Machine Design 14 June 2012

June 14, 2012
A Penton Media Publication

Tune in to EngineeringTV.com
Looks good!
Amateurs chase
rocket prize,
page 54
THE CHANGING
DYNAMICS OF LED
FABRICATION,
page 62
U. S.
MANUFACTURING
STRENGTHS,
page 68
PRECISION
PARTS WITH
HYDROFORMING,
page 76
VARIABLESPEED
PUMPS MAKE
HYDRAULICS
ENERGY EFFICIENT,
page 82
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RS# 101
COPYRIGHT 2012 NEWPORTELECTRONICS, INC. ALLRIGHTSRESERVED.
e-mail:info@newportUS.com
1-800-NEWPORT
Universal Inputs
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Thermocouple
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RTD
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Process Voltage
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Serial RS232/485
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Monitor and control your Wafer FAB, MEMS, Micro Electronics, Semiconductor
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RS# 102
FEATURES
REPORTERS NOTEBOOK
pressure data to the researchers
through the entire crash event.
The original ESA engineer
worked to convert the foil into a
strip of about 50 individual sen-
sors, each about a square centi-
meter. At the end of each strip is
a flexible printed-circuit board
with a 50-channel amplifier.
When it is attached to a fender
or bumper, it lets test engineers
know how fast that metal is
bending, as well as whether it is
bending 20 in one direction or
60 in the other.
VW has now used the sen-
sor in several crash tests and it
has contributed to changes that
make the cars safer, according to
VWmanagers.
ASwarmheads for space
Three identical Swarmsatellites will launch fromRus-
sias Plesetsk Cosmodrome next month on a four-year mis-
sion to explore the Earths magnetic field. This is the first
person responsible for
ground software devel-
opment at ESAs Ger-
man operations center.
Techtransfer for
piezofoil
Back in the early
1990s, a German en-
gineer was developing
a new type of pressure
sensor that would coat
the wings of Hermes,
a reusable manned-
shuttle that would be
launched into space
atop an Ariane 5 rocket
and then return to
Earth on it own, much
like the Space Shuttle. The sensor had to be light and thin
so it would not add bulk or drag to the airfoil. The engi-
neer turned to piezoelectric foil to do the job. Like other
piezo materials, the thin foil (30-microns thick) converts
vibrations and pressures into electrical pulses that can be
measured and interpreted.
The foil senors were successfully tested in a hyper-
sonic wind tunnel, but the Hermes project was cancelled.
So over the years, ESA has been looking for civilian uses
for the piezo sensors. One of the earlier applications was
converting the foil to paint and putting it on a human mo-
lar. Scientists used this instrumented tooth to measure
forces a toothbrush puts on teeth.
But just recently, Volkswagen saw the sensor demon-
strated at the Hannover Fair at a booth set up by ESAs
Technology Transfer Programme Office. They quickly de-
cided to use the piezo sensors on crash-test vehicles. Tradi-
tional sensors do well at recording pressure up to the point
of impact, then they are too often destroyed in the crash.
The foil versions, however, survive the crash, sending
Eventually ordinary
Earthlings may be able to
access spacecraft froma
browser screen.
U.S. citizens tend to think of NASA when
the topic turns to space exploration. But the
European Space Agency (ESA), established
in 1975 to combine the efforts of 19 European
nations, has its own ideas for advancing space
technology. Among the most interesting efforts
with which ESA is involved is one aimed at
extending Internet connections to spacecraft.
Though its annual budget is about $5.2 billion
compared to NASAs $18 billion, ESA is making
important strides in fundamental space research.
Nanosats totest software
Engineers and technicians at ESA today control satel-
lites and space experiments using Packet Utilisation Stan-
dards, a software suite that dates to 1994. There have been
upgrades since then, but the stumbling block to moving
to newer software is that space scientists and the organi-
zations that fund themmust ensure the software, includ-
ing operating systems, languages, and interfaces, is fit for
space.
No one wants to use new and possibly problematic
software on a multimillion-euro mission in space, says
Mario Merri, head of the Mission Data Systems Div. at
ESAoperations center.
Unfortunately, the only real way to prove software is fit
is to take it into space and run it through its paces.
To lower the cost of validating software, and to en-
sure no missions are endangered, ESA researchers devel-
oped Operations Satellites, dubbed Op-Sats. The 30 10
10-cm satellites mission is to test and validate critical
onboard and ground software. The spacecraft is outfitted
with off-the-shelf processors that have more computing
power than a satellite usually carries. It is also designed
to recover easily and quickly frombuggy software. Re-
searchers on Earth can replace the entire onboard software
suite with new and fresh code daily, letting developers
troubleshoot their work in a real but safe environment.
