I really save

money by installing
a smaller motor?

The truth? You just might be able to. If you look at

your entire drivetrain, you’ll probably find that if you
replace inefficient components (which can waste
up to 50% of the energy they use), you’ll be able
to install a new, smaller, high-efficiency DR motor
and still get the power output you need.

And, you’ll save energy at the same time, because

your current oversized motors may be wasting
energy to overcome the inefficiencies of your
entire drivetrain.

SEW’s new DR motor series is specifically designed

to work with a total system, including our helical
bevel gearboxes and electronic drives, to provide
you with maximum energy savings. Get the
whole story and learn how the DR motors are
the newest piece of the energy savings puzzle
at sewmotortruth.com.

sewmotortruth.com

RS# 115
 SCANNING FOR IDEAS
Edited by Stephen J. Mraz

Using electricity to keep hydraulic

and lubricating fluids clean
Mechanical filters have been
around for centuries, and Electrical
modern ones can keep hy- Overpressure Customer
controls and power
draulic and lubricating fluids bypass indicators
clean of particles larger than Inlet
5 microns. But particles smaller shutoff
than that slip by and create valve
sludge and varnish, damage Inlet
strainer Outlet
equipment, and drastically
shutoff
reduce the life of the fluid. Bal- valve
anced Charge Agglomeration,

Charging mixing
Prefilter vessel
a new fluid-purifying approach

Collection
from ISOPur Fluid Technolo-

vessel

0.5-in.
gies, North Stonington, Conn.
(www.isopur.com), helps inlet Pump/
filtration systems capture all
impurities by forcing smaller
particles to clump together,
thus making them “more eas-
ily removed by mechanical
filters.” This extends the life of the fluid and equipment,
and reduces maintenance, downtime, and defects due to
faulty machinery. It also means companies don’t have to
dispose of as much dirty oil as they once did.
The new method splits fluid flow into two streams.
One stream receives a strong positive voltage, giving
particles in that stream a positive charge. The other
stream gets a negative charge. When the streams re-
join, the positive and negative particles are attracted
to each other and clump together, forming ever-larger
particles that can be picked out by a mechanical fil-
ter. This works on sludge and ferrous and nonferrous
metal particles, as well as insoluble oxides and bio-
vessel
0.5-in. outlet
motor
Vent
sample
Drain Drain Drain
logical contaminants. And in the case of oil, once it is
clean, it acts as a strong solvent to break down varnish
and sludge, preventing valves from sticking and let-
ting machinery run properly.
The company makes several models with flow
rates ranging from 30 to 1,200 gph. They attach
to lubricating or hydraulic lines via a kidney-loop
hook-up to process fluid. It works on lubricating,
hydraulic, and machine oil, EDM and dielectric flu-
ids, vegetable oil, and phosphate ester, along with
many other nonconductive fluids.
RS# 401

Incoming fluids contain Particles are given a Negatively and positively

many particles too small +Vdc positive charge. charged particles clump
to be extracted together, becoming large
by mechanical enough to be filtered out by
filters. mechanical means.

Fluid flow Fluid flow

Particles are given

–Vdc a negative charge.

18 MACHINE Design.com MAY 20, 2010


Toggle Clamps with Safety Locks.
Carr Lane has introduced a variety of
new toggle clamps with optional
safety locks, including latch-action,
vertical-handle, horizontal-handle, and
push/pull types. All Carr Lane toggle
clamps have a comfortable handle
grip, in steel or optional stainless.
Carr Lane Mfg. Co., www.carrlane.com
RS# 193
Knobs, Handles, Hand Wheels. Need
to take hold? A variety of knobs,
handles and hand wheels, in metal or
plastic, are available from Carr Lane.
Many new items.






Carr Lane Mfg. Co., www.carrlane.com
Simple and Versatile...
Match Threaded Detent Pins
With A Variety of Knobs
Versatile threaded detent pins can be
fit with a wide selection of knob han-
dles for your application. These solid
quick-release pins have a ground
shank and a threaded end. Shank di-
ameters are available from 3/16" to
1/2", along with metric sizes, and grip
lengths from 1/2" to 4". Pins come with
built-in locking balls, which are held in
place by spring force — push to insert,
pull to remove.
Threaded detent pins are
available in stainless steel.
Knob handles can be or-
dered in steel, stainless
steel, or plastic.
Carr Lane has dozens of
alignment pin types






RS# 194 

























RS# 116

Hoist Rings. What an assortment!
Pivoting, swivel, and side-pull swivel
hoist rings, along with lifting eyes.
Choose from low profile versions to
heavy-duty, extra large hoist rings
with load capacities up to 250,000 lbs.
Carr Lane Mfg. Co., www.carrlane.com
Carr Lane has the best selection of ball lock and detent pins, as
well as dozens of other alignment pins for manufacturing.
Carr Lane offers standard components to help you increase
quality and productivity. Visit CarrLane.com and search
our online catalog for alignment pins and any of our
100,000 other products.
MANUFACTURING CO.
4200 Carr Lane Ct., P.O. Box 191970
St. Louis, Missouri 63119-7970
Phone: 314-647-6200, FAX: 314-647-5736
R

RS# 195 ISO 9001-2008 CERTIFIED Web Site: www.carrlane.com

 SCANNING FOR IDEAS

via
e e in f o rmationite at
tf r b s
Requesder Service We
Medium-pressure ball valve o u r Re a n.c om/rsc
achin edesig
for long-term service w w w.m

Stem and end-connection seal

maintains full pressure rating
throughout operating temperature
range. It also reduces seal wear.

Trunnion-style ball with direct-

load design reliably seals across a
full range of pressures.

Engineers at Swagelok, Solon Ohio (www.swagelok. Positionable Bottom-

com), have expanded the company’s FKB line of handle with loaded
medium-pressure ball valves by adding one capable of stop disk stem
handling pressures up to 15,000 psig. The 8FKB design
eliminates
two-way ball valve features a 316 stainless-steel
stem
body with reinforced PEEK seals. It blowout
operates in temperatures from 0 and
to 250°F (–17 to 121°C). And users enhances
have a choice of several O-ring ma- operator
terials, including nitrile, fluoroelas- safety.
tomer, and perfluoroelastomer.
It takes relatively little torque
to actuate the valve, and if pneumatic actua- End connections reduce
tion is required, the company makes ISO-5211- installation time and costs.
compliant actuators. The positionable handle They also resist vibrations.
gives users flexibility in laying out control pan-
els by reducing clearances with other components.
RS# 402

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RS# 117
20 MACHINE Design.com MAY 20, 2010
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RS# 118
REPORTER’S NOTEBOOK

Steam treating hay

makes it easier to bale
A farm manager has developed
a machine, the DewPoint 6110,
that frees farmers from rely-
ing on Mother Nature to make
their hay suitable for baling.
Until Dave Staheli and his firm
Staheli West, Cedar City, Utah,
developed the DewPoint, farm-
ers had to wait for the right
dew conditions to moisten hay
enough so that the nutritious
leaves wouldn’t fall off during
baling. Too much dew, or worse,
rain, and the hay is too wet.
Not enough dew, and most the
leaves end up on the ground, The DewPoint 6010, the red trailer between the tractor
and the baler, injects low-pressure steam into the hay
not in the bales. as it passed through on the way to the baler.
Inspired by a tortilla warmer
that used steam, Staheli built a
device that injects steam into
the hay as it is picked up. The 12 to 15% while baling. And the technical support, and the wide
wheeled machine rides between pressure exerted by the walls of variety of single-sourced com-
the tractor and baler. It includes the baling chamber (bale-cham- ponents the firm offers that work
a low-pressure boiler to make ber pressure) correlates well with well together. The machine also
steam, along with water and fuel bale moisture levels. incorporates an OnCell Cellular IP
tanks, a generator, water-feed Staheli chose controllers from modem from Moxa, Brea, Calif. It
system, and a DirectLogic DL06 AutomationDirect based on price, lets farm managers remotely mon-
PLC controller from Automation-
Direct, Cumming, Ga. There’s also
a C-More touchscreen control
panel, also from Automation-
Direct, in the tractor’s cab. The A touchscreen
controller in the
screen lets the driver control ev- tractor’s cab
ery aspect of the DewPoint, from lets the driver
start-up to shutdown. monitor and
The PLC controller accepts doz- adjust a variety
ens of discrete and analog inputs, of variables in
including boiler parameters, bale the DewPoint
temperature, and crop flow as 6010.
it moves through the DewPoint
Hay Baler. Based on these vari-
ables, especially bale chamber
pressure, the PLC determines the
right amount of steam to inject
via several distribution manifolds
mounted in the hay baler. The goal
is to get hay to moisture levels of

22 MACHINE Design.com MAY 20, 2010

The DewPoint 6110 s t f r e e
tion via
informaeb site at Simulation
Reque der Service W
adds the ideal amount o u r Re a
esig n.com/r
sc unlocks the
a chined
of moisture to make w w w.m mysteries of
perfect bales of crack formation
AuomationDirect, www.
hay anytime automationdirect.com Research physicists at Northeastern
Univ. in Boston using large-scale
Circle 406
Moxa, www.moxa.com computer simulations have finally de-
Circle 407 termined how cracks form and grow
Staheli West, www.staheliwest. in materials such as steel, glass, nano-
com Circle 408 structures, and human bone. “The
simulations help us understand what
path cracks follow as they propagate
when needed. in a stressed material,” says team
Farms equipped with a Dew- lead Alain Karma, director of North-
Point 6110 can bale any time of eastern’s
day or night, providing it isn’t rain- Center for Center for
ing and there isn’t too much dew Interdisciplinary Research Interdisci-
on the fields. In the past, farmers on Complex Systems, plinary Re-
had to wait for the right weather, Northeastern Univ., search on
then put a tractor and baler in the www.circs.neu.edu Complex
field to bale 40 to 60 acres. This Systems.
means medium-sized hay farms “This is
(2,000 acres), often needed four useful in developing materials for
sets of tractor and balers, with each aircraft turbine blades, microelec-
baler rig costing $250,000. And tronic circuits, and artificial bone that
in the course of a year, each baler can better resist crack formation and
itor and control several DewPoints might operate fewer than 100 hr. propagation.”
simultaneously. This is helpful In contrast, the DewPoint lets hay Researchers began by examining
when a farmer has inexperienced farmers cut their capital costs from the effects of two types of stress on
operators out in the field carrying 1 million dollars to $400,000. It also crack propagation: shearing and ten-
out baling operations. It lets the gives them much more latitude in sion. Shearing causes two contacting
farmer “look over the shoulder” of when they harvest and bale hay. layers to slide upon each other in op-
new operators and offer advice Not only is baling less expensive posite directions and parallel to the
and more conve- plane of contact. It happens when
nient, studies done material is twisted out of shape. The
Why wet hay bales are at the University of combination of shearing and tension
Wisconsin found initiates cracks.
fire hazards that leaf loss on hay Large-scale computer simulations
It seems counterintuitive that bales of wet hay baled with a Dew- revealed the surprising result that
can turn into fire hazards when packed into a barn, Point is only about shearing and tension cause cracks to
but it’s true. half that of hay baled take the shape of a helix. Based on
When hay is cut, it is not killed. The plant cells still breath at night during prime the results, the researchers developed
and metabolize, releasing heat into the bale. This is usually dew conditions. a theoretical equation to predict how
no problem other than the bales lose nutritional value. Using the machine the helix would rotate, expand, and
But if the bales’ internal temperatures are high enough, costs between $1 multiply in different materials.
and there’s enough moisture, bacteria on the hay can feed and $1.25/ton of hay, This research could lead to lighter
and multiply, bumping up temperatures to about 135°F. and that includes automobile and aircraft parts, and
These temperatures, along with excess water, make prime chemicals to treat composite artificial bones that don’t
breeding grounds for another form of bacteria which can, the boiler water, and fracture. The results are also providing
in turn, convert the hay into a porous carbon sponge and diesel fuel for the insight into the evolution of geologic
raise temperatures inside bales to 170°F. If this hay is then generator and to tow faults and fractures in the Earth’s
exposed to oxygen, it can self-ignite. the DewPoint. MD crust. MD

MAY 20, 2010 MACHINE Design.com 23

 REPORTER’S NOTEBOOK

Enhanced driver’s seat comfort is

in the bag — with polypropylene felt Alfmeier Präzision,
www.alfmeier.de
Fabrico, a division of
EIS, www.fabrico.com
Engineers in the Seating Comfort business unit of Alf-
Circle 409
meier Präzision AG, Treuchtlingen, Germany, ran into
a problem with lumbar-support devices they supply
luxury automakers like BMW. The modular subsystems
give the driver electropneumatic control over the Alfmeier took
seat contour with massage and memory func- the problem and a
tions, but the units were failing prematurely sample of a high-
and damaging adjacent seat foam. performance, high-
The electropneumatic, valve- cost material that met
driven unit lets the driver de- their needs to Fabrico,
termine the amount of air Kennesaw, Ga. Ultimately,
that inflates a rubber- Fabrico engineers recommended
bladder assembly, encasing the existing bladders in a
controlling softness “bag” of polypropylene felt.
and back support. The durable, silky material is commonly
The entire lumbar used as a filter in pharmaceutical, beverage,
support is composed and fuel applications. In addition to withstand-
of three 18-gage-thick ing inflation-deflation cycles of the bladders, the felt
bladders welded into a 414 meets U.S. and international supply specifications
× 54-mm assembly. It must The for flame retardancy of interior trim materials in pas-
perform reliably for 10,000 lumbar senger cars, multipurpose passenger cars, commercial
inflation-deflation cycles with a subsystem vehicles, and buses.
normal operating pressure of ap- developed by Fabrico engineers proposed four die-cut felt pieces
proximately 4.4 psi and hold 12 psi Alfmeier Präzision be wrapped around and between the lumbar bladders
for front seats in
without bursting. luxury cars uses
and sewn into a bag that would glide over the seat-
Alfmeier engineers discovered an air-actuated cushion foam instead of abrading it.
bladders rubbing against the foam polypropylene Currently, Fabrico procures the material, die-cuts
of the seat cushion caused prema- bladder that can and orients the parts, and ships kits from its plant in
ture wear to both the foam and be inflated and Ontario, Calif., to one in Monterey, Mexico, near the
the bladder, noise, and problems deflated at least Alfmeier assembly facility in Apodaca where the final
adjusting the back support. They 10,000 times. wrapping and sewing is done.
needed to isolate the bladder from The arrangement gave Alfmeier a local supplier,
the foam without affecting the and polypropylene felt cut the cost of protecting the
inflating and deflating process and lumbar support bladders while extending bladder life.
still meet customer flammability Lower costs made the system more attractive to cus-
standards. tomers, including Mercedes. MD

C A G E C o d e 5 V 12 2
Aerospace,

Precision
Medical, and
Defense
S PE C IALI STS

Bearings
sCustomer Focused and Solutions Driven
sDomestic and High Quality Imported Bearings mdsales@nationalprecision.com
www.nationalprecision.com
sSupply Programs Available for Manufacturers of all Sizes 800-426-8038

RS# 119
24 MACHINE Design.com MAY 20, 2010
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RS# 120
 THE
STRONGEST, REPORTER’S NOTEBOOK

MOST
DEPENDABLE Hydraulics researchers
BEARINGS stress energy efficiency
Energy efficiency was the focus
of the 7th International Fluid
Power Conference, held recently in
Aachen, Germany. So it’s not sur-
prising that many of the technical
discussions centered on hydraulic-
hybrid vehicles (HHVs).
HHVs offer greater power den-
sity than electric hybrids and are
therefore more efficient at recover-
ing and reusing braking energy,
explains Larry Hartter of FEV Inc.,
Auburn Hills, Mich. While electric
hybrids typically return 30% or less
of the braking energy back to the
wheels, hydraulic hybrids can re-
turn as much as 70%.
However, with R&D progress-
ing on several fronts, there is no
consensus on the best HHV design.
FEV favors serial hybrids. These typ-
ically have one or more pump/mo-
Symmco Sintered Bushings tors (P/Ms) connected to the driv-
At Symmco, Exceed The Standards
customer ing wheels, a P/M connected to the
satisfaction is internal-combustion engine, along
our priority. with interconnected accumulators.
Our unyielding There is no direct mechanical link
commitment to between the engine and wheels.
quality ensures When compared with other
that a wide designs, the series hydraulic hybrid
range of exceptional, long-lasting powder metal offers better fuel economy than
bearings and bar and plate stock will be readily parallel (launch-assist) hybrids
available when you need them most, including
that only recycle braking energy,
24-hour delivery when required.
says Hartter. And series hybrids
In addition to offering the largest inventory of eliminate the additional costs and
oil-impregnated bronze bearings and bushings in weight of hydromechanical (power
North America, Symmco also stocks:
split) hybrids.

1,000 sizes of sleeve flange and thrust washers
Though the series hybrid recov-

200 sizes of bars (cored and solid) in bronze
ers braking energy, decoupling the
and iron/copper
engine from the wheels is the pri-

50 sizes of bronze plate stock
mary reason for a series HHV’s high
Make Symmco Your One-Stop Solution fuel economy, says Hartter. This lets
the engine operate where it is most
efficient, that is, at higher torque
with fewer engine transients.
Your Key To Quality & Savings
RS# 121
Initial road tests of a hydrau-
lic-hybrid delivery vehicle work-
40 South Park St. Sykesville, PA 15865


ing a typical route in Detroit
ils
AV S
Eaton, www.eaton.com
Circle 410
FEV, http://fev.com Circle 411
Lumex, www.lumex.biz
Milwaukee School of Engineering,
www.msoe.edu
Parker Hannifin, www.parker.com
Circle 412
Voswinkel, www.voswinkel.net
transit buses, says Hartter.
Although fuel economy is the key
driver behind hybrid technology, pro-
ductivity and drivability demand equal
billing, says Andreas Johansson with
Parker Hannifin AB, Trollhättan, Swe-
den. Parker’s RunWise hydraulic-hybrid
transmission addresses those issues,
he says, and reduces fuel consumption
from 30 to 50% in Class 8 refuse ve-
hicles, compared to baseline vehicles.
The RunWise transmission has a
two-speed hydrostatic drive for ur-
ban driving combined with mechani-
cal direct drive for efficient operation
at highway speeds. It also has high-
pressure accumulators that capture
braking energy and reuse it to help
accelerate the vehicle. A digital con-
troller handles pump/motor opera-
tion, gear shifting, and accumulator
charging and discharging, as well as
operations of the diesel engine.
Compared with conventional
trucks, tests show the RunWise trans-
mission accelerates refuse trucks
faster without affecting fuel savings,
says Johansson. There is also less
brake wear, thanks to hydraulic-
energy recovery, and less noise. The
RunWise should pay for itself in fuel
and maintenance savings in 4 to
5 years, says Johansson.
Vincent Duray of Eaton Corp.,
Eden Prairie, Minn., explained the