The first Op-Sats could launch next year.
SpinninganinterplanetaryWeb
People increasingly take reliable and fast Internet ac-
cess for granted. Now space scientists want to extend the
same simplicity and reliability of the Web to astronauts on
the Moon or Mars. The first goal will be to let astronauts
communicate among themsleves, with control centers on
Earth, and with space ships and bases. But who knows;
someday top level Internet domains may include such
names as .moon, .mars, or .sstation.
To this end, ESA, NASA, and other major space or-
ganizations and industrial partners have been working
together as part of the Consultative Committee for Space
Data Systems. They have developed standards for hard-
ware and data exchange that should pay off even in the
short termfor commercial space-flight businesses, satellite
manufacturers, and space agencies.
Satellites have already been used for links between
Earth and mission spacecraft. In 2008, for example, ESAs
Mars Express acted as a data-relay node between NASA
technicians on Earth and their Phoenix Lander during de-
cent and landing on Mars, It will repeat that task in August
this year with NASAs Mars Science Laboratory.
And last December, ESAs worldwide tracking station
network handled contact between Russian controllers
and that countrys Phobos-Grunt mission to Mars. Then,
in October of this year, an astronaut on the International
Space Station will practice at remotely controlling a plan-
etary rover at ESAs operations center, simulating orbiter-
rover communication links on a planet like Mars.
Establishing technical standards and communica-
tion architectures isnt the most high-profile part of space
exploration, but its absolutely vital for ensuring that the
more-exciting efforts, like sending an astronaut to Mars,
will work when that time comes, says Nestor Peccia, the
Authoredby:
Stephen J. Mraz
SeniorLditor
stephen.mrazQpenton.
com
Resources:
European Space Agency,
www.esa.int
Internet
in
Space?
continued on page 22
EAAS used its
35-m-diameter deep-space
dish antenna in Spain to
relay transmission froma
Russian Mars mission to
controller in Russia.
The pressure senor used in VWcrash tests is based on pressure-
sensitive piezo filmand consists of 50 individual sensors, each 1
sq cm, and a 50-channel amplifier, all flexibly printed on a thin
and bendable circuit board.
Piezo material
suspended in a
paint was applied
to a human molar
to let scientists
measure the
force of a
toothbrush on a
tooth.
Op-Sats, here shown in
an artists conception,
are simple spacecraft
designed solely to test
software. They will have
a volume of about three
liters but will carry off-
the-shelf components
such as three-axis
attitude control systems,
deployable fixed solar
arrays, GPS receivers,
and UHF communication
systems. It will also
have state-of-the-art
components such as
S-band communications with an uplink rate four times greater
than any other ESAspacecraft and a miniaturized X-band
transcmitter providing up to 50 Mbps downlink. These rates are
up to several hundreds times better than any other satellite flown
before.
1UNL l4, 20l2 MACH|NL DESIGN.com 20 1UNL l4, 20l2 MACH|NL DESIGN.com 21
SEMICONDUCTORS
Most light-emitting
diodes are made in Asia,
but future generations
of LEDmanufacturing
equipment could
still be marked
Made in the U. S. A.
The bad news for makers of semicon-
ductor-manufacturing equipment is that
sales of most kinds of fab gear are flat to
down. The good news is that the U. S.
could end up playing a bigger role sup-
plying manufacturing equipment for the
emerging area of solid-state lighting.
The U. S. Dept. of Energy used stimulus
funds to amplify the supply-chain strengths
of the U.S. The DOE recognized that the
U.S. would be an unlikely place for LED
fabs, so it tried to seed the development of
LED-manufacturing equipment here, ex-
plains Tom Morrow, executive vice presi-
dent, emerging markets group and chief
marketing officer for SEMI, the association
Authored by:
LelandTeschler
Editor
Resources:
Intel, www.intel.com
Semicon West and Intersolar 2012, http://
semiconwest.org/
Will the U. S. be an
LED
ASSEMBLY
MECCA?
Thoughthe 300-mmwafer has become the industry standard,
chipmakers are transitioningto450-mmversions, like this example
at Innolas Semiconductor GmbH, a maker of wafer-sortingand
laser-markingsystems.
JUNE 14, 2012 MACHINE DESIGN.com 62
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vOLUML84
|SSUL9
1UNLl4,20l2
Internet in space?