Phone (814) 894-2461

ues pon ial O
AIL TO

demonstrated a 45 to 50% de- advantages of its parallel-hydraulic

Req able U Spec

FAX (814) 894-5272

AB CK

il d

www.symmco.com crease in fuel consumption. This hybrid called Hydraulic Launch

Ava ing An
LE

sales@symmco.com
FR

shows that series hybrids are a Assist (HLA). It contains hydraulic

kag
OM

Pac

viable option for commercial ve- components and controls similar to

WE MANUFACTURE hicles such as delivery trucks and those in a series hybrid. However, it
EVERYTHING WE SELL
26 MACHINE Design.com MAY 20, 2010
RS# 122
 REPORTER’S NOTEBOOK
augments, but does not replace, a
truck’s existing drivetrain.
Parallel hybrids use regenera-
tive braking to improve fuel econ-
omy in refuse trucks by 15 to 30%,
based on duty cycle, says Duray. It
also reduces brake wear.
Although a series hybrid saves
more fuel by managing engine
speed, admits Duray, parallel hy-
brids offer several advantages. For
example, it readily retrofits to exist-
ing vehicles. HLA’s modular design
lets it install in new or existing
vehicles without extensive altera-
tions or design changes to other
major vehicle subsystems. Parallel
hybrids connect to the vehicle’s
drivetrain between the transmis-
sion and differential.
Parallel hybrids also improve
acceleration and significantly
reduce heat generation, engine-
power output, and loads on the
torque converter and transmission.
This reduces failures in driveline
components or, as an alterna-
tive, permits smaller components
that lower initial investment and
weight. And the vehicle continues
to function even if the hybrid sys-
tem fails.
As noted previously, hydraulic-
hybrid vehicles and many other
machines rely on hydropneumatic
piston or bladder accumulators
to recover and reuse energy. But
under a wide range of operating
conditions, thermal losses in the
accumulators themselves can be
substantial, explains Alexander
Stroganov of Lumex Ltd., St. Pe-
tersburg, Russia.
His company has developed a
fluid-power storage device that
significantly reduces thermal
losses. Called a compressible metal
regenerator, it provides nearly
isothermal gas compression and
expansion. The design relies on a
series of flexible-metal leaves di-
viding the gas reservoir within an
accumulator shell — a design read-
ily manufactured via conventional
methods, says Stroganov.
Segmenting the gas volume
into thin layers with metal ele-
ments, he explains, improves heat
RS# 123
transfer and reduces temperature dif-
ferences. This increases reversibility
of gas compression and expansion
and, therefore, efficiency. Test results
in work cycles typical of hydraulic-
hybrid vehicles show the regenera-
tor’s power efficiency was in the 97%
range, versus about 80% for gas/oil
accumulators.
Hybrids weren’t the only focus at
Aachen. Engineers from Voswinkel
GmbH, Meinerzhagen, Germany,
introduced a new type of hydraulic-
hose fitting that reportedly improves
flow efficiency in hydraulic circuits.
They note that standard fittings,
when crimped, slightly collapse the
nipple and restrict the ID. The compa-
ny’s new uvos-m fittings have a cor-
rugated socket that, when crimped
onto hose, tightly grips the reinforce-
ment without nipple ID collapse, ac-
cording to the company’s Fritz-Georg
Weiland.
In size DN 19, the fittings increase
internal-flow area about 10%. For
flow rates of 200 lpm, pressure losses
drop by 24% in the DN 19 and by
34% in DN 25 fittings. On a mobile
machine with just two hydraulic
lines, the DN 25 uvos-m can save
about 130 liters of fuel/1,000 hr of
operation, says Weiland.
Even the type of fluid makes a
difference. Paul Michael of the Mil-
waukee School of Engineering ex-
plained that although straight-grade
hydraulic fluids are used in many
fluid-power applications, multigrade
hydraulic fluids are a better choice
in commercial vehicles and mobile
equipment where temperatures vary
widely. Even though they cost more
than straight-grade fluids, savings
with these so called energy-efficient
hydraulic fluids can be substantial.
At low temperatures, multigrade
fluids reduce hydromechanical losses
due to viscous drag. And at high
temperatures, volumetric efficiency
improves in many kinds of pumps.
Field trials in skid steer loaders and
excavators show this equates to
fuel-efficiency improvements of 14
to 22%, and machine productivity
improves as well. Savings are said to
exceed 10,000 Euros over the life of
the fluid. MD
RS# 124
 REPORTER’S NOTEBOOK

Software automates back-of-

the-envelope calculations
An engineer used Grafi-
Calc simulation software
to define the concept for
a machine intended to
punch-out dog-food bis-
cuits. The software lets
users “premodel” designs
before CAD by drawing
skeleton geometries that
represent the design’s
functional intent — not
its form. The process has
been likened to sketch-
ing on the back of an
envelope. GrafiCalc simu-
lates and solves kinemat- The GraphiCalc sketch captures the machine’s four-
bar linkage using lines (not the complete geometry
ics. It also handles static of the lapper arm). The geometry of the mechanism
and tolerance stack-up was back-solved using inverse kinematics to
analyses and includes a establish a constant velocity for the end of the
geometry Goal Seek fa- lapper arm, point C.
cility that helps optimize
designs in terms of shape, posi- was to establish equations for
tion, and fit criteria. servomotors so the bottom end of
The initial challenge in the de- a lapper arm moved at a constant
sign of the dog-biscuit machine velocity as a punch lowered. The

Wind-powered car goes for a

speed record
The world record for a wind-powered car is 126.1 mph, set last year by Brit-
ish engineer Richard Jenkins on a stretch of the Mohave Desert near the
California-Nevada border. But if engineering students at Lehigh Univer-
sity have their way, that
record won’t stand much
longer.
Their design for a
“land yacht” features not
sails but tall, inwardly
canted wings. According
to the student design-
ers, the yacht magnifies
wind speed by keeping
a narrow angle between
its vertical wings and
the wind direction. The
smaller the angle, the
more speed a yacht draws
from the wind. As the

RS# 125
30 MACHINE Design.com MAY 20, 2010
 Geomate Co., www.
inventbetter.com
Circle 413

engineer first sketched the skel-

eton geometry and constrained
it to reflect functional intents. The
engineer then back-solved the
geometry of the mechanism using
inverse kinematics to establish a
constant velocity for the end of the
lapper arm. He imported transient
values for the actuator’s length
into Excel to develop servomo-
tor equations. The software thus
helped conceptualize, analyze,
and validate critical engineering
parameters in the earliest stages
of design.
According to the engineer, the
analysis took about an hour to get
a solution with GrafiCalc. In con-
trast, he estimates a design time of
about one month using the “build-
RS# 126

3
test-fix” method with a midrange
CAD package and a motion-sim-
ulation add-on and data-analysis
software. MD

The Power
of
V

BEI Industrial
Encoders
Lehigh
University, www.
V V

lehigh.educ BEI Duncan

yacht moves, however, the wings BEI Ideacod

generate a force perpendicular
to the wind direction. The yacht’s 


   
 
 

wheels must counter this side
force to keep the vehicle running

 
 

straight. So students are busy   
 

 



designing tires and a suspension
that will supply this counter force 
 
but not increase drag or friction
enough to slow down the yacht.
The wings mount 15 ft from the
main fuselage. This configuration
should give pilots better aerody-
namic control over pitch, roll, and
yaw, the student designers say. MD  
  

RS# 127
MAY 20, 2010 MACHINE Design.com 31
 Customized
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154 Hobart St., Hackensack, NJ 07601

TEL: 201-343-8983 ) FAX: 201-343-2132
www.masterbond.com ) main@masterbond.com
RS# 128
 REPORTER’S NOTEBOOK

New Way Air Bearings,

Air bearing gives engineering www.newwayairbearings.com
Circle 414
students a feel for electronics
Not many engineering students have New Way Air Bearings,
an intuitive feel for the way capaci- Aston, Pa., fit the bill. Com-
tors, inductors, and resistors work pressed air sent to the
together in viscously damped bearing disperses between
systems. To give them that kind of the bearing and the surface
understanding, a professor at the through a carbon material
Massachusetts Institute of Tech- with thousands, perhaps
nology developed a lab curriculum millions of holes. This even
that explains electrical components dispersion of air gives the
in terms of their mechanical corollaries: bearings almost zero friction.
masses, springs, and dampers. But to The bearings are also relatively
make systems of mechanical and elec- inexpensive yet durable enough to
trical components more analogous, stand up to daily student use. They
the professor needed a zero-friction are also easy to use and align and
bearing. Using off-the-shelf roller bear- can be quickly set up and broken
ings, even those with the lowest rolling down, a must for lab setups that
frictions, would not work because even change every week. The bearings
that small amount of friction masks the also provide translation and rota-
effects of damping. tion motion. MD
Porous-media air bearings from

Vertical Motion Arms

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Any workspace. And any operator. Hoffman® SYSPEND™ offers:
Hoffman® Brand SYSPEND™ Vertical Motion Arms quickly field-adjust for different -
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RS# 129
©2010 Pentair Technical Products
 REPORTER’S NOTEBOOK
LOOKING BACK
10 YEARS AGO — 2000 of desktop will feature a seven-port universal serial
IBM rolls out a “Web” computer: technology bus, 256-bit encryption, a 15-in. flat dis-
IBM’s NetVista line of computers since its first play, and wireless LAN. Also included
claim to be the first designed from PC almost are CD/DVD and floppy drives, built-in
the ground up for fast, high- 20 years speakers, two slots, and three bays. The
bandwidth Internet access. ago. The computers will cost less than $2,000.
IBM heralds it as the most com-
dramatic and significant roll out puter 30 YEARS AGO — 1980
Tail fins may cut aircraft’s fuel use:
Engineers are Lockheed-Georgia Co.
estimate a newly designed twin fin for
2XUGHVLJQRU\RXUV the C-130 Hercules transport will cut

&XVWRP*HDUER[HVJHWZKDW\RXZDQW
fuel consumption by at least 3% on
long flights and 6% for low-altitude
missions.
Called
an af-
terbody
strake,
the
device
consists
of two
7-ft-long
0DQXDO
alumi-
,QOLQH &XVWRPIODQJH num/fi-
berglass fins which are attached under-
neath the propjet’s tail section. The fins
are designed to eliminate turbulence
and reduce drag. While the strakes
can achieve significant fuel savings,
another option is to burn the same
amount of fuel but boost the aircraft’s
speed by 18 knots, from 300 to 318.

50 YEARS AGO — 1960

3UHFLVLRQ 0DULQH,3 Nuclear punch for a lightweight
fighter: Head of the line of mixed mis-
siles that are carried by the Air Force’s



"


 F-102 is the GAR-11 Nuclear Falcon. The








 
 first air-to-air missile with nuclear capa-








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 bility, it is










 

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 designed
for use in
















# head-on
attacks on
Call us at 1-888-260-7466 or fax us at 516-867-5656 supersonic
or Email us at sales@rinomechanical.com bombers.
Hughes
See us at www.RinoGB.com Aircraft
Co. devel-
oped the
0HFKDQLFDO&RPSRQHQWV,QF weapon with a radar-guidance system,
which can launch it without the pilot
1RUWK0DLQ6WUHHW)UHHSRUW1< seeing the target, and guide it to en-
3KRQH)D[ sure a “kill.” Described as small, consid-
ering its capabilities, the Falcon is 7-ft
long and weighs 200 lb. MD

34 MACHINE Design.com MAY 20, 2010

RS# 131
 REPORTER’S NOTEBOOK
IN-STOCK PRODUCTS
Electronic-components distributor
Digi-Key Corp., Thief River Falls,
Minn., has expanded its inventory
to offer products from the following
companies: The Mini-Fit H20 sealed
connector system from Molex, Lisle,
Ill.; the Zippy2 Ethernet Combo
RS# 132
36 MACHINE Design.com
Board, the KSZ8851SNL-BBE-EVAL
evaluation board for the KSZ885SNL
Ethernet controller from Micrel Inc.,
San Jose; sealed power plugs and
jacks from Switchcraft Inc., Chi-
cago; and the PTSM Series PCB ter-
minal blocks from Phoenix Contact
Inc., Middletown, Pa.
MAY 20, 2010
COMPANY NEWS
RESEARCH GRANT
RE2 Inc., Pittsburgh, Pa., has been
awarded a Small Business Innova-
tion Research grant to research
and design a modular intelligent
manipulation system with intuitive
control for the U.S. Army’s Tank
and Automotive Research, Devel-
opment and Engineering Center.
RE2’s design will increase the ef-
fectiveness of robotic manipula-
tors on UGVs by giving operators
the sensation that his or her arm is
actually manipulating an object.
RE2 is a developer of modular ma-
nipulation systems.
3D PRINTERS HIT
THE MARKET
Stratasys Inc., Eden Prairie, Minn.,
has delivered its first shipments
of Hewlett-Packard 3D printers
to five European markets: France,
Germany, Italy, Spain, and the
U.K. The printers are codeveloped
by HP and Stratasys, an additive-
fabrication-system maker.
STOCK EXPANSION
Mouser Electronics Inc., Mans-
field, Tex., an electronic-compo-
nent distributor, has more than
doubled its stock of interconnect
products from Hirose Electric
Co., Simi Valley, Calif. The products
include FFC / FPC connectors, wa-
terproof circular connectors, and
I/O connectors.
FREE VISION TECHNOLOGY
SEMINARS
Cognex Corp., Natick, Mass., a
supplier of machine vision and
industrial-ID systems is offering
free vision-technology seminars to
be held throughout the U.S. and
Canada. The half-day event dem-
onstrates vision and industrial ID
systems for automated inspection
tasks and traceability initiatives in
the automotive, pharmaceutical,
food, beverage, consumer pack-
aged goods, pharmaceutical, med-
ical, and electronics industries.
For more dates, information, and
online registration, go to www.
cognex.com/seminar or call (800)
677-2646. MD
RS# 133
 REPORTER’S NOTEBOOK
CALL FOR ENTRIES
The American Welding Society
(AWS), Miami, has issued a call for
entries for the 8th Annual Image
of Welding Awards. The awards
are open to all welding-industry
professionals.
Awards are issued in seven
#
 
categories: Individual (you or
other individual), Section (AWS
local chapter), large business
(200 or more employees), small
business (less than 200 em-
ployees), distributor (welding
products), educator (welding
teacher at an institution, facil-
COMPANY NEWS
ity, etc.), and educational facility
(any organization that conducts
welding education or train-
ing). Deadline for submission is
July 12, 2010. Go to www.aws.
org/awards/image.html for nomi-
nation forms and information.
AWARDS
Taiyo Yuden (U.S.A.) Inc.,
Schaumburg, Ill., has named
Avnet Electronics Marketing
Americas, Phoenix, as its 2009
Distributor of the Year. Avnet
distributes Taiyo Yuden’s surface-
mount and leaded passive com-
ponents, Bluetooth modules,
power electronics modules,
power supplies and recordable
digital media. Avnet distributes
  electronic components from






  leading manufacturers and asso-
ciated design-chain and supply-


 
  chain services.

 



  
Bosch Rexroth, Rochester,


 
 Mich., a specialist in drive and



 $
 control technologies, received
an MI Earth Day Award during

 
 
 the MI Earth Day Fest in Roch-

    
 ester, Mich. The award recog-
nizes a company operating in


 
 Michigan that is dedicated to
clean technologies and prac-
tices. Bosch was honored for its
%
 
 & industry-leading, fuel-efficient

 
 
& and vehicle-emission-reducing
technologies, such as hydraulic
  
 
 
&
 hybrid technology, along with its
work in other areas such as solar

 
   energy, wind energy, and ocean
energy development.
' 
( 
 STRATEGIC PARTNERSHIP

 
   AGREEMENT
Kollmorgen, Radford, Va., a man-

 


  ufacturer of driverless-control
    
  
 technology, and Knapp System-
integration GmbH, a warehouse
automation specialist, have
reached an agreement, where
Knapp will license and integrate


 Kollmorgen’s NDC Suite technol-
ogy in warehouse applications



  for automated order-picking and


  
 
    automating standard forklifts for
operatorless transport applica-
tions on a global basis. MD
RS# 134
38 MACHINE Design.com MAY 20, 2010
 
 





















   

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RS# 135
Select Wire-Reinforced
Hoses Based on Working
Pressure Requirements
Hydraulic hose reinforcement varies with its
rated working pressure.
Hoses with low working pressures normally
use fabric reinforcement, while those handling
higher pressures use high-strength steel wire.
Steel wire reinforced hoses come in two types:
wire braid and spiral wire.
Wire braid hoses can handle working
pressures up to 6,000 psi, depending on size.
These “two-wire” braid hoses are frequently
found in high-pressure hydraulic applications
on construction equipment. Operating pressures
range from 6,000 psi for 3/16” I.D. to 1,825 psi
for 2” I.D. hoses.
By contrast, spiral wire hoses generally handle
up to 5,000 psi in larger diameter sizes, up to
2” I.D. Typically, "four-wire" and "six-wire"
spiral hoses are used where extremely high-
impulse pressure surges are encountered.
Gates newest advancement is its M-XP™
hydraulic hose, which combines the flexibility
of wire-braid construction with the strength
and performance of spiral-wire reinforcement.
M-XP hose has been tested at an industry-
leading 1,000,000 impulse cycles – five times
the SAE standard. This capability increases
service life and makes Gates M-XP hose ideal
for out-of-sight and hard-to-reach applications
like boom arms and scissor lifts.
Gates M-XP hose is engineered with one-
half the SAE bend radius requirement, which
reduces hose length requirements and allows
for greater flexibility and easier installation in
confined spaces.
Visit www.gates.com/mxp
RS# 136
40 MACHINE Design.com
BERKE ON SAFETY
Investigating farm
accidents isn’t just child’s play
A farmer seriously injured his foot, leg, and ankle when he was thrown from a
hay rack. His father had been towing the rack behind a tractor and baler while
his son stacked bales onto the hay rack.
When they finished, they pulled onto country roads to deliver the hay to a
barn a few miles away. The father was still driving the tractor and the son was
sitting on a bale in the middle of the rack.
At a four-way stop, the father slowed and made a sharp right-hand turn.
Bales of hay bounced out of the rack on both sides, and the son was thrown from
the vehicle to the right.
The injured man sued his father and his father’s insurance company for his
injuries and damages. The court case hinged on whether the man had been
doing something that caused his fall, independent of his father’s actions while
driving.
Two witnesses said the hay rack’s right wheels hit one of Minnesota’s famous
springtime potholes about 30 ft from the intersection. The right-hand wheels
then ran onto a 25-ft-long, 6-in.-high curb that led to the intersection before
bouncing off the curb with enough force to throw hay bales and the son from
the hay rack.
The insurance company’s expert witness had a doctorate in physics and was
a professor at a local university. His careful mathematical analysis indicated the
son could not have been thrown off the hay rack by the same force that threw
bales of hay in all directions. If he had been sitting as still as a bale of hay, the
centrifugal force of the vehicle taking the turn would have thrown him off the
left side of the hay wagon, not the right.
Therefore, the professor concluded, the man must have been doing some-
thing that caused him to fall off the right side of the rack, independent of the
vehicle’s path.
I was an expert witness for the plaintiff. I often use models of machines when
evaluating safety during hazard analyses and when presenting cases to juries in
court. However, in this case, I used toys to prove to myself and the court how the
accident happened.
All of the farm implements in the case were at least 30-years old. Using the
Internet, I found a manufacturer that makes toy versions of each piece of equip-
ment involved in this accident, including bales of hay, at 1:48 scale.
Thanks to the accuracy of the models and an understanding wife, I recreated
the accident scene on my dining-room table. After playing with the scaled-
down accident scene for a while, I was able to reproduce the accident as it was
described by the witnesses.
Despite the fact that I was, in fact, using toys to prove my analysis of the ac-
cident, when I showed my findings to insurance-company representatives, the
case settled quickly. This is just the latest example I’ve seen that pure mathemati-
cal analysis is no substitute for physically recreating an accident scenario.
— Lanny Berke
Lanny Berke is a registered professional engineer and Certified Safety
Professional involved in forensic engineering since 1972. Got a question about
safety? You can reach Lanny at lannyb@comcast.net.
Edited by Jessica Shapiro
MAY 20, 2010
 M-XP™ hose brings together the
best of spiral-wire and wire-braid.

Introducing a revolution in hose performance

and economy. Gates new M-XP hydraulic hose
combines the flexibility and economy of wire-
braid construction with the strength and
performance of spiral-wire reinforcement.

There are a million reasons to spec this hose.

Tested at 1,000,000
impulse cycles (five
times the SAE standard)
at 212°F, M-XP hose
can handle 4,000 psi high-impulse applications
in all sizes. It is ideal for out-of-sight and hard-to-
reach applications like boom arms and scissor
lifts used in mobile equipment, construction and
other industrial markets.

And the benefits don’t stop there. M-XP hose

is engineered with one-half the SAE bend radius
requirement for greater flexibility, easier handling
and reduced hose length. Plus, it can be fitted
with economical one-piece MegaCrimp® couplings
rather than more expensive spiral-wire fittings.

Strength and flexibility. It all adds up to a hose assembly that delivers

high performance and low cost.

One unique combination. See what M-XP hose will do for your next
hydraulic application. For more information,
visit www.gates.com/mxp

RS# 137
 WORLD’S SMARTEST DESIGN ENGINEER

Design Engineers enjoy

Over the
80 years
MACHINE DESIGN
has been
communicating
with design
engineers,
few things
have excited
engineers Design engineers can test their expertise in eight different categories.
as much as
That’s why our annual Indy 500 issue ways to engage, challenge, and test your
fast cars, cool garners a lot of attention, our Web knowledge while offering educational
site gets particularly higher volume moments and some fun along the way.
gadgets, and when we feature racing lawnmowers We wanted something deserving of your
or the latest mountain bike, and why time, knowledge, and energy.
real learning thousands of you are currently playing After months of brainstorming de-
our new, online game called THE tails, categories, rules, and prizes, we
opportunities. WORLD’S SMARTEST DESIGN ENGINEER. began developing questions, writing
We began work on this monumental game requirements, and bringing our
project close to a year ago, thinking of Lee Teschler avatar to life.

Rittal – The System.

INDUSTRIAL ENCLOSURES POWER DISTRIBUTION ELECTRONIC P

42 MACHINE Design.com MAY 20, 2010

 a challenge “Questions were very
interesting and fun.
I like the variety of
the categories.”

Be A LUNCH
BUNCHER
If you haven’t yet signed up to play,
why not check it out. We’ ve made the
registration process easier and the
flow of the game faster. Since many of
you enjoy playing at lunchtime, we’ve
just begun a “Lunch Bunch” program
where you can register several
engineers from your company and
compete against each other. You’ll
be hearing more about this in the
coming weeks, but in the meantime,
as Avatar Lee says “Better Study Up.”
The game is a great place to learn!
The scoreboard lets players check their ranking against opponents.

“Challenging and educational, I found

out what I need to brush up on.”
The game officially launched on If you’ve been playing the game tions and will alert you when those
March 1st and, to date, you have and responded to our request are complete.
already answered 263,019 ques- for feedback, we thank you. Your Check out our new Game Blog
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RS# 138
MAY 20, 2010 MACHINE Design.com 43
 INDY 500

IndyCar 2012
the
race is on Safety, better efficiency,
and more-exciting racing
are revving up the chassis
designs competing to run at
IndyCar events in 2012.

Auto racing is about more than getting cars to go as fast as possible. Premier groups
like the Indy Racing League (IRL) also want to keep drivers safe, fans engaged, and
technology relevant to real-world consumer applications. They also want more
teams competing.
To that end, IRL’s IndyCar chassis is getting a refresh. Officials are hoping to
choose a chassis and engine platform for the 2012 season by June 1 of this year.
Early this year, IRL President Brian Barnhart outlined what the organization
is looking for in a new car, and designers were quick to respond. Five firms have
entered the competition for the 2012 chassis, including current chassis construc-
tor Dallara, Parma, Italy, and LeMans and ChampCar designer Lola, Huntingdon,
Cambridgeshire, U.K. Swift Engineering, San Clemente, Calif., a seasoned design
firm, notably of the current Formula Nippon design, is also developing an entry.

44 MACHINE Design.com MAY 20, 2010

 DeltaWing Racing Cars
DeltaWing is taking a radical approach on many fronts. In addition to being supported by key IRL
teams rather than an established chassis builder, DeltaWing has pledged an open-source design pro-
cess. Anyone can access the car’s specs and CAD drawings, and anyone can submit original design
ideas.
The concept has produced a radical design, including a 160-lb, 2.0-liter, 300-hp, four-cylinder, turbo-
charged engine, that is projected to weigh 1,030 lb with a driver and cost around $600,000. The engine
and transmission are nonstressed members of the chassis, so the car can accommodate different pow-
ertrains. DeltaWing is pushing for IRL to restrict fuel-delivery rate to the engines and leave other engine
specs up to teams.
The smaller powerplant and mass are made possible in part by bodywork that nearly encloses both
sets of wheels. Distance between front wheels is 24 in. while in back it is 70 in. Cutting the drag of open
wheels, narrowing the track, and beefing up the front fairing, let DeltaWing cut the drag coefficient 60%
to 0.24. Replacing the rear wing with a vertical fin keeps the car stable in turns but doesn’t add drag
on straightaways. And the absence of front and rear wings makes the car less sensitive to “dirty” air
when following closely and leaves a cleaner wake.
Simulation and full-size wind-tunnel testing confirm that 80% of the aerodynamic downforce acts
on the rear of the car, which also supports 72.5% of the mass. This aero and mass balance give better
traction to the 12.5-in.-wide rear tires during acceleration without adding weight. Stability is also en-
hanced by a six-speed, driver-controlled differential with full torque vectoring and active stagger that
eliminates the need for different diameters on the inner and outer tires on oval tracks.
Bodywork in front of the front wheels and behind the engine absorbs crash energy to further pro-
tect the driver. Tegris polypropylene composite from Milliken & Co., Spartanburg, S.C., will add impact
and intrusion resistance without adding weight to DeltaWing’s prototype. Compared to glass and
carbon-fiber composites, Tegris resists two to five times the impact energy, has comparable
stiffness, and is easier to manufacture and recycle.

Authored by:
Jessica Shapiro
Associate Editor
jessica.shapiro@penton.com
Key points:
t

'JWF
DPNQBOJFT
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QSPQPTFE

designs for the 2012 IndyCar Chassis,
to be selected by June 1.
t

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encourage close racing, save fuel, and
keep the series affordable for teams.
t

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versions of the current chassis and
radical new concepts.
Resources
BAT Engineering, nextindycar.
The field’s two relative newcomers are BAT Engineering, Indianapolis, led wordpress.com
by principals with experience at Lola and other race-car constructors such as Dallara, www.dallara.it
Reynard and March, and DeltaWing Racing Cars, Indianapolis, featuring the
technical head of Target Chip Ganassi Racing which took the IndyCar champi- DeltaWing Racing Cars,
deltawingracing.com
onship in 2008 and 2009.
Honda Performance Development,
Car criteria racing.honda.com/hpd/
IRL clearly set out its expectations for the new car in February. The new Indy Racing League, www.indycar.com
chassis must meet current safety standards, but winning designs need to pro- Lola Group, www.lola-group.com
pose additional ways to prevent crashes and make them less dangerous for driv-
Swift Engineering, www.
ers, crew, and spectators. swiftengineering.com
“It is often said about the 3S of racing — safety, strength, and speed — that

MAY 20, 2010 MACHINE Design.com 45

 INDY 500

BAT Engineering
Former Lola chief designer and
Reynard North America president
Bruce Ashmore, former March
chief designer and engineer Alan
Mertens, and longtime open-
wheel racing engineer Tim
Wardrop made a safe cockpit
the top priority of their clean-sheet
design. They consulted with IRL safety and technical
directors Jeff Horton and Les Mactaggart and Indianapolis surgeon Dr. Terry Trammell.
A stiffer suspension, stronger suspension mounts, and less fragile body work promote fast,
close racing with less chance of having race-ending contact with other cars. More-crushable
structure, bodywork that extends to the outer edges of the tires, and a stressed engine that
helps hold the car together in a crash will protect racers and spectators.
Although some of these stiffening and crashworthiness improvements add weight, Ashmore
says the new car’s weight will be “very similar” to that of the current model. Enhanced efficien-
cy comes from smoother, more-aerodynamic contours. The current chassis has a lot of angular
bodywork specifically designed to reduce downforce and slow the overpowered cars down.
Although the engine will ultimately be IRL’s decision, Ashmore would like to see a V6 twin
turbo. Such a car would be slightly cheaper to build and have fewer parts that could break dur-
ing long races. League organizers could bleed off turbo-induction pressure so cars could run a
safe 500 hp on ovals and get the 750 hp they need to perform on road courses. Twin turbos have
better cooling performance than a centrally located single unit.
“Turbos are relevant technology for modern vehicles,” Ashmore says. “In a truck or SUV that is
mostly driven on flat roads with a single
occupant, a V6 gives enough power;
you don’t need a V8. When you are tow-
ing a boat and transporting six people,
a turbo could nearly double your horse-
power.”
BAT Engineering proposes to build
its chassis within a 30-mile radius of the
Indianapolis Motor Speedway. The com-
pany says it is already forming partner-
ships with local firms and organizations
to prepare for the production of a 2012
chassis that will cost about half what the
current model does.

you need safety first,” says Andrea Toso of Dallara. “If you
are fine with safety, then you move to logistical and engi-
neering strength, including reliability, economics, support,
and distribution. If you are fine with strength, then you go
to speed or performance. And anytime you have an issue
in the safety or strength department, you have to address it
right away, even by conceding on speed.”
IRL’s second priority is keeping IndyCar races inter-
esting. Specifically, they want cars to be less sensitive to
turbulence generated by competing vehicles or have cars
leave cleaner air in their wakes.
The car has to be able to hit a lap speed of 235 mph with
less engine power than the current 630 hp. It will have to
generate less drag to do so, while at the same time creat-
ing enough stable downforce to permit safe cornering in
traffic.
Third, the league wants these changes, and racing in
general, to be affordable for teams. Officials are hoping

46 MACHINE Design.com MAY 20, 2010

  




 


    

 


  

 


   


 
 

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RS# 139
 INDY 500
Dallara
Dallara designed the current, 2003-vintage IndyCar. The
Italian firm says any of its three proposed 2012 chassis would
be built near Speedway, Ind., and cost 55% less than the cur-
rent design. The cars weigh 1,390 lb without a driver or fuel.
This compares to 1,530 lb for the current design.
A 570-hp in-line four-cylinder turbocharged engine could
the new car will cost 40 to 50% less than the current
model. IRL predicts costs savings will come mainly
from reducing the inventory teams need to compete
on both oval and road or street courses.
According to Toso, this means a car with all the
options, including oval and road course suspension,
aero, and differential packages; sensors, electronics,
and data acquisition; and fuel hardware, should cost
less than $400,000. A fully loaded car currently costs
around $700,000.
Also on the economic front, IRL has specified that
the new chassis must be built in the U.S., preferably
in Indiana. And most entrants have pledged to base
manufacturing around the Brickyard in Speedway,
Ind., near Indianapolis.
According to Bernard, a U.S.-built car would let
the league “take advantage of more-competitive pric-
ing and the existing American supplier network for
parts,” as well as protecting teams from currency
fluctuations.
The fifth requirement is for a lighter chassis that
will have aerodynamic effects similar to the current
model. A lighter car would need less power to meet
target speeds and have better fuel efficiency.
Team’s strategies for building lighter cars would
48 MACHINE Design.com MAY 20, 2010
take the car up to 225 mph on laps at the Brickyard, or the
cars could sport a turbo V6. Either engine would be a stressed
member which lightens the cars by eliminating the frame.
Bodywork slightly wider than the tire tracks keeps wheels
from interlocking. The cars are also shaped so that aerody-
namics keep them on the ground in a rear-end collision or a
crash into the wall. Updated aero packages make the cars less
sensitive to the wakes of nearby racers.
Design decision-makers
Decision day is June 1, and hitting that deadline is a must,
as IRL President Brian Barnhart estimates IRL will need 18 to
20 months to build, test, and begin making chassis for the
start of the 2012 season.
The final decision will be made by IRL CEO Randy Bernard,
who took over from Tony George March 1. Bernard will have
help from an advisory committee, dubbed ICONIC for its goal
of finding an innovative, competitive, open-wheel, new, in-
dustry-relevant, and cost-effective design.
The committee is chaired by retired Air Force Gen. William
R. Looney III, and IRL team owners elected Gil de Ferran, co-
owner of Luczo Dragon Racing/de Ferran Motorsports, In-
dianapolis, to represent them.
Bernard named Barnhart, former IRL vice president of com-
petition Tony Cotman, and promoter and Texas Motor Speed-
way president Eddie Gossage to the committee.
Technical experts include Rick Long, a high-performance
engine developer, Tony Purnell, a former technical consul-
tant to FIA, the European motorsport organization, and Neil
Ressler, former chairman of Jaguar Racing in Formula One
and former vice president and chief technical officer of re-
search and vehicle technology at Ford.
RS# 140
 INDY 500

Swift Engineering
California-based Swift Engineering focused its aerodynamics study on the wings, seek-
ing to reduce downforce and the turbulence they create. Designers at Swift have come
up with two different chassis designs, although the company only
intends to build a single winning model. The
sharp-nosed “23” model has fully exposed
wheels, a sculpted front wing, and a
substantial back wing with end-
plates. Bodywork on the “32” in-
cludes front and side pods that
protect both sets of wheels
and rear-wing end plates that
are continuations of the rear
bodywork.
Both models dis-
pense with cowlings cov-
ering parts of the engine. “We saw
an opportunity to showcase the en-
gine and other ‘jewelry’ while preserv-
ing efficiency with a much smaller
fairing,” said Casper Van der Schoot,
Swift’s director of motorsports. The change has little aerodynamic impact, but cuts down on
sponsorship space.
A tilted rear underwing borrowed from the company’s Formula Nippon racer is said to
sweep up the car’s wake, leaving cleaner air behind it that should promote closer racing
and passing. Swift also intends to place LED lights on the roll hoop, side pods, and upper
bodywork to signal spectators the car’s position, fuel level, and throttle and brake positions
throughout the race.
Although producing the cars in Swift’s California facilities meets IRL’s US-manufacturing
requirement, it may knock down the firm’s feel-good points for not locating in Indiana.

Race
position

Fuel level

Throttle
and
brake
position

also play into the sixth requirement: IRL wants the new
chassis to be relevant to the consumer auto industry.
Seventh on the list is an updated aesthetic. Specifically,
IRL wants more space for sponsor logos. They also want
it to be easier for fans to identify cars and drivers they are
rooting for.
The final requirement is one of the vaguest: The car
should be “green.” “The IRL prides itself on its role in the
greening of racing and wants to maintain its position as
a leader in environmentally friendly initiatives with this
chassis,” states the league’s press release establishing car
criteria.
Prospects for some items that have long been on the
wish list of some fans and commentators, like a multichas-
sis or multiengine series, are slim.
“Intense competition and battles with other race-car
manufacturers is a fantastic spectacle and a rich environ-
ment for our engineers,” says Lola head of special proj-

50 MACHINE Design.com MAY 20, 2010

RS# 141
 INDY 500

MOTION CONTROL
SOLUTIONS FOR Lola
MEDICAL Designers at British
firm Lola, known for their Le-
Mans Prototype (LMP) 1 and 2
APPLICATIONS... chassis and ChampCars, have
come up with two visually different cars to add variety to the grid and accommo-
date two engine manufacturers, if IRL chooses to go that way. The company plans
INDUSTRIAL to wind-tunnel test both 1,380-lb configurations in the wind tunnel across the
SHOCK entire ride height range to ensure parity.
ABSORBERS One body style might have a slight edge on oval courses while the other is
better for road races, so Lola engineers are designing a series of sized and con-
figured aero blockers for the underbodies of the cars. The blockers would detract
HYDRAULIC slightly from the cars’ aerodynamic efficiency and keep the two body styles on a
DAMPERS level playing field.
A large central underbody panel boosts downforce and let designers shrink
front and rear wings that can leave turbulence in a car’s wake. Rear-wing end-
GAS plates also minimize vortex rings that form over the back of the car at race speeds
SPRINGS and inhibit passing. The front and lower rear wings also serve as bumpers to limit
Available in 316L wheel-to-wheel contact if cars collide.
stainless steel
The bones of Lola’s designs will work for both IndyCar races and IndyLights
development series with slight changes to the upper body work, a concept Lola
TUBUS engineers say makes both series safer for drivers and keeps teams’ costs down.
ELASTOMER “The crossover will encourage new teams to enter both IRL and Indy Lights,” says
BUMPERS Peter McCool, Lola head of special projects.

ROTARY
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ects Peter McCool. “However, it is
not conducive to keeping cost down,
which has been a key criteria. But a
return to multichassis grids may well
be an option in stronger economic
times.”
It appears IRL will stick with its
single-engine format and its current
engine supplier, Honda. But what
kind of powerplant they will provide
remains unclear. Discussions last year
leaned toward switching from a four-
camshaft, normally aspirated V8 to
a turbocharged, four or six-cylinder
engine with dual overhead cams. So
the 2012 car might sport a fuel-effi-
cient, turbocharged, four-cylinder
engine. MD

52 MACHINE Design.com MAY 20, 2010

RS# 143
 FASTENING & JOINING

Engineering tricks
make
parts stick
Adhesive bonding
improves the looks
and durability of
low-surface-
Polypropylene (PP), polyethylene (PE), and other thermoplastic olefins attract
energy plastics,
designers because of their low cost and excellent physical properties. The poly-
mers are durable, flexible, and resist moisture, heat, and solvents. Unfortunately,
but pretreatment
some of these properties also make the plastics difficult to bond with conven-
tional adhesives.
or special adhesive
PP, PE, Teflon, and other hard-to-bond polymers are called low-surface-
energy (LSE) plastics, and engineers typically turn to mechanical fasteners and
formulations
ultrasonic welding to assemble LSE plastic structural components. But these ap-
proaches can affect cost, service life, and aesthetics. As designers specify more
are a must.
LSE plastics, they need more-efficient, reliable, and economical ways to join
LSE plastics. Authored by:
Mechanical fasteners constrain components, increasing the risk of cracking
and failure at attachment points from material expansion and contraction, flex- Jeremy Cooler
ing, and vibration. Ultrasonic welding is time consuming and often dimples the Technical Specialist
surface, harming product appearance. Fabrico
Kennesaw, Ga.
Adhesives, on the other hand, distribute loads evenly, reducing joint stress.
They resist flexing, vibration, and impact. Adhesives seal joints to minimize Edited by Jessica Shapiro
corrosion and fill in surface gaps that mechanical fasteners or ultrasonic meth- jessica.shapiro@penton.com
ods can’t fix. Key points:
Practical and economical adhesives for joining LSE plastics were not avail- t

-PXTVSGBDFFOFSHZ
QPMZNFST
BSF

able until recently, however. New liquid and viscoelastic adhesives are changing EVSBCMF
GMFYJCMF
BOE
MPX
DPTU
CVU

the outlook for adhesive-based assembly of LSE plastics. hard to bond with conventional
adhesives.
Surface dynamics t

4VSGBDF
FOFSHZ
JT
B
SFMBUJWF
RVBOUJUZ

Polymer surface energy is important because it determines if adhesives can UIBU
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BO
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UP

spread out over the bonding surface, a process called wetting out that is neces- XFU
UIF
TVSGBDF
sary to create strong bonds. The surface energy, or wettability, of a material is t

3BJTJOH
UIF
QPMZNFS
TVSGBDF
FOFSHZ

measured in dynes per centimeter. Plastics with relatively high surface energy UISPVHI
QSFUSFBUNFOU
PS
MPXFSJOH

— acrylonitrile butadiene styrene (ABS) and polycarbonate, for example — UIF
BEIFTJWFT
TVSGBDF
FOFSHZ

bond readily because they are easily wet by conventional adhesives. QSPNPUFT
CPOEJOH
Properly prepared aluminum with a surface energy of 840 dynes/cm strongly Resources:
bonds with adhesives, which explains why modern aluminum-skinned aircraft Fabrico, www.fabrico.com
are relying more on adhesives and less on rivets for structural assembly. i#BTJDT
PG
%FTJHO
&OHJOFFSJOH

At the lower end of the spectrum, PP and PE have surface energies around Adhesives,” machinedesign.com/
30 dynes/cm. Polytetrafluoroethylene (PTFE), the original coating for nonstick article/adhesives-1115
cookware, is the LSE champ at 19 dynes/cm. i#BTJDT
PG
%FTJHO
&OHJOFFSJOH

Measuring the contact angle of a water droplet on the surface of a material deter- +PJOJOH
QMBTUJD w
machinedesign.com/
mines surface energy. Contact angles greater than 90° indicate lower surface energy article/joining-plastic-1115
and a surface that is more difficult to wet. When the contact angle approaches 180°,
the surface is very difficult to wet and water “beads up” as on a waxed car.

54 MACHINE Design.com MAY 20, 2010

 Conversely, contact angles less than 90° indicate higher surface energy and a
surface that is easier to wet. On a surface producing a contact angle approaching
0° water forms a sheet.
The better a liquid adhesive wets a material surface, the more area it can
cover. This has two beneficial results: a stronger chemical bond and stronger
mechanical bond.
The chemical bonds get a boost from more attraction and interaction of re-
active groups in the adhesive and the substrate. Mechanical bonds form when
adhesive penetrates the surface, filling in microscopic irregularities and pro-
ducing adhesive interlocks.

Better bonding
Absolute surface energy numbers are of less interest to engineers than the
relative magnitude of the plastic’s surface energy and that of the adhesive. Ide-
ally, the surface energy of a plastic should be 7 to 10 dynes/cm higher than the
surface energy of an adhesive. A liquid or pressure-sensitive adhesive with a
surface energy of 20 dynes/cm will spontaneously wet out LSE plastics with sur-
face energies of 30 dynes/cm or more.
Therefore, engineers can make LSE plastics easier to bond by either raising
the surface energy of the plastic or lowering the surface energy of the adhesive.
To boost a plastic’s surface energy, engineers usually pretreat the plastic with
primers, flame, plasma, or corona-discharge processes. These change the sur-
face chemistry and render the plastic wettable by conventional adhesives.
Plastic pretreatments add cost and time to production processes. In addi-
tion, the surface energy effects of flame, plasma, and corona-discharge treat-
ments may only last minutes, days, or weeks depending on the plastic. Primers
may pose environmental issues that engineers must weigh.
The other approach, lowering the surface energy of the adhesive to attain an
aggressive bond, involves adding tackifiers to the adhesive formulation. In some
cases, engineers use double-coated or transfer tapes to improve tackiness.
Newly formulated acrylic-liquid adhesives and pressure-sensitive-adhesive
tapes strongly bond with many LSE plastics without priming or other pretreat-
ments. One approach uses a two-part, solvent-free, room-temperature-curing
acrylic adhesive that skips curing ovens, UV lamps, and heaters. The resulting
structural bonds resist chemical attack, water, humidity, and corrosion and have
overlap shear strength over 1,000 psi.
When substrates are thin, lightweight, or flexible, a thin bonding product ad-
heres as well or better than liquid adhesives. For such parts, a pressure-sensitive,
double-coated or transfer tape gives LSE materials bonds that resist temperature
extremes and solvents and have peel strength comparable to those of liquid
RS# 144
 FASTENING & JOINING

Help for hard-to-bond surfaces

Transportation
The high performance and lower
cost of low-surface-energy (LSE)
plastics makes them attractive ma-
terials in the transportation sector.
Designers use LSE-specific liquid
adhesives and thin-film-bonding
systems instead of mechanical fas-
teners or welding to attach polypro-
pylene fenders, bumpers, body trim,
body panels, and other items in ve-
hicles and recreational trailers.
Most automobile interior trim Thin bonding systems must withstand
pieces are now LSE plastics. Thin extreme temperatures and UV exposure
bonding systems can handle the ex- to attach low-surface-energy plastics
treme temperatures in auto interiors in automotive interiors. The adhesives
and hold these parts in place for the replace mechanical fasteners that would
life of the vehicle without unsightly compromise vehicle aesthetics.
mechanical fasteners.
Flexible LSE-rubber gaskets laminated with die-cut, thin bonding films, let assem-
blers peel and stick the gaskets where they are needed. These gaskets bond to ad-
vanced LSE paint systems that are impervious to conventional adhesives.
Die-cut, thin bonding films also permit peel-and-stick attachment of heat-shield
materials and sound-dampening foams in all-terrain recreational and work vehicles
with hoods and other body panels made from LSE plastics or blends. This approach
eliminates time-consuming, labor-intensive, and environmentally hazardous liquid-
contact-adhesive processes.

Appliances
Powder coating provides a last-
ing, durable, LSE finish for house-
hold and industrial appliances. New
thin bonding film formulations
let manufacturers securely attach
sound-deadening insulation, metal
identification and serial labels, and
internal LSE plastic components
that operate at elevated tempera-
tures to the hard-to-bond paint.
This eliminates conventional fas-
teners that detract from modern
design aesthetics and may promote
corrosion and stress cracking.

Electronic and Medical

Polypropylene film’s dielectric
properties make it the insulation of New adhesive formulations let
choice for many electric and elec- manufacturers attach labels, ID tags,
tronic applications. Thin bonding insulation, and internal parts to appliances
with low-surface-energy powder-coat
systems create a durable, cost-effec-
finishes.
tive bond for this LSE plastic.
In the competitive medical disposables market, thin bondings film laminate low-
cost LSE plastic into diagnostic strips.

RS# 145

56 MACHINE Design.com MAY 20, 2010

HELI-CAL® Flexure Technology:
Gives more design possibilities
to fit your application!

Machined Springs U-Joints

Standard Couplings Custom Couplings

For the whole picture, visit www. Heli-Cal.com

AS9100B
ISO 9001:2000 PRODUCTS COMPANY, INC.
RS# 146

 "&

(


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(
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#
 


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#


(


 
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 FASTENING & JOINING

WETTING A contact angle less than 90°

Adhesive (top) indicates the substrate
material has higher surface
energy and is readily wet out
by the adhesive. Good wetting
Substrate promotes stronger adhesive-
substrate bonds through chem-
ical and mechanical interaction.
A contact angle greater than 90°
(bottom) is indicative of a low-
NONWETTING surface-energy (LSE) substrate.
Adhesive Such substrates are difficult
to wet out with conventional
adhesives. Pretreatments, spe-
cialty adhesive formulations, or
both can let LSE substrates form
Substrate strong bonds with similar and
dissimilar materials.

structural adhesives. RELATIVE SURFACE ENERGY OF MATERIALS

Other adhe-
Surface Contact
sives for LSE plas- Material Energy Angle
tics use cyanoacry- (dynes/cm) (°)
late chemistry. The Copper 1,103
high-strength, one- Aluminum 840
part adhesives cure Glass 250 to 500
at room temperature Polycarbonate (PC) 46 75
and produce strong Acrylonitrile butadiene
bonds on LSE plas- 35 82
styrene (ABS)
tics without olefin Polypropylene (PP) 30 88
primers.Accelerators Polyethylene (PE) 30 88
can be added to the Polytetrafluoroethylene
19 120
formulation to speed (PTFE)
cure in low-humid-
ity environments.
Some cyanoacrylate adhesives and assembly using less-skilled labor.
permit light-accelerated curing to Adhesives add little additional weight
increase bond depth and strength. to assemblies, cause no change in part
The short cure times let manufac- dimensions or geometry, and readily
turers process relatively small plastic bond dissimilar substrates and heat-
parts in seconds rather than minutes sensitive materials. And because the
in high-volume applications. Cure limitations of conventional fasten-
strength can be boosted further with ing techniques are not an issue, engi-
plasma, primer, or corona discharge neers have more latitude in specify-
pretreatment of the LSE plastic. ing component thickness and shape.
Designers are using new liquid-
LSE-adhesive advantages adhesive, thin-film/foam bonding
This new generation of liquid systems instead of mechanical fasten-
adhesives, adhesive tapes, and thin- ers and ultrasonic welding to attach
film/foam bonding systems create polypropylene fenders, bumpers,
strong bonds with LSE plastics that body trim, body panels, and other
resist impact, shock, and fatigue bet- items on vehicles and recreational
ter than conventional mechanical trailers. They attach name plates,
and ultrasonic fastening. protective windows, and warning la-
The availability of reliable adhe- bels to industrial equipment and are
sive-bonding alternatives for LSE finding specialized niches in diag-
plastics promises faster production nostic medical products. MD
RS# 147
58 MACHINE Design.com MAY 20, 2010
FAST, FURIOUS AND FULLY LOADED MOTION CONTROLLERS

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RS# 148
 HYDRAULICS

Sizing The right size

tubing limits

tube lines fluid-friction

losses that cause

for pressure drop,

heat generation
efficient and, in case of
suction lines,

hydraulics pump-damaging
cavitation.

The right tubing and fittings are critical for trouble-free thickness. Here’s a simple procedure for sizing tubes.
PQFSBUJPO
PG
GMVJEQPXFS
TZTUFNT
1SPQFSMZ
TJ[FE
UVCFT

which may differ for various parts of a hydraulic system, Flow diameter
also give the best combination of efficient and cost-effec- The first step is to determine required flow diameter.
tive performance. The accompanying “Recommended flow diameter” table
A tube that is too small raises fluid velocity, which has gives guidelines for specific flow rates and types of line.
many detrimental effects. In suction lines, it leads to cavi- The table is based on the following recommended flow
tation that starves and damages pumps. In pressure lines, velocities:
it causes excessive friction losses and turbulence, both re- t

1SFTTVSF
MJOFT


GQT
PS

NFUFSTTFD
sulting in high pressure drops and heat generation. High t

3FUVSO
MJOFT


GQT
PS

NFUFSTTFD
heat, in turn, accelerates wear in moving parts and ages t

4VDUJPO
MJOFT


GQT
PS

NFUFSTTFD
seals and hoses. The end results are shorter component life
and wasted energy and, therefore, low levels of efficiency. If flow velocities differ from these, calculate the re-
On the other hand, tubing that’s too large unnecessar- quired flow diameter based on:
ily increases costs. It can also consume valuable real estate
that makes it more difficult to fit tubing into confined
spaces and restricts engineers in configuring adjacent Temperature derating factors
equipment and components. And oversized tubing can Maximum
operating
Steel, C-1010 Stainless steel
Copper
Aluminum,
Monel,
Type
and C-4130 6061-T6
simply be harder and more time consuming to install. It temperature, °F 304 316 400
100 1.00 1.00 1.00 1.00 1.00 1.00
also weighs more than necessary, and that hurts fuel con- 150 1.00 0.91 1.00 0.85 1.00 0.97
sumption on mobile equipment. 200
250
1.00
1.00
0.84
0.79
1.00
1.00
0.80
0.80
1.00
0.94
0.94
0.91
Matching tubing to an application involves selecting 300 1.00 0.75 1.00 0.78 0.80 0.88
350 0.99 0.72 0.99 0.67 0.60 0.86
the right material and determining optimum OD and wall 400 0.98 0.69 0.97 0.50 0.43 0.85
500 0.96 0.65 0.90 0.84
600 0.61 0.85 0.84
700 0.59 0.82 0.84
WHAT’S THIS? 800 0.57 0.80 0.83
When you see a code like this, take 900 0.54 0.78
1,000 0.52 0.77
a photo of it with your smart phone 1,100 0.47 0.62
(iPhone 3G-S gives best results) and, 1.200 0.32 0.37
using software from www.neoreader.
com, you will be connected to relevant Derating factors are based on allowable design stresses
content on machinedesign.com at various temperatures per ASME B31.1.

60 MACHINE Design.com MAY 20, 2010

 Leading Edge
Authored by:
Burleigh Bailey
Clutches &
Research & Development
Manager
Brakes
Tube Fittings Div.
Parker Hannifin Corp. Standard or Custom Designs
Columbus, Ohio for Virtually Any Application
Edited by
Kenneth J. Korane Torque Ratings From
ken.korane@penton.com 1 oz.in. to 3,000 lb.ft.
Key points:
t


5VCJOH
UIBUT
UPP
TNBMM
Single or Multiple Disc Designs
causes excessive flow
velocity, turbulence, and
cavitation. Power On or Spring-Set
t


5VCJOH
UIBUT
UPP
CJH

increases cost, space Cost Effective and
requirements, and weight. Value Engineered
t


4J[F
UVCJOH
CBTFE
PO

material, diameter,
and wall thickness to Electric, Mechanical, Air
Rigid tubing is rugged and handles meet pressure and flow or Hydraulic Actuation
high pressures. Sizing it properly requirements.
gives the best combination of cost
and performance. Resources:
Parker Hannifin, www.
parker.com

d = 0.64(Q/V)0.5
where d = tube ID, in.;
Q = flow, gpm; and V = Design and derating factors
velocity, fps. Severity of
Description
Design Derating
service factor factor
Moderate mechanical and
A (Normal) 4.00 1.00
For metric units: hydraulic shocks
Severe hydraulic shocks and
B (Severe) 6.00 0.67
dm = 4.61(Qm/Vm)0.5 mechanical strain
Hazardous application with
where dm = tube ID, mm; C (Hazardous)
severe service conditions
8.0 0.50

Qm = flow, lpm; and Vm = Derating factors provide a measure of

velocity, meters/sec. safety against unknowns in materials and
operating conditions.
Diameter and
thickness
Next determine tube
OD and wall thickness.
Design stress ratings
Allowable design stress, psi
Material and type Tube specification
Using the “Pressure rat- (Design factor of 4 at 72°F)
SAE J356, J524,
ings” table, find the diam- Steel C-1010 12,500
J525
eter and thickness com- Steel C-1021
Steel, HSLA
15,000
18,000
SAE J2435, J2467
SAE J2613, J2614
bination that satisfies the Stainless steel, 304
18,800
ASTM A213, A249,
& 316 A269
following two conditions: Alloy steel C-4130 18,800 ASTM A519
1. Has recommended Copper, K or
Aluminum 6061-T6
Y 6,000
10,500
SAE J528, ASTM B75
ASTM B210
design pressure that Monel, 400 17,500 ASTM B165
equals or exceeds Allowable stress levels shown here are for fully
maximum operating annealed tubing.
pressure.
2. Provides tube ID that equals or exceeds the required flow diameter deter-
mined earlier.  
Design pressures in the table are based on a severity of service rating “A” (de-
sign or safety factor of 4) as listed in the “Design and derating factors” table. ^^^JQTJVJVT
In more-severe operating conditions, multiply values in the pressure-ratings
RS# 149
 HYDRAULICS
/LQHDU
6KDIW0RWRU
table by the appropriate derating factors before
determining the tube OD and wall thickness Recommended
combination. Contact a reputable tubing sup- flow diameters
plier when in doubt. Recommended flow

Maximum flow rate,

Allowable stress levels and the underlying diameter, in.
specifications used to arrive at the pressure

Pressure lines

Suction lines
gpm

Return lines
ratings are given in the “Design stress ratings”
chart. Values are for fully annealed tubing.
Or calculate design pressure based on Lame’s
equation, 0.25 0.064 0.101 0.160
0.50 0.091 0.143 0.226
P = S((D2 – d2)/(D2 + d2)) 0.75 0.111 0.175 0.277
1.00 0.128 0.202 0.320
where D = tube OD, in.; d = tube ID, in. (D – 1.25 0.143 0.226 0.358
2T); P = recommended design pressure, psi; S 1.50
1.75
0.157
0.169
0.247
0.267
0.392
0.423
= allowable stress for a design factor of 4, psi; 2.00 0.181 0.286 0.453
2.50 0.202 0.319 0.506
and T = tube wall thickness, in. 3.00 0.222 0.350 0.554
dep
p For thin wall tubes (D/T ≥ 10) the following 3.50
4.00
0.239
0.256
0.378
0.404
0.599
0.640
equation may be used: 4.50 0.272 0.429 0.679
5.00 0.286 0.452 0.716
P = 2ST/D. 5.50 0.300 0.474 0.750

More Ef¿cient than a U-Shaped The design factor is generally applied to the 6.00
6.50
0.314
0.326
0.495
0.515
0.784
0.816
material’s ultimate strength (or tubing burst 7.00 0.339 0.534 0.847
The Linear Shaft Motor does not 7.50 0.351 0.553 0.876
produce eddy currents, maximizes
pressure) to provide a margin of safety against 8.00 0.362 0.571 0.905
8.50 0.373 0.589 0.933
usage of all magnetic Àux, and unknowns in material and operating condi- 9.00 0.384 0.606 0.960
uses less power while producing tions. Apply the derating factors listed here di- 9.50 0.395 0.623 0.986
10.00 0.405 0.639 1.012
equal force. rectly to values in the pressure ratings table to 11.00 0.425 0.670 1.061
12.00 0.443 0.700 1.109
determine maximum recommended working 13.00 0.462 0.728 1.154
Precision and Speed Simultaneously pressures. That is, multiply values in the table by 14.00 0.479 0.756 1.197
15.00 0.496 0.782 1.239
If you need a more precise, faster the derating factors. 16.00 0.512 0.808 1.280
17.00 0.528 0.833 1.319
linear motion system, our Linear Besides severity of service, high operating 18.00 0.543 0.857 1.358
Shaft Motor outperforms more temperatures also reduce allowable working 19.00 0.558 0.880 1.395
20.00 0.572 0.903 1.431
traditional ball-screw systems. You pressure in tubing. Temperature-derating fac- 22.00 0.600 0.947 1.501
will also eliminate many of your 24.00 0.627 0.990 1.568
tors for various tube materials are given in the 26.00 0.653 1.030 1.632
machining and maintenance costs. 28.00 0.677 1.069 1.693
accompanying table. Where applicable, apply 30.00 0.701 1.106 1.753
The Nippon Pulse Advantage derating factors for severity of service and tem- 32.00 0.724 1.143 1.810
34.00 0.746 1.178 1.866
perature to the design pressure values (from the 36.00 0.768 1.212 1.920
When you choose one of our mo- 38.00 0.789 1.245 1.973
tors, you’re doing more than just
table) to calculate the maximum recommended 40.00 0.810 1.278 2.024
buying a quality product. You’re working pressure. For example, the combined 42.00 0.830 1.309 2.074
44.00 0.849 1.340 2.123
bene¿tting from the Nippon Pulse derating factor for 316SS tubing for B (severe) 46.00 0.868 1.370 2.170
48.00 0.887 1.399 2.217
Advantage. To learn more, contact service and 500°F operation is 0.67 × 0.9 = 0.60. 50.00 0.905 1.428 2.263
a sales engineer at 540.633.1677. 55.00 0.949 1.498 2.373
60.00 0.991 1.565 2.479
Selection example 65.00 1.032 1.629 2.580
70.00 1.071 1.690 2.677
Here’s an example of the tube-sizing pro- 75.00 1.109 1.749 2.771
cess for pressure, return, and suction lines for 80.00
85.00
1.145
1.180
1.807
1.862
2.862
2.950
a hydraulic power unit using petroleum-based 90.00 1.214 1.916 3.036
95.00 1.248 1.969 3.119
hydraulic fluid. Operating temperature range 100.00 1.280 2.020 3.200
is –20 to 140°F, maximum operating pressure is 110.00 1.342 2.119 3.356
Also Available from Nippon Pulse 120.00 1.402 2.213 3.505
tin-can steppers, hybrid motors, 3,500 psi, maximum flow rate through each line 130.00 1.459 2.303 3.649
140.00 1.515 2.390 3.786
linear steppers, drivers, controllers, is 10 gpm, and severity of service is A (normal). 150.00 1.568 2.474 3.919
prototyping, system engineering, and 1. Select tube material. Carbon steel, C-1010, 160.00
170.00
1.619
1.669
2.555
2.634
4.048
4.172
product/application support is an economical choice. It is suitable for 180.00 1.717 2.710 4.293
190.00 1.764 2.784 4.411
petroleum fluids, has an operating tem- 200.00 1.810 2.857 4.525
perature range of –65 to 500°F, and meets

130
Flow diameters listed
maximum operating pressure requirements. here are based on
Tubing suppliers provide data on many maximum allowable
other materials, such as alloy and stainless velocity of fluid
1LSSRQ3XOVH steels, copper, aluminum and Monel, as well through the line.
<RXU3DUWQHULQ0RWLRQ&RQWURO as plastics such as nylon and PVC.
ZZZQLSSRQSXOVHFRP«LQIR#QLSSRQSXOVHFRP
2. Size the tube. According to the Flow diam-
RS# 150
62 MACHINE Design.com MAY 20, 2010
 Revolutionizing
Encoder
Technology

The Benefits of Capacitive Technology

Flexible- 9 shaft adapters mate with various motors
Rugged- resilient to dust & dirt, temperature & vibration
Green- less than 10 mA current consumption
Simple- quick & easy to assemble on a motor

AMT100 AMT203 AMT303

Incremental Encoder Series
16 programmable resolutions up to
2048 PPR via onboard DIP switch
 Single pulse index per revolution
 Optional line driver available
Absolute Encoder Series
12 bit resolution
 Zero position programmable by SPI
command or by ground trigger
 Incremental A, B outputs for
high speed applications
Commutation Encoder Series
Three phase U, V, W
- U , V, W line driver optional
Pole count, commutation angle and zero
position programmable via SPI interface
Resolution programmable via SPI interface
Operates with 2, 4, 6, 8, 10 pole pair motors

CUI has developed a unique and versatile line of modular rotary encoders that utilize patented capacitive technology to convert motion into
a readable digital signal. Utilizing an AISC rather than an optical disk, the AMT offers a number of advantages in the areas of engineering,
purchasing, and inventory control when compared to other encoder technologies used in today’s motion control applications.
Learn more at www.amtencoder.com/technology

www.amtencoder.com

RS# 151
 HYDRAULICS

eter table, recommended IDs

for lines at 10 gpm flow rate are:
Pressure ratings
Design pressure, psi
0.405 in. for the pressure line,

Wall thickness, in.

(4:1 design factor)
0.639 in. for the return line, and

Tube OD, in.

Tube ID, in.

(304, 316, 4130,

Stainless steel
1.012 in. for the suction line.

Steel 1010

Steel 1021

Copper
HSLA)
3. Pressure rating. Now, using the
pressure-rating table, find tubes
with IDs equal to or greater than 0.250 0.020 0.210 2,150 2,600 3,250 1,050
the above flow diameters, and wall 0.250 0.028 0.194 3,100 3,700 4,650 1,500
0.250 0.035 0.180 3,950 4,750 5,950 1,900
thicknesses appropriate for design 0.250 0.049 0.152 5,750 6,900 8,650 2,750
0.250 0.058 0.134 6,900 8,300 10,400 3,300
pressures of 3,500-psi minimum 0.250 0.065 0.120 7,800 9,350 11,750 3,750
for the pressure line and about 0.250 0.083 0.084 9,950 11,950 15,000 4,800

500 psi for return and suction 0.500 0.028 0.444 1,500 1,800 2,200 700
lines. Because derating factors for 0.500
0.500
0.035
0.049
0.430
0.402
1,850
2,700
2,200
3,250
2,800
4,050
900
1,300
severity of service and maximum 0.500 0.058 0.384 3,250 3,900 4,850 1,550
0.500 0.065 0.370 3,650 4,400 5,500 1,750
operating temperature are both 0.500 0.072 0.356 4,100 4,900 6,150 1,950
1.0, design pressure values in the 0.500
0.500
0.083
0.095
0.334
0.310
4,800
5,550
5,750
6,650
7,200
8,350
2,300
2,650
tables do not need to be reduced. 0.500 0.109 0.282 6,450 7,750 9,750 3,100
0.500 0.120 0.260 7,200 8,650 10,800 3,450
0.500 0.134 0.232 8,050 9,650 12,150 3,850
Next, match tube IDs and pres- 0.500
0.500
0.148
0.188
0.204
0.124
8,950
11,050
10,750
13,250
13,450
16,600
4,300
5,300
sures in the tables for these condi-
0.625 0.072 0.481 3,200 3,850 4,800 1,550
tions. For the pressure line, select 0.625 0.083 0.459 3,750 4,500 5,650 1,800
0.62-in. OD × 0.083-in. wall tubing. 0.625 0.095 0.435 4,350 5,200 6,550 2,100
0.625 0.109 0.407 5,050 6,050 7,600 2,450
The 0.095 and 0.109-in.-thick wall 0.625 0.120 0.385 5,600 6,700 8,450 2,700
0.625 0.134 0.357 6,350 7,600 9,550 3,050
would also be satisfactory if 0.083-in. 0.750 0.035 0.680 1,200 1,450 1,850 600
wall is not readily available. 0.750
0.750
0.049
0.058
0.652
0.634
1,750
2,100
2,100
2,500
2,600
3,150
850
1,000
For the return line, either 0.75 × 0.750 0.065 0.620 2,350 2,800 3,550 1,150
0.750 0.072 0.606 2,650 3,200 3,950 1,250
0.035 in. or 0.75 × 0.049 in. would 0.750 0.083 0.584 3,050 3,650 4,600 1,450
meet requirements. Also note that 0.750 0.095 0.560 3,550 4,250 5,350 1,700

the type of fitting can affect tub- 0.875 0.065 0.745 2,000 2,400 3,000 950
ing selection. Here, for instance, 0.875
0.875
0.072
0.083
0.731
0.709
2,200
2,600
2,650
3,100
3,350
3,900
1,050
1,250
SAE J514 flareless fittings (Parker 0.875 0.095 0.685 3,000 3,600 4,500 1,450
0.875 0.109 0.657 3,500 4,200 5,250 1,650
Ferulok) would require 0.75 × 0.875 0.120 0.635 3,900 4,700 5,850 1,850
0.065 in. because 0.065 in. is the 0.875
0.875
0.134
0.148
0.607
0.579
4,400
4,900
5,300
5,900
6,600
7,350
2,100
2,350
thinnest wall recommended for this 1.000 0.035 0.930 900 1,100 1,350 450
1.000 0.049 0.902 1,300 1,550 1,950 600
fitting with 0.75-in. tubing. This 1.000 0.058 0.884 1,550 1,850 2,300 750
1.000 0.065 0.870 1,750 2,100 2,600 850
would reduce flow diameter about 1.000 0.072 0.856 1,950 2,350 2,900 950
3% below recommended, but is still 1.000 0.083 0.834 2,250 2,700 3,400 1,100
1.000 0.095 0.810 2,600 3,100 3,900 1,250
in the acceptable range. The alter- 1.000 0.109 0.782 3,000 3,600 4,550 1,450
1.000 0.120 0.760 3,350 4,000 5,050 1,600
native would be 0.87 OD × 0.072-in. 1.000 0.134 0.732 3,800 4,550 5,700 1,800
wall tubing, which is excessively 1.000
1.000
0.148
0.156
0.704
0.688
4,200
4,450
5,050
5,350
6,350
6,700
2,000
2,150
large. Fitting manufacturers provide 1.000 0.188 0.624 5,500 6,600 8,250 2,650
1.000 0.220 0.560 6,550 7,850 9,800 3,150
tube thickness recommendations 1.250 0.049 1.152 1,000 1,200 1,550 500
for various fittings and sizes. 1.250
1.250
0.058
0.065
1.134
1.120
1,200
1,350
1,450
1,600
1,850
2,050
600
650
For the suction line, use 1.25 OD 1.250 0.072 1.106 1,500 1,800 2,300 750
1.250 0.083 1.084 1,750 2,100 2,650 850
× 0.049 to 0.083-in. wall tube for SAE 1.250 0.095 1.060 2,050 2,450 3,050 1,000
J514 37° flare (Parker Triple-Lok) or 1.250
1.250
0.109
0.120
1.032
1.010
2,350
2,650
2,800
3,200
3,550
3,950
1,150
1,250
SAE J1453 O-ring face seal (Parker 1.250 0.134 0.982 2,950 3,550 4,450 1,400
1.250 0.148 0.954 3,300 3,950 4,950 1,600
Seal-Lok) fittings and 1.25 OD 1.250 0.156 0.938 3,500 4,200 5,250 1,700
1.250 0.188 0.874 4,300 5,150 6,450 2,050
× 0.095-in. wall tube for flareless 1.250 0.22 0.810 5,100 6,100 7,700 2,450
fittings. This table shows the recommended
One final consideration is choos- OD and thickness for tube that meets
ing the right wall thickness for bent an application’s required flow velocity
tubing. If bending without a mandrel, and strength. For a more complete
then wall thickness of less than 7% of listing, visit http://www.parker.com/
tube OD is not recommended. MD literature/Tube%20Fittings%20
Division/General%20Technical.pdf
RS# 152
 3PRING
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RS# 153 RS# 154


 
 









 
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RS# 155
 MEDICAL INDUSTRY FOCUS

Connecting
with
portable
medical devices
As medical
equipment becomes
more portable and
is used in small
clinics and homes,
connectors must By shrinking
the distance
be safe, simple, and between pins
to less than
reliable. 1 mm, small
connectors
such as this
QLC model
Engineers designing connectors for for portable
portable medical equipment must medical
take several factors into consider- equipment can
ation, including size and insertion house 260 pins.
force, shielding from interference,
and preventing electrical shocks.
Here’s a closer look at mechanical, electrical, and safety mountings that measure just 74 × 19.4 × 18.5 mm. Having
requirements, as well as customer concerns. more pins lets engineers choose from a variety of ground-
ing schemes to maintain signal integrity, and this makes
Mechanical considerations these connectors well suited for portable ultrasound ma-
Connectors must often be small but have high pin chines, patient monitors, and test equipment.
counts. Customers are also demanding more mating cy- Engineers have devised several approaches to extend-
cles (connect-disconnect) along with consistent and reli- ing connector life, including new materials and entirely
able connections. In many cased, customers also want new designs. For example, modern connectors with rug-
zero-insertion-force (ZIF) designs. ged nickel-plated aluminum housings can have minimum
To meet demands for smaller connectors with more rated lives of 20,000 mating cycles with no performance
pins, designers are working to cut pin spacing to less than loss. Such connectors can also be mated and unmated in
1 mm. This can shrink the size of the connector by more less than 2 sec and cost 25% less per mated line than high-
than 60% compared to older connectors with the same density rack-and-panel versions.
number of pins. As a result, some connectors boast 260 Designers have also come up with a quick-disconnect
contacts, each with a 0.8-mm contact pitch, in PC-board breakaway connector that includes a simple push/pull

66 MACHINE Design.com MAY 20, 2010

 Zero-insertion-force
connectors extend
life cycles and reduce
cross-talk.

Authored by:

mating mechanism rated at more than 5,000 cycles. And the coupling mechanism’s
Carl Bunke
Project Engineer, Advanced
canted spring cuts the time it takes to hook up medical gear. Technology
Breakaway features that remove the danger of tearing connectors off equipment ITT Interconnect
or out of walls are another recent innovation. Breakaway connectors are often used Solutions
in portable medical imaging and diagnostic equipment because they are rugged and White Plains, N.Y.
reliable enough to withstand field use. Some breakaway connectors feature a spring Edited by Stephen J. Mraz
probe pin and pad contacts for durability and to withstand harsh environments. stephen.mraz@penton.com
The probe pin in the plug connector works across multiple sizes. An internal clip
ensures individual pins and sockets remain electrically connected and accommo- Resources:
ITT Interconnect
date misalignments. The spring probe lets the connector receptacle house individual Solutions, www.ittcannon.
touch-pad areas, providing reliable electrical contacts. Further, the spring probe and com
touch pads make connectors easy to clean in the field. The individual touch pads, for
instance, contain no crevices that let contaminants accumulate.
ZIF connectors, besides being easy to engage and disengage, also rate high in
terms of mating cycles, durability, and minimizing cross-talk. This lets them serve
well in patient monitors and portable imaging equipment
like ultrasound devices. ZIF connectors often use landed
contacts, which eliminate engagement forces and reduce Tools for getting the
wear on the contacts to the short time they are pressed
together and lightly wiped past each other during cam-
perfect connector
and-lock operations. As a result, contacts in the plug and Design-failure-mode-effects analysis (DFMEA) and
receptacle do not touch each other while connector halves process-failure-mode-effects analysis (PFMEA) play sig-
are being engaged. Not only do these connectors have nificant roles in meeting the mechanical and electrical
minimum rated lives of 10,000 mating cycles, they can be design challenges of building the right connector for
mated in less than 2 sec. a specific application. DFMEA explores ways products
might fail during real-world use, while PFMEA investi-
Electrical considerations gates whether manufacturing process will be able to
Once engineers determine a connector’s mechanical handle a given design.
characteristics, electrical issues come into play, including Another tool, 3D modeling, often via stereo-lithogra-
contact resistance and shielding requirements. phy (SLA) or selective-layered sintering (SLS), is also cru-
Contact resistance impedes current flowing through cial to successful medical-connector designs. It has be-
the connector. One way to decrease this resistance is by come the preferred way to make connector prototypes.
choosing the right material. For example, gold plating over Manufacturers can also drop a 3D model of a connector
contacts made of high-conductivity copper alloys lowers into a model of the customer’s equipment to verify that
resistance. If strength is a concern, consider using beryl- it will meet design specifications.
lium copper as the base material. Beryllium copper also
has low stress relaxation which boosts the number of mat-

MAY 20, 2010 MACHINE Design.com 67

 MEDICAL INDUSTRY FOCUS

Quick-disconnect breakaway
connectors from ITT feature a spring
probe pin and pad contacts that
accommodate misalignments.

ing cycles the connectors

will withstand.
Spring-
probe-and
pin-pad
designs
mentioned earlier also reduce electrical resistance, thanks
to the internal clip that always provides a highly conduc-
tive path.
Shielding against EMI and RFI signals, another consid-
eration, is critical for devices such as pacemakers and pa-
tient monitors. Signal noise can affect a pacemaker’s oper-
ation and corrupt data in monitors. In these applications,
it is also vital that connectors use nonmagnetic materials
because magnetic emissions degrade image clarity and
increase signal noise. As a result, connector manufacturers
rely on stainless steel, alloys, and brasses, as they offer non
or low-magnetic fields, thus keeping EMI/RFI from inter-
fering with equipment. Shielding effectiveness lets some
connector manufacturers offer EMI performance greater
than 85 dB at frequencies from 40 MHz to 10 GHz.
Another method of minimizing effects of EMI/RFI is to
overmold the connector cable. This is often accomplished
by attaching a stainless-steel shield over the shell (the
shielding lies between the wires and connector jacket), and
then premolding or overmolding the end of the cable to
the connector. So when there is EMI/RFI, it is absorbed by
the overmolded cable, thus minimizing insertion loss and
any electrical variations. The overmold also adds tensile
strength to the cable.
Some connectors use springs and shield-locking
mechanisms to ensure pressure around the perimeter of
the mated connector is uniform and creates an EMI/RFI
shield. By eliminating EMI/RFI disruptions, signal noise

RS# 156
can’t affect pacemakers, nor can it corrupt data or images
traveling from or stored in patient monitors and diagnos-
tic equipment. And shield cans placed on PC boards pro-
tect circuits from signal interference.
Filter connectors also play a critical role in manag-
ing and controlling EMI and RFI. Some connectors have
standard filtering features, including individual isolat-
ed-pin filtering for high-frequency
noise, built-in ground plane barri-
ers in connector inserts, and shield
cans on PC boards to protect circuits
from signal interference.
But the filter-design approach is
more effective. It lets engineers de-
fine and change individual circuit
capacitance, ground, and electro-
magnetic-pulse (EMP) performance
during development.
To ensure medical devices work,
especially in critical applications,
engineers must design intercon-
nects that are reliable and maintain
signal fidelity. This can be done by
using breakaway connectors, EMI-
shielding, and grounding-electron-
ics cables. Such designs allow for
shell-to-shell grounding at less than
10 mΩ, as well as EMI performance
of greater than 85dB at frequencies
from 40 MHz to 10 GHz. Perfor-
mance is further enhanced by ter-
mination processes which allow for
360° shield/connector coverage.
Complex EMI/RFI electronic is-
sues have driven connector manu-
facturers to develop higher-per-
formance and more-cost-effective
EMI-suppression methods, includ-
ing spring-probe contacts a chip-on-
flex (CoF) filter. CoF filters, using
a flex circuit with chip capacitors,
are surface-mounted to a pad on the
feed-thru contact. This replaces tra-
ditional planar-array block capaci-
tors and while provides reliable fil-
tering. In addition, the filters per-
form well despite thermal shocks
and vibrations.
Safety considerations
From a safety aspect, portable
medical devices need finger protec-
tion and touchproof connectors.
IP2X, a finger-protection standard,
requires that a connector’s live or
electrified parts cannot be touched
by a human finger. Because por-
table medical equipment may need
to be repaired in the field, touchproof connectors pre-
vent health-care professionals and patients from getting
shocked when they touch a connector. Touchproof con-
struction often involves placing a plastic plunger over
male pins, letting only the female contacts touch the male
pin. Making pins on the active side of the connector touch-
proof using any means eliminates the risk of shocks. MD
Precision Motion Control
High Precision HD Gear
CSF Component Sets provide
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The CSF-2UH Series is a housed Harmonic
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160:1 and provides peak torque ranging from
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positional accuracy better than 1 arc-minute.
Zero Backlash Gearhead
The CSF-GH is a precision, zero-backlash
gearhead designed to easily mount to any
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output bearing provides option for flange or
shaft output. The CSF-GH has a peak torque
ranging from 18 Nm through 2,630 Nm,
depending on the unit size. Gear reduction Hollow Shaft Brushless Actuators feature a through-bore up to
ratios of 50:1 through 160:1 are available.
14mm in diameter and provide high-torque and exceptional positioning accu-
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1.5 arc-minute is achieved. The FHA Mini Series is available in three frame sizes
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The SHF-2UH is a zero-backlash Harmonic
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TOTAL MOTION CONTROL
an integral cross roller output bearing and a
large hollow shaft. Peak torques ranging from
9.0 Nm through 1,840 Nm and hollow shaft I.D. Call to speak with an
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depending on the unit size. 800.921.3332 www.HarmonicDrive.net
RS# 157
MAY 20, 2010 MACHINE Design.com 69
 Get in the Groove . . .
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Circle 158
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RS# 161 RS# 162

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RS# 159 RS# 160

 MOTORS & DRIVES TECH GUIDE

Medical-device
makers warm up
Piezoceramic
to piezomotors
motors and actuators
avoid several problems
that beset ordinary
motors in medical uses.

Authored by:
Jim McMahon
President
Zebra Communications
Simi Valley, Calif. A miniature
Piezoelectric motors and actuators have many advantages
Edited by Robert Repas piezo-linear
over conventional electromagnetic (EM) motors for med- motor mounted
robert.repas@penton.com ical equipment. Current medical applications for piezoelec- on the left side
Key points: tric devices include ultrasonic emitters, artificial fertiliza- of the circuit
t

1JF[PFMFDUSJD
NPUPST
BOE
BDUVBUPST
BSF
tion, medical nanomicroliter pumps, micromonitoring, board can reach
not affected by electromagnetic fields. surgery devices, and MRI-compatible robots. They are velocities of
t

1JF[P
EFWJDFT
DBO
SFBDI
BDDFMFSBUJPOT
particularly useful for pick-n-place systems as used for 200 mm/sec.
of more than 10,000 g and response microdose dispensing, cell penetration and cell imaging in The right side of
times of less than 0.01 msec. cytopathology, and medical material handling. the board holds
the motor-drive
t

5IF
FGGJDJFODZ
PG
QJF[PFMFDUSJD
NPUPST
electronics.
JT
OPU
SFEVDFE
CZ
NJOJBUVSJ[BUJPO Piezoelectric actuators
Resources: A piezoelectric (or just piezo) actuator is a solid-state de-
vice that uses the change in shape of a piezoelectric material when an electric
Pari Pharma, www.paripharma.com field is applied to create motion. A piezoelectric-ceramic element produces
Physik Instrumente L.P., mechanical energy in response to electrical signals, and conversely, is capable of
www.pi-usa.us Circle 621 producing electrical signals in response to mechanical stimulus.
Zebra Communications, The use of piezoelectric materials dates back to 1881 when Pierre and
www.zebracom.net Jacques Curie observed that quartz crystals generated an electric field when
Tiny Motors Make Big Moves, tinyurl. stressed along a primary axis. The term piezoelectric derives from the Greek
com/38p4yym word “piezein,” meaning to squeeze or press, relating to the electricity that re-
Micro Moves, tinyurl.com/3xnc5h4 sults from pressure applied to a quartz crystal.
[Open in new window] Piezoelectric ceramics consist of ferroelectric materials and quartz. Piezo-
ceramic elements typically start as high-purity powders of piezo materials such
as PZT (plumbum, zirconate, titanate) that are pressed to shape, fired, elec-
troded, and polarized. Polarization uses high electric fields to align the material

72 MACHINE Design.com MAY 20, 2010

RS# 163
 MOTORS & DRIVES TECH GUIDE

oscillation creates only a

domains along a primary axis. few nanometers of move-
Piezoelectric actuators in their ment, but the number of
basic form produce small dis- vibrations per second is so
placements, but generate huge high that the rotor appears
forces. The minute size of the to move with a smooth mo-
displacement is the basis for tion over a virtually unlim-
the high precision motion they ited travel range.
can deliver. Today’s ultrasonic reso-
Long travel ranges use a nant motors, such as the
clever arrangement of multiple PILine model developed
actuators or the operation of a by Physik Instrumente,
single piezo element at its reso- Auburn, Mass., are char-
nant frequency. These types of acterized by speeds to
piezomotion devices are called 500 mm/sec. Such mo-
piezomotors. tors can produce acceler-
Two piezomotors in par- ations to 10 g. The motor
ticular seem to work best for mechanisms are also stiff,
medical applications. The first a prerequisite for their fast
is an ultrasonic piezo-linear step-and-settle times of a
motor, also called a resonant few milliseconds with res-
motor. The second is a piezo- olutions to 0.05 μm.
stepper motor. Both versions Piezo-stepper-linear mo-
provide unlimited travel or The atomizer head of a Pari Pharma eFlow tors usually consist of sev-
movement, yet both are differ- Rapid Electronic Nebulizer uses an annular eral individual piezoactuators
ent in their design, specifica- piezotransducer to atomize liquids for aerosol and generate motion through
tions, and performance. delivery of medications. a succession of coordinated
clamp/unclamp and expand/
How it moves contract cycles. Like the resonant motor, each extension
Ultrasonic piezoelectric motors use ultrahigh-fre- cycle provides only a few microns of movement. Continu-
quency acoustic vibrations on a nanometer scale to cre- ous motion arises from the high operating frequency that
ate linear or rotary motion. Though identified as acoustic can create speeds up to 10 mm/sec.
energy, the frequency of the vibration is far beyond human Unlike the ultrasonic piezomotors that function
hearing. Large travel ranges at high speeds typically use through vibrations, piezo-stepper motors like Physik’s
ultrasonic linear drives. The 50-nm resolutions they ex- PiezoWalk can achieve forces of up to 700 N (155 lb) with
hibit makes them a better alternative to electromagnetic picometer (ρm or 1 × 10-12-m) resolution. A resolution of
motor-spindle combinations. The ultrasonic drives are 50 ρm (0.00005 μm) has been demonstrated. The motor
substantially smaller than conventional EM motors, and can perform extremely high-precision positioning over
they don’t need the drivetrain elements that convert rotary long travel ranges. When it reaches position, it can switch
to linear motion.
Piezoelectric linear motors Various-shaped piezo devices serve specific purposes. Two linear
use a rectangular monolithic pi- stages (bottom and right) flank a circular rotary stage that uses
ezoceramic plate as the stator ele- three pushers that rotate the center collar.
ment, segmented on one side by
two electrodes. Depending on the
desired direction of motion, one
of the electrodes is excited to pro-
duce high-frequency eigenmode
oscillations (one of the normal vi-
brational modes of an oscillating
system) from tens to hundreds of
kilohertz. Attached to the plate
is an alumina friction tip called
a pusher that presses against the
moving portion, the rotor of the
motor. As the piezo plate vibrates,
the pusher produces microim-
pulses against the rotor and drives
it either forward or backward. Each

74 MACHINE Design.com MAY 20, 2010

 Challenge Answer

One control IndraMotion MTX

system for many CNC System
machine types ?

Stacks of encapsulated piezoceramic material

will drive a rod actuator arm through the
circular hole at the top of the stack.







to a highly dynamic motion system for tracking, scanning,

 

or active-vibration suppression. Both the ultrasonic piezo-
 









 

motors and piezo-stepper motor can operate in the pres-

ence of strong magnetic fields or at low temperatures.

Types of actuators
There are a number of different piezoactuators and
motor types currently available. Simple piezoactuators
expand proportionally in relation to the drive voltage and
are typically classified as stacked, shear, tube, or bender.
The stacked actuator is the most common type. It devel-
ops a high force with fast response over a short travel. The
shear actuator works best for lateral motions, such as fast,
XY systems. It develops high force at high frequencies, but
 
  

travel is typically limited to 20 μm. Tube actuators mostly
serve in microdispensing applications and AFM scanners.
Although the bender actuator can reach several millime-
ters of travel, its low force and low frequency limits its use.
The virtually frictionless flexures and motion ampli-
fiers used with flexure-guided piezoactuators give longer
travel with an extremely straight motion. The motion is
basically proportional to the drive voltage and integrated
multiaxis systems are available. The “frictionless” opera-
tion minimizes wear and tear over an extended motion
range of 2 mm or more.
As referenced earlier, ultrasonic-friction motors are
based on high-frequency oscillation of a piezoplate (sta-
tor) to give unlimited high-speed motion with response
times in the tens of milliseconds. This oscillation transfers
to a slide or rotor via friction but this limits resolution
typically to 50 nm.
Likewise, piezo-stepping motors basically possess un-
limited motion range by an accumulation of small control-
lable steps. Direct piezo actuation can develop picometer



 

 



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CNC platform for cutting, forming and
automation machinery. Implement it
today: IndraMotion MTX gives you
the tools and functionality to achieve
efficient, flexible and productive machine
control, whether controlling one machine
or a fully automated production system.
The Drive & Control Company
Automation House
Bosch Rexroth Corporation Q www.boschrexroth-us.com Q 1-800-REXROTH
Learn more about our GoTo program for fast delivery: www.boschrexroth-us.com/goto

resolution using a dither mode while generating forces

to 155 lb for off-the-shelf units. This motor has a fast re-
sponse of less than 1 msec with high stiffness.
UItrasonic transducers use plate or disk-driven piezo
elements with a high frequency at resonance. These ac-
RS# 164
 MOTORS & DRIVES TECH GUIDE

PiezoWalk Principle
accuracy even
Miniature ultrasonic This miniature Preload
when powered
ultrasonic
motor motor has only down.
four parts, Piezo de-
Piezoelectric Spring
an ultrasonic vices provide
actuator
piezoresonator faster accelera- Ceramic runner
and two lateral tion and so can
sliders pressed react in a mat-
against it ter of micro-
by a spring s e c on d s . Ac -
doubling as celeration rates Preload
the moving
of more than
carriage.
The load is 10,000 g with In one type of piezoactuator,
the PZT material consists of two
Slider mounted response times levels that move at right angles.
directly to the of 0.01 msec are In a typical operation, the base
carriage spring. possible. material extends to push the tip
Piezoelec- against a ceramic runner. The tip is
tric motors are them powered to push the runner
useful for medi- in the desired direction. Voltage is
tuators are typically used as sensors, transducers, or in cal and biotech- removed from the base to release
nebulizers. nology applica- the runner, and the tip them returns
tions as they do to its normal position.
Improved performance not create elec-
Piezoelectric motors make medical devices smaller, tromagnetic in-
more precise, lighter, and easier to control. For example, terference — nor are they influenced by it — eliminating
piezomotors are smaller and more compact than elec- the need for magnetic shielding. This is particularly im-
tromagnetic motors, yet can provide a greater force. The portant for motors within strong magnetic fields, such as
efficiency of electromagnetic motors falls as their dimen- those in MRI equipment. Small piezomotors find use in
sions shrink because more of their electrical power gets MRI-monitored microsurgery while larger piezomotors
converted to heat. The efficiency of piezoelectric mo- rotate patients and equipment. The magnetic fields and
tors stays virtually constant. For the same volume and metal components in conventional electric motors make
weight, the stored energy density of a piezomotor is 10× it impossible for motorized medical devices to function
greater than that of an electromagnetic motor. The most within MRI equipment.
advanced piezomotors are found in compact, high-speed Because piezomotion depends on crystalline effects
micropositioning stages smaller than a matchbox. The and not rotating parts like gears or bearings, piezomotors
smallest piezomotor-driven stages are currently found in are virtually maintenance-free and do not need lubrica-
autofocus devices for cell-phone cameras. tion. Additionally, they can be sterilized at high tempera-
The higher force-to-size ratio of piezomotors lets en- tures, a significant advantage in medical applications.
gineers design smaller equipment and instrumentation Static operation, even while holding heavy loads for
devices while maintaining or improv- long periods, consumes practi-
ing performance through a number cally no power. Also, because
of different factors. For example, the Piezo stack miniaturization does not reduce
direct-drive principle of piezomotors the efficiency of piezoelectric
eliminates the need for supplemen- ΔL Polarization motors, they are still effective in
tary transmissions or gear trains found power ranges below 30 W. This
with conventional electromagnetic makes piezomotors prime can-
motors. The mechanical-coupling el- didates for use in battery-op-
ements otherwise needed to convert erated, portable, and wearable
the rotary motion of classical mo- L medical devices because they
tors to linear motion are unnecessary. can extend the life of a battery
Elimination of mechanical coupling as much as 10×.
avoids the usual backlash effects that When at rest, piezomotors
limit accurate positioning. The intrin- do not generate heat. They also
sic steady-state autolocking capabil- eliminate servo dither and the
ity of piezoelectric motors also does A piezo stack does just that, stacks heat that accompanies it.
away with servo dither inherent in different piezo material to extend In principle, piezomotors are
electromagnetic motors. Piezomotors the overall length and motion. vacuum compatible, a need for
can hold their positions to nanometer many applications in the medi-

76 MACHINE Design.com MAY 20, 2010

 Linear piezomotor
Bearing
Mounting The ironless maxon winding.
platform High efficiency, no magnetic
Glued cogging.
friction
bar

Excitation
electrode
Friction tip
Piezoactuator (stationary

A compact piezomotor linear-translation stage uses a

single actuator to push a bearing along a mounting-
platform guide.

cal industry. They can also continue to operate at cryo-

genic temperatures close to 0°K.
Piezomotors are also not flammable and, therefore,
safer in the event of an overload or short circuit at the maxon DC motor
output terminal, a considerable advantage for portable
and wearable medical devices.

Medical applications
Finally, it is useful to consider medical uses where pi-
Close to 100%.
ezoactuators excel. In Optical Coherence Tomography,
piezoelectric motors impart rapid periodic motion to the
unit’s reference mirror and imaging optics. To create 2D
and 3D images from optical-interference patterns, opti-
cal fibers must move both axially and laterally during the
scan. Piezomotors provide more-precise movements im-
When energy-efficient drives are called for, maxon DC
proving image resolution over conventional electromag- motor provides the answer: the premium DC motors with
netic motors. ironless rotor come in a comprehensive selection – Ø 6 to
Piezoelectric actuators are finding use in transdermal- 65 mm, 0.3 to 250 watts – and feature high power density
drug delivery and systems for needle-free insulin injec- and a more than 90% efficiency factor. Feedback devices,
tion. End-effect manipulation of endoscope and gastro- gearheads and control electronics are also available for a
complete drive system.
scope devices also employ piezoelectric devices.
The microrobot bases used with biomedical microtools
such as tweezers, scissors, and drills are powered by piezo- maxon motor is the world’s leading supplier of high-preci-
sion drives and systems of up to 500 watts power output.
motors. Confocal microscopy in ophthalmology also uses maxon motor stands for customer specific solutions, high
piezoelectric motors for quality assurance of implants. The quality, innovation, competitive prices and a worldwide dis-
optics must move precisely to adjust the focal plane and tribution network. See what we can do for you:
for surface scanning. Piezoelectric positioning systems are www.maxonmotorusa.com
integrated directly into the optics.
As shown, the growing need for accuracy in the micron
and nanometer range, miniaturization of components, the
dynamics of streamlining, and immunity from electrical
interference push the physical limits for electromagnetic
drive systems. Piezoelectric motors look to fill the gaps
when the older technology hits its limitations. MD
RS# 165
MAY 20, 2010 MACHINE Design.com 77
 MOTORS & DRVES TECH GUIDE PRODUCTS
Ethernet-based servodrive
The Ethernet-based Advanced Koll-
morgen Drive (AKD) is available for
120/240-Vac or 480-Vac operation, with
a power range of 3 to 24-Arms continu-
ous current, 9 to 48-Arms peak. The unit
supports a variety of feedback devices
— mart feedback devices (SFD), Endat,
BiSS, Analog sine/cos encoders,
incremental encoders, Hiperface,
and resolvers — and Ethernet
Motion buses — EtherCAT, CANopen,
and Modbus/TCP.
The AKD’s autotuning algorithms
automatically adjust all gains, including
patent-pending observers. This func-
tion also provides immediate and adaptive
responses to dynamic loads and promises
precise control of all motor types.
The AKD features 27-bit resolution,
a powerful dual processor system that
executes servoalgorithms with high resolu-
tion for very-fast settling times, torque loop

"1,Ê7 Ê6
, /9Ê"Ê

 -Ê updates in 0.67 μsec, 6.25-μsec velocity, and
125-μsec position loops.

Ê
Ê/
/Ê" -Ê7/Ê/ ÊÊ Additional features optically isolated I/O

-Ê7
/Ê
 -Ê1-ÊÊ
that reduces noise and eliminates the need
for additional hardware; SIL-qualified, over-

/ Ê,
ʺ

 Ê19-°» voltage, current, and temperature detection;
option cards that increase available I/O and
add NVRAM; and multiaxis machine-control

ÌÊ-
]ÊÕÀÊÛ>ÌÊ>`Ê capability.
>VViÃÃÀiÃÊÌ> iÊÌiÊyiÝLÌÞÊ Kollmorgen, 203A West Rock Rd., Rad-
vÊÕÀÊÜ`iÊÀ>}iÊvÊV>LiÃÊÌÊ ford, VA 24141, (540) 633-3545, www.
ÌiÊiÝÌÊiÛi°ÊÊ>``ÌÊÌÊ kollmorgen.com
ÕÀÊV>LiÃ]ÊÞÕÊV>Êw`Ê>ÞÊ
vÊÌiÊiÝÌÀ>ÃÊVÕ`}Ê
À`Ê RS# 622
/iÀVÕ«iÃ]ÊÀiÃÃÌ>ViÊ
À«Ã]Ê
>LiÊ>ÀiÃÃ}]Ê*«Õ ÌiÀiÌiÀÃÊUÊ/ÕLiÊ«ÀLiÃ
>Ìi`Ê
>LiÃÊ/À>V Ã]Ê/iÀ Permanent-magnet motors
VÕ«iÃÊ>`Ê,/½Ã°
The IronHorse permanent-magnet dc
ÀÊÛiÀÊÈäÊÞi>ÀÃ]Ê-
Ê>ÃÊ
LiiÊÌiÊ«ÀÛiÊi>`iÀÊÊÌiÊ 56C-frame motors feature totally enclosed
`iÛi«iÌÊ>`Ê>Õv>VÌÕÀ nonvented (TENV) and totally enclosed
}ÊvÊÃÕ«iÀÀÊyiÝLiÊ>`Ê fan-cooled (TEFC) models. Constructed of a
VÌÕÕÃÊyiÝÊVÌÀÊV>LiÃÊ rolled-steel frame with cast-aluminum end
ÌÕÀ}ÊV>LiÊVÕÃÌiÀÃÊÌÊ
À`Ê}À«Ã bell, the motors are available in 0.33 to 2 hp.
Ã>ÌÃwi`ÊVÕÃÌiÀð With a base 1,800 rpm, the motors are
ÀÊÀiÊvÀ>ÌÊÀÊÌÊ designed
ÀiμÕiÃÌÊ>ÊÕÊiÊ
VViÃÃÀiÃÊ for use
V>Ì>}ÊÀÊ>ÊiÝLiÊ
ÌÀÊ on unfil-
>`Ê
ÕÌ>ÌÊ
>LiÊV>Ì>}]Ê tered SCR
VÌ>VÌÊÕÃÊÌÊvÀiiÊ>ÌÊ£nÈÈ (thyristor)
ÇÓÓÓÇ{° Type 115

>LiÊ>ÀiÃÃ}
or 230-V
rectified
ac inputs,
when
used with
an appropriate SCR drive or with PWM-type
dc adjustable-speed drives.
Additional features include linear speed/
-«iV>ÌÞÊ
V>Lià torque characteristics over the entire speed

>ÊÞÕÀÊV>ÊÊ range, high starting torques for heavy-

Ài«ÀiÃiÌ>ÌÛiÊ
Ì`>ÞÊ load applications, reversible rotation, and
 dynamic-braking capability for faster stops.





 
Large brushes provide for longer brush life.
AutomationDirect, 3505 Hutchinson
Rd., Cumming, GA 30040, (800) 633-0405,
ÓÎÊ>`ÃÊ,>`]Ê>Àwi`]Ê ÊäÇää{Ê
ÇΰÓÇÈ°äxääÊUÊ>Ý\ÊÇΰÓÇÈ°£x£xÊ www.automationdirect.com/dc-motors
ÜÜÜ°Ã>LV>Li°VÊUÊvJÃ>LV>Li°V RS# 623

RS# 166
78 MACHINE Design.com MAY 20, 2010
  
 

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RS# 175 RS# 174

 SOFTWARE REVIEW

Scalable software for gearbox and driveline engineering

RomaxDesigner provides a suite of tools for mechani-
cal analysis of rotating structural components such
as gears, shafts, bearings, clutches and synchronizers,
and spline connections and housings. Engineers de-
signing gearboxes, transmissions, vehicle drivelines
at a system level, as well as providers of components,
will find value in the consolidated analysis approach
this software provides. The unified approach is es-
pecially valuable when there are multiple nonlinear
interactions contributing to load, component stress, The gearbox model with
and misalignment. When components are operating helical and hypoid gears
near to their limits, the increased accuracy provided provides an example
by the detailed analysis modules lets users maintain of the complex designs
adequate safety factors while avoiding defensive RomaxDesigner supports.
overdesigns.
RomaxDesigner is duced-stiffness matrix from
modular software, with a finite-element model) or
a base package allow- as a finite-element model
ing system-level design solved in an advanced mod-
and analysis, and with ule. Users can define a bear-
modules that allow the ing simply as a rotatable
detailed analysis of indi- support with specified flex-
vidual components. The ibility; a catalog-level de-
base software can analyze sign with ISO capacities and
systems on parallel axes, macrogeometry; or with
with extensions available An analysis in full microgeometry, life ad-
RomaxDesigner shows the
to analyze perpendicu- deflection of the gears and
justment factors, and high-
lar shafts and planetary shafts under load. speed inertial effects. As the
systems. Even in the base model develops, users can
package, users can build add further detail to
and analyze complex sys- each component.
tems, including nonlinear The software then
and 3D effects. simulates the effect
Users define each The of a duty cycle or
system component with straight- series of loads on the
a level of complexity ap- forward entire system, with
propriate to the needed shaft multiple conditions
design is
analysis. Base modules let of speed, load, and
made up of
users define each compo- standard temperature defined,
nent using an industry- shaft allowing simultane-
standard closed-form features. ous cumulative dam-
equation. With more- age analysis of all
advanced modules, indi- components. Users
vidual components can can define and apply
be converted to models multiple duty cycles,
with finite-element attributes. For example, a housing reflecting different applications.
can be defined according to its stiffness, (using a re- RomaxDesigner models shafts for deflection and
stress using closed-form equations for beam seg-
ments. Advanced modules provide the capability to
WHAT’S THIS?
When you see a code like this, take use FE models for more-complex shaft geometry. Us-
a photo of it with your smart phone ers can choose from predefined materials and stress
(iPhone 3G-S gives best results) and, concentration factors, or develop their own. The base
using software from www.neoreader.
com, you will be connected to relevant
package can model parallel and concentric shafts. Per-
content on machinedesign.com pendicular shafts and moving axis (planetary) shafts
are modeled with extended modules. An additional

80 MACHINE Design.com MAY 20, 2010

 bearing life, the models include
the effects of misalignments de-
veloped through the flexibility
of any coupled components. A
bearing preload tool automates
studies of bearing life as a function
of preload. RomaxDesigner does
not currently include the effects
of localized housing distortion on
bearing roundness, nor a direct
way to calculate the effects of ther-
mal expansion on bearing fit and
preload. These features have been
proposed for a future release.
Advanced bearing-analysis
modules provide detailed analyses

A New Part wizard makes it simple

to select assemblies and components.

module analyzes shaft fatigue. The

software can define and analyze
shafts that are connected at non-
90° angles, though the gear defini-
tions for these systems are limited.
The base package provides
standard bearing-life and load-ca-
pacity analysis using ISO 281:1990
or ISO 291:2007. The program also
includes a modified rating with a
closed-form calculation of effects
of misalignment. A built-in data-
base includes data from four bear-
ing manufacturers’ catalogs. Users
can define and save additional
bearings. A bearing search tool
allows quick access to all four cata-
logs and user-defined bearings.
Bearing models provide non-
linear stiffness interactions with   
  

    
  
adjacent components, which     
  
     ! " #$   %&!! #   
can be critical when calculating   '
gear-support stiffness, gear-mesh      #  %&!! #     
misalignments and preload re- ! (
 
quirements. When calculating  )*   
#" !$
" #
  (" 
 +  ( ( 
 


 

Jonathan Adler  
  #
 
       "
Engineer – Specialist in product ,   #
design and systems analysis  -,(  ($    

McLaren Performance  
     
Technologies Inc. 

Livonia, Mich.

    

www.mclarenperformance.com
 

 
        


Edited by:
Leslie Gordon,  

  
leslie.gordon@penton.com

    

RS# 171
MAY 20, 2010 MACHINE Design.com 81
 SOFTWARE REVIEW

(ISO 281 Supplement 4), including
contact stress, fluid-film thickness,
and stress-based life calculation.
Advanced bearings can be defined
with an assortment of predefined
roller and raceway crowns, or with
a measured crown.
RomaxDesigner models may
include spur and helical gears,
and with the perpendicular-axis
module, bevel and hypoid gears.
The base software models gears
with enough detail to analyze their
effects on the rest of the system.
Additional modules allow design
and rating to AGMA, DIN and ISO
standards. For parallel-axis gears,
additional modules permit macro-
geometry definition and optimiza-
tion for manufacturability as well
as detailed analysis of microgeom-
etry for contact stress and trans-
mission error. RomaxDesigner
graphics are suitable for a variety
of reporting illustrations, such as
system topology and component
deflection.
For parallel and perpendicular-
axis gears, modules provide in-
terfaces to more detailed analysis
software, such as Simpack, LDP,
and AnSol. They act as a “front end”
for even more-computationally
intensive formulations of bending
and contact stress. The combina-
tion of these software packages is
particularly powerful, as it permits
cumulative damage-life analysis
including the nonlinear effects of
gear-tooth deflection and bearing
stiffness, acting on a fully devel-
oped tooth profile. Additional
modules focus on NVH and dy-
namic characteristics, such as gear
rattle and whine, system modal
analysis, and clutch analysis. Mod-
ules are also available to automate
optimization and for the sensitivity
analysis of system and component

Leading Edge Solutions designs.

The developer does not include
self-directed tutorials with the
For over 40 years Thomas has been providing leading edge pump and software, but the company does
compressor solutions to medical original equipment manufacturers provide user training directly. The
around the world. Whatever the medical application, Thomas has a trainers customize course content
proven track record of providing on-target solutions that not only meet and duration to meet the needs
the application’s requirements, but also routinely add value in terms of each organization. A one-week
of performance, size, weight and efficiency that time and again make training session would be suf-
our customer’s products better and more successful. ficient to cover the basic modules
and a few advanced topics. Many
For more information, visit gd-thomas.com highly specialized software pack-
ages require constant use to
become and stay proficient. I find
that RomaxDesigner does not
require this level of attention. En-
gineers with other responsibilities
will find this software functional
even if not used on a regular basis.
The software comes from Ro-
max Technology, based in Not-
tingham, U.K., with offices in Asia,
PUMP AND COMPRESSOR SOLUTIONS FOR OEMS WORLDWIDE
Europe, and North America (www.
romaxtech.com). MD

RS# 172
82 MACHINE Design.com MAY 20, 2010
 SPOTLIGHT SAFETY SENSORS & NETWORKS
Modular
safety control
The samosPro modular
safety control processes
up to 96 safety inputs and
48 safety outputs simul-
taneously. The control
monitors safety sensors
such as emergency stop
pushbuttons, light curtains,
and interlocking installations on
guard doors. The short reaction
time lets protective measures
mount closer to dangerous areas
of a machine. Measuring just
22.5-mm wide, the control lets
the units be used in construction
widths starting from 45 mm.
Gateways, such as Ethernet/
IP, Modbus/TCP, Profibus-DP,
and Profinet IO, transmit more
than 50 bytes bidirectionally
between a PLC or HMI and the
samosPro safety control, ensur-
ing fast and comprehensive diag-
nosis and visualization of control
data. Using samosPlan, users
program the control. Replaceable
programming memory, called sa-
mosMemory, holds the relevant
application program for the ma-
chine or system.
Wieland Electric Inc., 49 Inter-
national Rd., Burgaw, NC 28425,
(910) 259-5050, www.wielandinc.
com RS# 446
formation via
Request free in ice Web site at
our Reader Serv
sc
design.com/r
w w w.machine
Rotary encoders with
integrated safety technology
The RVS58S incremental rotary encoders, with integrated
safety technology, are designed for use in safety-aligned
systems up to SIL3 in accordance with IEC 61508, perfor-
mance Level “E” in accordance with IEC 13849, and Cat-
egory 4 in accordance with DIN EN 954-1. The encoders,
with self-diagnostics, are also suitable as a motor feedback
system for safe drives in accordance with IEC 61800-5-2.
The encoders have a sin/cos interface, 1,024 or 2,048 signal
periods, and are thermally stabilized for high-resolution interpolation.
The encoders operate at 5 Vdc ±5% and 200-kHz maximum output
frequency in temperatures ranging from –20 to 80°C. They are rated
to handle 40-N axial shaft loads at 6,000 rpm (maximum) or 10 N at
12,000 rpm (maximum), and 60-N radial shaft loads at 6,000 rpm (maxi-
mum) or 20 N at 12,000 rpm (maximum).
Pepperl+Fuchs, 1600 Enterprise Pkwy., Twinsburg, OH 44087;
(330) 486-0001, www.pepperl-fuchs.com
RS# 447
Safety network controller
The NE0A-SCPU01 safety network controller provides 12 safety inputs,
two test outputs, and six safety outputs, and can be used as a stand-
alone controller, a safety slave, or a DeviceNet standard slave. The
controller’s preconfigured and TUV-certified program templates make
the selection process easy. Designers can create safety circuits and save
them as reusable templates for fast and simple standardization.
The NE0A includes safety function blocks for E-stop,
door switch, external-device moni-
toring (EDM), safety light curtain,
limit switch, enabling switch, and
mode selector.
Omron Scientific Technologies,
6550 Dumbarton Circle, Fremont,
CA 94555, (888) 510-4357, www.sti.
com/controllers/NE0A/index.htm
RS# 448
Absolute encoders fulfill
safety requirements
The Posital Optocode Series of absolute en-
coders are now available as a safety version.
The encoders comply with the new Machin-
ery Directive by fulfilling the requirements
of IEC 61508 and EN 62061. Operated with
protective extra low voltage (PELV), the encoders are for use in drive
technology, lift applications, mobile machines, construction machinery,
and machine tools.
Fraba Inc., 1800 E. State St., Suite 148, Hamilton, NJ 08609, (609) 750-
8705, www.posital.com RS# 449
MAY 20, 2010 MACHINE Design.com 83
 -ICRO
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%LECTROFORM,ENS(OLDERS
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FOR%NDOSCOPIC6IDEOS  )(0*(+ 5  -/(& 5  (+ & 5 ,+)4  6

%LECTROFORM8 RAY6ISIBLE KNF applied its 60+ years of diaphragm pump experience to bring you
#ATHETER4ARGETS a new pump designed to provide increased pneumatic performance
-INIATURE &LEXIBLE3HAFT 0RECISION &LEXIBLE and compact size.The 2-head design with leak-tight internal
-ETAL"ELLOWS #OUPLINGS %LECTROFORMS )NTERCONNECTRIC
#ONTACTS connectors features low pulsation and minimum noise emissions.

Sealed compressor housing provides quiet operation

Internal head connections configured for reduced pulsation
-OLDSFOR#ATHETER4IPS
Clean, corrosion-resistant oil-free transfer of your media

For analyzers, medical devices, imaging, pneumatics

Motors include DC, low EMI/RFI BLDC or ironless-core

Small quantities are available for prototyping use
Your special OEM projects are always welcome
1*- KNF NEUBERGER, INC.
0(/.%&!8
INFO SERVOMETERCOMWWWSERVOMETERCOM .$$ 
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RS# 168 RS# 169

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RS# 170 RS# 167

 PRODUCTS Request free in
formation via
ice Web site at
our Reader Serv
sc
design.com/r
w w w.machine

Profinet connectors
The Hummel M23-based Profi- for transmission of signal and power achieve maximum
net high-speed industrial Ethernet power density/effectiveness within the M23 housing (Sig-
connector, combines Ethernet, nal 4 × 2 each 0.6-mm contacts) 0.08 to 0.34 sq mm – 28 to
data, or power lines in one single 22 awg (CAT6 - 0.25 sq mm) and 12 × 1 (0.25 to 1.5 sq mm).
interconnect package. The con- Sealcon, 14853 E. Hinsdale Ave., Suite D, Centennial, CO 80112,
nector carries up to five individual (800) 456-9012, www.sealconusa.com RS# 465
EMI-shielded circuits and guarantees
safe transmission up to Gigabit range
without interference. Connecting com-
ponents are HF-technically matched to a
resistance of 100 Ω at 100 Mbit, eliminat-
ing cross-talking.
The brass-alloy-cast connectors are
flame resistant (Twinax-inserts are V0
rated according to UL-94); vibration
safe, and have crimp contacts. Available
options include straight, elbow, and
panel mounts (front and rear); crimp and
PCB-mount connectors, I/O modules,
adapter, flange, and conduit adapter.
The unit has four shielded Twinax-inserts
for data transfers, 12 additional contacts

Machined springs
Machined springs provide linear de-
flection rates and, unlike traditional
wire wound springs, virtually all re-
sidual stresses are absent. There are no
internal stresses to overcome before
deflection occurs. All coils deflect
under load.

Machined springs with two or

more integral coils have redundant
elastic elements should a failure occur,
and the failed coil will be physically
trapped by a second coil (or multiple
coils). In many cases, a broken spring
will continue to function.
With machined springs, perpen-
dicularity, parallelism, lateral bend-
ing, and axial and torsional rates are
guaranteed.
Helical Products Co. Inc., Box 1069,
Santa Maria, CA 93456, (877) 353-
9873, www.heli-cal.com
RS# 466
RS# 176
MAY 20, 2010 MACHINE Design.com 85
PRODUCTS

Pneumatic assembly tools perform teners; stake, punch, pierce, and flare;
numerous manufacturing func- seal, emboss, and notch; and clamp
tions, improve product quality, and and hold assemblies.
Pneumatic increase productivity. Available as Fabco-Air Inc., 3716 NE 49th Ave.,
hand or bench models, the tools Gainesville, FL 32609, (352) 373-3578,
assembly make plumbing assemblies; splice www.fabco-air.com
tools wire rope and cable; crimp electrical RS# 467
components; swage mechanical fas-
Data acquisition and
display stations
The DXAdvanced R4 is latest version
"--
4&/4034n of the Daqstation data-acquisition
and display stations with high-capac-
SUPERTEAM ity memory and an option for strin-
gent pharmaceutical applications. An
XXXBMMTFOTPSTDPN Advanced Security option delivers full
compliance with FDA regulation 21
CFR Part 11. This is complimented by
Amplified Very Low Pressure Sensor a multibatch option that allows chan-
Includes a PCB mountable feature with dual pressure ports.
nels to be grouped and recorded to
Pressure ranges are available from 1/4 to 30 inch H2O full discrete batch records with indepen-
scale. Offset voltage errors are significantly reduced by dent start and stop control.
electrical cross coupling technology. Standard features include 400 Mbyte
www.allsensors.com/mad/amp.htm of internal Flash mem-
ory, with an optional
USB interface. Custom
Amplified Mini Low Pressure Sensor graphics let
users
Available in pressure ranges of 1, 5, 10, 20, and 30 inch H2O full design
scale. Output is available as a calibrated amplified signal with custom
superior output offset characteristics. display
www.allsensors.com/mad/mini.htm
screens.
An alarm-
annunciator display mode uses ISA
sequencing, which replaces common
Surface Mount Basic Pressure Sensor annunciator lamp panels.
Surface mount basic pressure sensors provide a low-cost solu-
Two models are offered — the
tion in a small footprint. Pressure ranges include 1, 15, 30, and DX1000 with two to 12 universal
100 PSI. In addition, an unprecedented 10 inch device is also inputs, 5.5-in. color display; and the
available with position sensitivity better than 0.03% full scale. larger DX2000 with 4 to 48 universal
www.allsensors.com/mad/smt.htm inputs and 10.4-in. color display.
Modbus RTU and TCP, EtherNet/IP,
and Profibus DP protocols aid instal-
Millivolt Low Pressure Sensor lation on control networks, and the
DXAdvanced R4 can interface with
Available in pressure ranges of 1, 5, 10, 20, and 30 inch H2O PLCs and other control products as a
full scale. Millivolt output is temperature compensated and data source or to add graphical data
calibrated to zero. www.allsensors.com/mad/mv.htm display and recording functions. An
external input option lets the DX2000
handle up to 300 additional inputs
Request our latest sensor Databook today! from external I/O for a total system
capacity of 348 inputs.
®
ALL SENSORS Yokogawa Corporation of America,
High accuracy. Low pressure. We are pressure sensors. 2 Dart Rd., Newnan, GA 30256, (770)
254-0400, www.yokogawa.com/us
408.225.4314 (P) 408.225.2079 (F) INFO@ALLSENSORS.COM RS# 468

RS# 177
86 MACHINE Design.com MAY 20, 2010
 $KJST(HKM@BI<IO The World Encoders!
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Qube 2.25" $120.00 RS $238.00 21/22 $ N/A $190.00 711
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:HVROYHSUREOHPV RS# 178 formerly Koyo Encoder, Inc. Toll Free: 1-800-903-9093
  




 








 






RS# 180

Build the Perfect

Rise of the Beast of a Line
Machines With Visumatic
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RS# 179
PRODUCT LIT
Tensioners
The Multi-Jackbolt Tension-
ers make large-diameter
bolting safer for workers, re-
duces installation and removal
times, and requires only hand/air
tools. The DVD, “The Simple Solution to
Bolting Problems,” explains the technol-
ISO 9001:2000
MEETING YOUR NEEDS FOR
PRECISION STAINLESS STEEL
EAGLE STAINLESS Tube & Fabrication Inc.
10 Discovery Way Franklin Massachusetts
phone 800-528-8650 fax. 800-520-1954
88 MACHINE Design.com
ogy in detail, com- (800) 345-2658, www.superbolt.com
pares this bolting RS# 469
method to others,
and covers common Motion-control
applications in a wide
variety of industries. components and systems
Superbolt Inc., Box 683, The 56-page Advanced Motion Sys-
1000 Gregg St., Carnegie, PA 15106, tems for Defense, Aerospace, and
National Security
includes multiaxis
motion simulators,
pedestals, precise
ISO 13485:2003 AS 9100 B
two-axis azimuth/
elevation gimbals,
vacuum-rated
motion systems,
advanced system
controls, and
high-performance
linear and rotary stages and gantries.
The brochure covers single, two,
and three-axis motion simulators,
advanced motion-simulator controls,
electro-optics test systems, high
load-capacity linear and rotary stages,
high-vacuum and clean-room-ready
systems, prototype laser and micro-
wave-beam steering systems, and
solar tracking and telescope systems.
One section covers high-performance
components that include rotary
stages, linear stages, and gantries.
Aerotech Inc., 101 Zeta Dr., Pitts-
([WHQVLYHLQYHQWRU\RI burgh, PA 15238, (412) 963-7470,
7XELQJ%DU6WRFN+ROORZ www.aerotech.com/PDFfiles/
%DU)ODQJHV3LSH)LWWLQJV CA0410BMil_Aero.pdf RS# 470
&XWWROHQJWKVWDLQOHVVWXELQJ
Metal stamping
&1&PDFKLQHGVWDLQOHVVSDUWV The eight-page 2010 Metal Stamp-
ing Brochure details the company’s
%HQGLQJDQGFRLOLQJRIVWDLQOHVV high-quality metal-stamping capabili-
DQGRWKHUPDWHULDOV ties. Stampings are
available in sizes
5HGUDZLQJRIVWDLQOHVVWXELQJ including flat blank-
URGDQGEDUVWRFN ing and piercings
up to 12 × 12 in.,
metal forming in
thicknesses from
0.005 to .134 in.,
www.eagletube.com and draws up to
3-in. deep and 8 in.
in diameter. Also covered are the
company’s “Dock-to-Stock” and “Just-
in-Time” programs.
Boker’s Inc., 3104 Snelling Ave., Min-
MD&M West Booth 3025 neapolis, MN 55406, (800) 927-4377,
www.bokers.com RS# 471
RS# 181
MAY 20, 2010
D
ATA FILE
Literature Advertising Section
To advertise in the DATA FILE sections
call 216.696.7000 or e-mail
laurel.hirkala@penton.com
4 Axis Driver + Controller
Measures Just 2.25” Square
The product is a miniature 4 axis
stepper motor controller and driver
measuring 2.25” x 2.25” x 0.6”. The
controller-driver is capable of driv-
ing each motor at 1 Amp of current
at 1/16th micro-step resolution. The
controller performs fully profiled
moves and accepts high level com-
mands from RS232, RS485 or USB. On boards program stor-
age allows stand alone operation. Connections for limit / home
switches for each channel , and dual encoders for position
monitoring and correction are supported.
www.allmotion.com
(408) 460-1345
All Motion
RS# 250
AutomationDirect’s Volume 13
Free Catalog now available
AutomationDirect’s volume 13 cata-
log offers over 8,500 industrial auto-
mation products for a wide range of
applications. The latest two-volume
edition features product descriptions,
technical data, and photos for PLCs,
touch screen monitors, AC and DC
motors, text panels, sensors, encod-
ers, pushbuttons, switches, drives,
and more. Printed separately from the
“Desk Reference” are a complete prod-
uct price list and a product overview.
For a free copy, in print or on CD, or more information, visit
www.automationdirect.com or call 800-633-0405.
RS# 253
EDGE WELDED
BELLOWS
BellowsTech, LLC de-
signs & manufactures
precision bellows in a
full range of diameters
and thicknesses rang-
ing from .394” (10 mm)
to 26” (660 mm) in
diameter. Available in
an array of dimensional
configurations & alloys including Titanium, 316LSS, AM350 SS,
Aluminum, and Inconel/Hastelloy.
Email: www.bellows@bellowstech.com, for NEW 12 page brochure.
BellowsTech, LLC / PMG, LLC
RS# 256
Caplugs Offers
Comprehensive Catalog
Caplugs offers a new 144-page,
full-color catalog. This comprehen-
sive catalog features a complete
line of product protection devices
with more than 5,000 caps, plugs,
tubes, netting, containers, edge lin-
ers and wraps.
To request a copy of Caplugs new
catalog visit www.caplugs.com. To
speak with a customer service rep-
resentative, call 1-888-CAPLUGS
or e-mail our sales department at
sales@caplugs.com.
Caplugs
RS# 259
Galil’s “Pocket PLC”
Has Lots of I/O
RIO Pocket PLC is smart,
compact, low-cost, and packed
with I/O. 32 digital and 16 analog
I/O in 3.9 x 4.3 x 1.3” package.
Ethernet/RS232, RISC processor,
PID process loops, counters, timers, data logging, email
alerts. Network multiple RIOs. $295 qty 1/$195 qty 100.
Call Galil at 800-377-6329 or http://www.galilmc.com/
pocketplc for specs and free tutorials.
Galil Motion Control
RS# 262
RS# 248
Get SmartMotor™
driven Actuators FAST
New OEMDynamics Catalog
shows Thrust Curves for a vast
array of belt and ball-screw
driven actuators pre-assembled
with Animatics SmartMotors and
their built-in control systems.
Just Apply Power, communicate
serially, or download a simple
program to complete your
Automation task. Log onto
www.oemdynamics.com for
complete information.
Animatics
RS# 251
RS# 254
Custom Integral Style
Studded DualVee®
Guide Wheels
Affordable, swaged integral style
studded DualVee guide wheels in
concentric and eccentric versions
are now available from Bishop-
Wisecarver. Studded wheels are
offered in stainless steel with low
temperature, high temperature or
custom grease, and in sizes 0-4.
No minimum order quantities and short lead times. Consult our
Applications Engineers for custom stud lengths.
888.580.8272; www.bwc.com
RS# 257
Motion Control with
CounterBalance
Corporation
CounterBalance
Corporation has many
solutions for heavy lid
applications. Designed to
provide precise balancing
of delicate or heavy
loads. CounterBalances can be designed to integrate
hinge and attaching features…a complete system.
CounterBalance engineers offer design assistance to
improve quality and reliability of balancing systems. Call
or contact us at 215-957-9260 or http://www.cbal.com.
CounterBalance Corporation
RS# 260
Gems Fluid Sensors &
Controls Master Catalog
This 340-page Master Catalog
details the broad portfolio of
Gems liquid level, flow, and pres-
sure sensors, miniature solenoid
valves, and pre-assembled flu-
idic systems designed for OEMs
across a wide range of indus-
tries. Provides full specifications,
dimensions and part numbers.
800-378-1600
www.GemsSensors.com
Gems Sensors & Controls
RS# 263
MAY 20, 2010
Decelerate loads, prevent im-
pact damage, improve product
performance, increase cycle
speeds and reduce noise. New
ACE Controls Main Catalog
includes industrial and safety
shock absorbers, as well as
models for the PET & GLASS
industries. Additional motion
control catalog products include:
gas springs, hydraulic dampers,
velocity and feed controllers.
ACE Controls Inc
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Fax (248) 476-2470
Email: shocks@acecontrols.com
www.acecontrols.com
RS# 249
Sealing Solutions to
Suit Your Needs
From engineering to manu-
facturing and inspection,
Apple Rubber Products sup-
plies high performance seals
and parts directly from their
USA plant. Choose from
Standard O-Rings, Miniature
Seals, Housing (Face) Seals,
Medical Seals, Silicone Parts,
Custom Shapes, FilterSeals®,
and Composite Seals. Pick the sealing category that’s
right for you: www.applerubber.com/products
Apple Rubber Products
RS# 252
BEI Industrial Encoders
Design & Specifying Guide
65 full color pages of product
specifications, design examples,
drawings and accessories - all
dedicated to encoder feedback
solutions. Includes rotary and
linear encoders, electronic mod-
ules, wireless interfaces, cables,
connectors and accessories.
Special sections include hazard-
ous and extreme environments.
Call 800-ENCODER or visit www.beiied.com/catalog
BEI Sensors
RS# 255
Boker’s Free 2010
Washer Catalog
Washer Catalog features over 24,000
non-standard flat washer sizes avail-
able with no tooling charges. ODs of
0.080” to 5.140”, a range of IDs and
thicknesses, as well as 2,000 material
options provide endless washer pos-
sibilities. Materials include numerous
carbon steels, stainless steels, alumi-
nums, brasses, coppers and non-me-
tallics. ISO 9001:2008 Registered.
Boker’s, Inc.
(888) 927-4377, FAX: (800) 321-3462
Email: sales@bokers.com
URL: www.bokers.com/mdd
RS# 258
RS# 261
New Loctite® Threadlockers
Loctite® 243™ Medium Strength
Blue Threadlocker and Loctite® 263™
High Strength Red Threadlocker provide:
'
upgraded temperature resistance –
up to 360°F
'
oil tolerant curing on as-received
fasteners without cleaning
'
primerless performance on both
inactive and active metals
For a free sample and more info,
go to www.useloctite.com/MA23
RS# 264
MACHINE Design.com 89
NEW REVISED 2010 ELECTRIC HEATER CATALOG
Hotwatt manufactures electric heat-
ers including cartridge, air process,
immersion, strip and finned strip,
tubular and finned tubular, band,
crankcase, foil, flexible glasrope and
ceramic heaters. We have been
manufacturing resistance heating el-
ements since 1952 and offer a wide
variety of heaters for OEM, industrial,
medical, commercial and military ap-
plications.
E-mail: sales@hotwatt.com
Web Page: www.hotwatt.com
HOTWATT, INC.
RS# 265
SELF-LUBRICATING GEAR
SOLUTIONS CALCULATED FOR LIFE
The Intech Power-Core™ gears are precision
machined and offer solutions to applications
in which lubrication, wear, noise, vibration,
inertia, shock load, moisture and chemicals
present a problem for nylon, Delrin or metal
gears. Metal Core provides for a secure at-
tachment to the shaft and higher torque trans-
mission. Gear design and sizing is backed
by durability calculation using proprietary
software.
Intech Corp., 250 Herbert Ave., Closter, NJ
07624. (201) 767-8066; Fax: (201) 767-7797.
www.intechpower.com
RS# 268
EPOXIES MADE TO ORDER
For specialized needs, Master Bond can custom
formulate an epoxy adhesive, sealant, coating,,
potting, and encapsulation compound to meet
your specifications. We offer unsurpassed
technical expertise and have years of experience
in solving complex problems. Special formulations
can be made in small to large quantities. These
formulations can increase productivity, eliminate
waste and improve product reliability. Additionally,
our products can be supplied in simple, easy to use
packaging.
Master Bond, Inc.
Phone: (201)343-8983
Fax: (201)343-2132
E-mail: main@masterbond.com
RS# 271 www.masterbond.com
From .007" to 1" diameter.
Most machinable materials.
RS# 274
860-542-5543
www.nemb.com
SEALS, ACTUATORS,
GRIPPERS AND BAGS
Solve difficult closure prob-
lems with custom-built, fab-
ric-reinforced, fully molded
elastomeric Seal Master®
inflatable seals. With close
tolerance capability and re-
sistance to compression,
they’re ideal for imaginative production and processing
applications too. Engineered specialties include fabric-
reinforced bags, bladders, plugs and other custom rubber
products. Design assistance offered.
Seal Master Corp., Kent, OH
RS# 277
Vinyl & Rubber Extrusions
Trim-Lok Inc. releases a brand new
FREE “Catalog 500” featuring “How
to Order” steps for the first time
customer, along with an expanded
line of complete trims and seals.
FREE samples may be requested.
Latest additions include our Flap
Seal, Fire Retardanct Trim, adn
Hatch Seal. Contact us toll fee at
1-888-874-6565, e-mail us at info@
trimlok.com or visit us on-line at
www.trimlok.com
Trim-Lok Inc., Buena Park, CA
RS# 280
90 MACHINE Design.com MAY 20, 2010
Introducing IBOCO’s
new full-line catalog
IBOCO’s new catalog features more of
the products you asked for:
· TS Solid Duct
· TSH solid duct with mounting holes
· NEW Din Rail Cutter
· Liquid-tight conduit and connectors
PLUS
· Wire duct and conduit cutting tools
And ask for our New Brochure
featuring our full line of polycar-
bonate enclosures.
Integrated Panel Management
IBOCO® RS# 267
Fax: 732-417-1166
www.iboco.com
e-mail: iboco@iboco.com
RS# 266
High- Performance
Magnets
New catalog features high
performance magnet materials
such as NdFeB and SmCo,
molded magnets, ceramic and
alnico magnets. MCE offers
magnet circuit design,
custom fabrication, assembly,
and advanced coatings.
Complete traceability is offered.
Phone:(310)784-3100,
Fax:(310)784-3192; mcesales@mceproducts.com;
www.mceproducts.com
Magnetic Component Engineering
RS# 269 RS# 270
Tough As Nails, CoilBoss™ Retractile Cords
Northwire’s CoilBoss Retractile
Cords literature outlines in-
stock and custom-configured
options offered to exceed your
requirements. Guaranteed to
perform, CoilBoss improves
the wiring life of applications
requiring movement. Shipped
fast with no minimums.
715.294.2121;
www.northwire.com/brochure
Northwire
RS# 272 RS# 273
Miniature RFID Data Loggers and Readers
OM-84 Matchbook™ Series
Omega’s new CE compliant OM-80
series of data loggers and readers
are economical, accurate and
provide a reliable solution
for cold chain environmental
monitoring. The OM-84 model
features a miniature weather-
resistant design with a factory
replaceable battery. Each logger
can store up to 10,000 readings
and is reusable. Stored data can be downloaded and saved to
your computer using the reader and software that is included. Each package
of data loggers comes with a certificate stating NIST-Traceability (No Points).
Built-in LEDs display high and low alarm verification indicating whether or
not measured temperatures have remained within the user programmable
alarm window throughout deployment. This product is ideal for produce, sea-
food, dairy, supermarkets, or any applications where temperature monitor-
ing is needed. Price starts at $90 for a pack of 5.
Omega Engineering, Inc.
RS# 275 RS# 276
P/M Structural Parts
Spiral Retaining Rings The use of powder metal parts
& Wave Springs can result in substantial sav-
Smalley’s complete product line ings. Symmco P/M parts offer
is now available in one easy to high quality and high precision,
navigate catalog. The new cata- with possible savings of 90%
log includes over 7,000 standard
or more over machined parts.
wave springs, spiral retaining Helical gears available. Short
rings and snap rings. Smalley’s
runs are our specialty. Press
new catalog offers simplified
part selection, special design capacity from 2.5 to 750 tons.
and engineering tools and the Huge inventory of stock sin-
latest applications of Smalley tered bronze bearings, bar and
products. (847) 719-5900. rectangular plate also available. 24 hour service. (814)
E-mail: info@smalley.com, Web: www.smalley.com/getcatalog 894-2461, fax (814) 894-5272. www.symmco.com
Smalley Steel Ring Company Symmco, Inc., Sykesville, PA
RS# 278 RS# 279
TURCK Sensors Catalog New Motion Control Website
Includes 17 New Product Types
Experience the new look
TURCK’s extensive Sensors Cata- and feel of Wittenstein. In-
log details the company’s full sen- cluding alpha gearboxes,
sors line, including 17 recently
introduced product varieties. The
custom servo solutions
and simulation systems
catalog also features a new section
dedicated to specialty sensors and - the world of motion is
only a mouse click away.
harsh duty sensors, designed to
withstand the most challenging ap- Put your web in motion
with Wittenstein.
plication environments. It addition-
ally details related sensor cordsets
and accessories. Visit us today at www.wittenstein-us.com
Phone: (800) 544-7769
URL: www.turck.us
Wittenstein
RS# 281 RS# 282



%&' ((%&#( From Prototype
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102,0,((.
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The Lens
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1000s of Lens Sizes in Stock
Most Lenses Ship Same Day
Custom Lens Manufacturer for all Applications
Medical Imaging Lenses UV Quartz Lenses
Microscope Objectives & Eyepieces CCD/CMOS Lenses
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Image/Barcode Lenses Your Custom Lens
Mo re Than 7 5 Years - The Original
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In USA: 516-624-2444
Email: info@ukaoptics.com

 
  © 2010 Universe Kogaku (America) Inc.


  
   RS# 185
! " #
$ RS# 184

LET US GIVE YOU A HAND

WITH YOUR CUSTOM
WIRE FORMS!
We have greatly expanded our capabilities
with multiple CNC machines! Our fully
automated CNC bending center allows us to
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KKN70#4-4+8'
'0610XJGNFJ
LNNgGFIgGKKN
JGJgGNIgEEEM
e-mail: sales@westernwireprod.com
999T9'56'409+4'241&T%1/999T%7561/9+4'(14/+0)019T%1/
RS# 182 RS# 183
 BUSINESS INDEX
Air Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Alfmeier Prazision AG . . . . . . . . . . . . . . . . . . . . . . . . . 24
All Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Altech. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
American Welding Society . . . . . . . . . . . . . . . . . . . . 36
AutomationDirect . . . . . . . . . . . . . . . . . . . 6, 22, 70, 78
Avago Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Avnet Electronics Marketing Americas. . . . . . . . . 38
B&R Industrial Automation . . . . . . . . . . . . . . . . . . . . . 6
BAT Engineering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
BMW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
RS# 186
92 MACHINE Design.com
Balluff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Bishop-Wisecarver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bosch Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cameron Compression . . . . . . . . . . . . . . . . . . . . . . . 95
Cognex Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dallara . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DeltaWing Racing Cars. . . . . . . . . . . . . . . . . . . . . . . . 45
Digi-Key Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 70
Dynaflo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Eaton Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Ecoloc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
MAY 20, 2010
Ensinger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Fabrico. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 54
FEV Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Ford. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Forest City Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Fortus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fraba Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 96
Geomate Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Gerwah . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Hewlett-Packard. . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 96
Hirose Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Honda Performance Development . . . . . . . . . . . . 52
Hughes Aircraft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
IBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ISOPur Fluid Technologies . . . . . . . . . . . . . . . . . . . . 18
ITT Interconnect Solutions . . . . . . . . . . . . . . . . . . . . 67
Indy Racing League. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Jaguar Racing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
KNF Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Knapp Systemintegration GmbH . . . . . . . . . . . . . . 38
Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 78
LehIgh University . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lemo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Lockheed-Georgia Co. . . . . . . . . . . . . . . . . . . . . . . . . 34
Lola . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Luczo Dragon Racing/de Ferran Motorsports . . 48
Lumex Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
March . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Massachusetts Institute of Technology . . . . . . . . 33
McLaren Performance Technologies Inc. . . . . . . . 81
Mercedes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Micrel Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Milliken & Co.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Milwaukee School of Engineering . . . . . . . . . . . . . 28
Minco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Molex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Moxa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
New Way Air Bearings. . . . . . . . . . . . . . . . . . . . . . . . . 33
Nippon Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Northeastern Univ. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Omron Scientific Technologies . . . . . . . . . . . . . . . . 83
Pari Pharma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Parker Hannifin AB. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parker Hannifin Corp., Tube Fittings Div. . . . . . . . 61
Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Phoenix Contact Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Physik Instrumente L.P.. . . . . . . . . . . . . . . . . . . . . . . . 74
Pneumatech Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
R&W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
RE2 Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Reynard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ringfeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rittal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rollon Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Romax Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Shimpo Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Smalley Steel Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Solid Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Staheli West . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Stratasys Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Swagelok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Swift Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Switchcraft Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Taiyo Yuden (U.S.A.) Inc. . . . . . . . . . . . . . . . . . . . . . . . 38
U.S. Army. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Voswinkel GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wago Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wieland Electric Inc. . . . . . . . . . . . . . . . . . . . . . . . 83, 95
Wittgenstein . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Zebra Communications . . . . . . . . . . . . . . . . . . . . . . . 72
This index includes all significant references
to parent companies mentioned in feature
editorial material within this issue of
MACHINE DESIGN. It doesn’t cite companies
listed solely in the Products and Lit Section.
Page numbers listed refer to the pages
where the articles begin.
ADVERTISER INDEX
RS#. . . COMPANY. . . . . . . . . . .PAGE
142. . . . . ACE Controls, Inc.. . . . . . . . . . . . . 52
110. . . . . Aerotech, Inc.. . . . . . . . . . . . . . . . . 12
188. . . . . All Motion, Inc. . . . . . . . . . . . . . . . 94
177. . . . . All Sensors. . . . . . . . . . . . . . . . . . . . 86
155. . . . . Ametek Inc . . . . . . . . . . . . . . . . . . . 65
152. . . . . Animatics Corporation . . . . . . . 64
111. . . . . Apple Rubber Products . . . . . . 13
103. . . . . Automation Direct . . . . . . . . . . . . .3
145. . . . . Balluff Inc. . . . . . . . . . . . . . . . . . . . . 56
127. . . . . BEI Industrial Encoder Div . . . . 31
192. . . . . Bimba Manufacturing Co . . . . BC
154. . . . . Boker’s Inc. . . . . . . . . . . . . . . . . . . . 65
164. . . . . Bosch Rexroth. . . . . . . . . . . . . . . . 75
108. . . . . Caplugs . . . . . . . . . . . . . . . . . . . . . . 10
149. . . . . Carlyle Johnson Machine
Company, LLC . . . . . . . . . . . . . . . . 61
116. . . . . Carr Lane Mfg Co.. . . . . . . . . . . . . 19
190. . . . . Cicoil Corp. . . . . . . . . . . . . . . . . . . . 96
107 . . . . . Clippard Instrument Lab Inc. . . . . . 9
122. . . . . Contitech. . . . . . . . . . . . . . . . . . . . . 27
189. . . . . CounterBalance Corp . . . . . . . . 95
151. . . . . CUI Inc. . . . . . . . . . . . . . . . . . . . . . . . 63
175. . . . . D&R Products . . . . . . . . . . . . . . . . 79
105. . . . . Digi Key . . . . . . . . . . . . . . . . . . . . . . . .7
106. . . . . Dynetic Systems. . . . . . . . . . . . . . . .8
181. . . . . Eagle Stainless & Fabrication, Inc. 88

#
"$#
#

104. . . . . ebm-papst . . . . . . . . . . . . . . . . . . . . .5
134. . . . . Fabrico . . . . . . . . . . . . . . . . . . . . . . . 38

#!
!
$"##"

158. . . . . Forest City Gear . . . . . . . . . . . . . . 70
148. . . . . Galil Motion Control Inc . . . . . . 59
136. . . . . Gates . . . . . . . . . . . . . . . . . . . . . . . . . 40
137. . . . . Gates . . . . . . . . . . . . . . . . . . . . . . . . . 41
176. . . . . H.A. Guden Company . . . . . . . . 85
157. . . . . Harmonic Drive LLC . . . . . . . . . . 69
126. . . . . MITRPAK. . . . . . . . . . . . . . . . . . . . . . 31
109. . . . . Moog Components Group . . . 11
135. . . . . Moog Inc . . . . . . . . . . . . . . . . . . . . . 39
119. . . . . National Precision Bearing . . . 24
141. . . . . NB Corp . . . . . . . . . . . . . . . . . . . . . . 51
Static Control
113. . . . . Newark. . . . . . . . . . . . . . . . . . . . . . . 15
150. . . . . Nippon Pulse America Inc . . . . 62
With
153. . . . . Ogura Industrial Corp.. . . . . . . . 65
101. . . . . Omega Engineering Inc . . . . . IFC
Conductive
167. . . . . One Planet . . . . . . . . . . . . . . . . . . . 84
Brushes


124. . . . . Parker Hannifin. . . . . . . . . . . . . . . 29
129. . . . . Pentair. . . . . . . . . . . . . . . . . . . . . . . . 33
102. . . . . Phillips Plastics Corporation . . . .1
117. . . . . Physik Instruments Lp. . . . . . . . 20
185. . . . . Precision Paper Tube Company91
162. . . . . Protex Fasteners Ltd. . . . . . . . . . 71
SOLUTIONS
191. . . . . Proto Labs, Inc. . . . . . . . . . . . . . . IBC
160. . . . . Quality Bearings & Components 71
156. . . . . Quickparts.com Inc. . . . . . . . . . . 68
125. . . . . Reid Supply Company. . . . . . . . 30
. . . . . . . . . Rino Mechanical Components Inc 34
138. . . . . Rittal Corporation . . . . . . . . .42-43
147. . . . . Rotor Clip Company. . . . . . . . . . 58
166. . . . . SAB North America. . . . . . . . . . . 78
187. . . . . Sealeze Corp . . . . . . . . . . . . . . . . . 93
183. . . . . Sepac. . . . . . . . . . . . . . . . . . . . . . . . . 91 Sealeze’s line of brushes for
168. . . . . Servometer /Precision Mfg.
Group, LLC. . . . . . . . . . . . . . . . . . . . 84 static control offers:
115. . . . . SEW Eurodrive. . . . . . . . . . . . . . . . 17 )


131. . . . . Shenzhen Power Motor "##
!"
Industrial Co., Limited . . . . . . . . 35
)


132. . . . . Smalley Steel Ring Company. 36
123. . . . . Spirol International Corp . . . . . 28
! $!
121. . . . . Symmco Inc.. . . . . . . . . . . . . . . . . . 26 )
"#+#%
140. . . . . TDK Lambda Americas Inc . . . 49
Eliminate Static
159. . . . . Techno Inc. . . . . . . . . . . . . . . . . . . . 71
172. . . . . Thomas Products Div. . . . . . . . . 82 )

!%
!$#
"
133. . . . . Haydon Kerk Motion Solutions 37
146. . . . . Helical Products Company, Inc. 57
161. . . . . Igarashi Motor Sales. . . . . . . . . . 71
174. . . . . igus, inc. . . . . . . . . . . . . . . . . . . . . . . 79
171. . . . . Keystone Electronics
Corporation . . . . . . . . . . . . . . . . . . 81
169. . . . . KNF Neuberger, Inc. . . . . . . . . . . 84
139. . . . . Lee Company . . . . . . . . . . . . . . . . 47
143. . . . . Lin Engineering . . . . . . . . . . . . . . 53
114. . . . . LINAK. . . . . . . . . . . . . . . . . . . . . . . . . 16
118. . . . . Loctite Corp.. . . . . . . . . . . . . . . . . . 21
173. . . . . Magnetic Component
Engineering, Inc. . . . . . . . . . . . . . 79
128. . . . . Master Bond, Inc. . . . . . . . . . . . . . 32
178. . . . . Master Bond, Inc. . . . . . . . . . . . . . 87
165. . . . . Maxon Motor Usa . . . . . . . . . . . . 77
92 . . . . . . Trim-Lok Company. . . . . . . . . .186 )

$

!#"


112. . . . . Turck Incorporated . . . . . . . . . . . 14 (
"##
$
#"
170. . . . . Ultra Motion Company. . . . . . . 84 )

!%
!#!
"#'
184. . . . . Universe Kogaku Inc . . . . . . . . . 91 
!
"

$!
#
#
"#"

179. . . . . Visumatic. . . . . . . . . . . . . . . . . . . . . 87 !

!
'


&#
!
"!

182. . . . . Western Wire Products Co. . . . 91 "(
"#*!
!$"



*

163. . . . . Wolong Electric Group Co., Ltd. 73 !!&&
#
800.787.7325
180. . . . . World Encoders, Inc . . . . . . . . . . 87
144. . . . . World Success International
Dev Ltd. . . . . . . . . . . . . . . . . . . . . . . 55 e-mail: industrial@sealeze.com
120. . . . . ZERO-MAX . . . . . . . . . . . . . . . . . . . 25 www.sealeze.com
While every effort has been made to
ensure the accuracy of this index, the
publisher cannot be held responsible for
any errors or omissions.
RS# 187
MAY 20, 2010 MACHINE Design.com 93
 BUSINESS STAFF
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RS# 188
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BACKTALK

CAGI award winners

A team of engineering students from the University of Wisconsin-Madison
walked away with this year’s top prize in the 2009-2010 National Innovation
Award contest sponsored by the Compressed Air & Gas Institute (CAGI).
Team WALKS design uses compressed air to power a “Weight-assisted
lifting and kinesthesia system” (WALKS) to assist physical therapy and re-
habilitation patients by supporting up to 90% of their body weight while
promoting a natural walking motion. Mentored by CAGI member Titus
Mathews of Pneumatech Inc., students Axel Dahlberg, Jonny Jordan, Centennial celebration
Stefanie Knauf, Pat Verstegen received a $2,500 prize, and $8,000 went to
their advisor Heidi-Lynn Ploeg for the school’s mechanical-engineering Wieland Electric is celebrat-
department. ing its 100th year of develop-
According to the judging panel, Team WALKS design “recognizes the ing plug-and-play electrical in-
need and opportunity for this type of device to help reduce the escalating terconnect products. Friedrich
costs of health care.” Wieland founded the family
Second place went to Team Spin Zone from Buffalo State College for run business in October 1910
their “Onboard vehicle-compression storage system,” which uses a double- in Bamberg, Germany. In 1990,
acting cylinder to capture and store energy from a vehicle’s suspension a U.S. subsidiary, Wieland Elec-
system. The $1,500 prize went to team members Brad Wargula, Kenny tric Inc., began operating in
Stafford, Matt Geil, Jason Zaepfel, Sara Ward and Miles Williamson, and Burgaw, N.C. The company’s
faculty advisor Dr. David Kukulka received $4,000 for the school’s mechan- “Contacts are Green” motto
ical-engineering department. CAGI member, Ed Czechowski, of Cameron demonstrates their commit-
Compression, mentored the team. ment to innovative environ-
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96 MACHINE Design.com MAY 20, 2010
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RS# 191
 BIMBA GOES

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RS# 192