Lventuallyordlnaryearthllngsmay
beabletoaccessspacecraftfroma
browserscreen.
20
Will the U. S. be
an LED assembly
mecca?
Mostllght-emlttlng
dlodesaremadelnAsla,
butfuturegeneratlons
ofLLDmanufacturlng
equlpmentcouldstlll
bemarkedMadelnthe
U. S. A.
62
54
82
76
68
From Engineer to Rocketman
Atralnedmechanlcalenglneerwho
serlouslydabbledlnrocketryasa
hobbylstbulldsarocketthatcllmbs
to overl00,000ft.
Made in America?
whatlttakestocompetltlvely
manufacture ln theU. S.
Hydraulic controls
transform press technology
Hydraullcmotloncontrollers
brlng hydroformlngpresseslnto
the 2lst century.
Energy-efficient
hydraulics slash machine
operating costs
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1UNLl4,20l2 MACH|NLDESIGN.com 2
A
B
P3-HSI P3-HSO
Machine Process Start
1
Enable
VELOCITY MOVE
Module Name: Feed Conveyor
Channel: 2 Channel Name: CHAN-2-0.1.1
Move Setup
Direction Positive
Velocity Fill Index Speed
500
Ramp Rate Conveyor Ramp Rate
1000
Stop Setup
Immediate Stop

In Progress ConveyorMove In Progress
1
Complete Conveyor Move Complete
0
Move Status Conveyor Move Status
2
P3-HSO
2-channel
High-speed Output
$
349
Pulse/Direction,
Quadrature X1
and Quadrature X4
P3-HSI
2-channel
High-speed Input
$
329
Pulse/Direction,
Step Up/Step Down
and Quadrature
With the Productivity3000
controller, you get the power you
need for advanced applications.
Download the free
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Start with the $599 CPU - 50Mb of memory supports
large programs, with tagname database and program
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ports make integrating a large system easier than
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Now with High-speed Motion Control
These new 2-channel modules add high-speed and motion
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Simple Instructions
Our standard instructions were designed to make your
everyday motion applications simpler. The Find Home, Set
Position, Simple Move and the Velocity Move instructions
(to name a few) were created to get you up and running
sooner. Capabilities such as Registration, Jerk Control and
Channel Scaling were included to give you the flexibility
to accomplish those jobs.
Drop-in Hardware Confguration
Install a high-speed module into the system hardware
configuration and define each channels behavior, status bits,
limits and scaling without the need for an external
configuration utility or software.
Application Example
High-speed outputs synchronize
the speed of the servo drive
controlling the fill conveyor. The
conveyor is synchronized with the
rotational speed of the
turntable based on the
signal(s) from the table
encoder feedback via the
high-speed input module.
http://bit.ly/p3000
RS# 103
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ON THE COVER
DerekDevlllelaunches
one of hlsearlyrockets.
EDITORIAL
PowerPolntcanklll
EDITORIAL STAFF
LETTERS
SCANNING FOR IDEAS
Alr-poweredgrlnderboastshlghpower-to-welghtratlo
|oncannoncleansasltshoots
REPORTERS NOTEBOOK
LOOKING BACK
SENSOR SENSE
worldsblggestsensor:anlcecubeI
COMMENTARY
Doesmodel-basedenglneerlngmakesenseI
VANTAGE POINT
8enefltsofafocuseddlstrlbutorsprogram
INVENTORS CORNER
Apphelpskldsflghtleukemla
SOFTWARE REVIEW
Professlonaldesktop3Dprlnterlseasytouse
SOFTWARE PRODUCTS
PRODUCT SPOTLIGHT
Plastlcs&elastomers
PRODUCTS
DATA FILES
AD INDEX
BUSINESS INDEX
BUSINESS STAFF
BACKTALK
48
20
40
47
8
l0
l2
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50
52
92
94
96
98
l22
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l25
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Manufacturing Intelligent Compressed Air Products Since 1983
ll5l0GoldcoastDrlve-Clnclnnatl,Ohlo-45249-l62l-(800) 903-9247
fax:(5l3)67l-3363-L-mall:techelp@exalr.com-www.exalr.com
LXA|R
Tese have serious limitations.
On hot summer days when
the temperatures of the room
and inside of the enclosure
are about equal, theres
not enough dierence for
eective heat exchange.
They fa|| when dust and
d|rt c|ogs the h|ter
The coo||ng capac|ty |s
||m|ted due to amb|ent
cond|t|ons
EXAIR Cabinet Cooler
Systems
EXAIR has a complete line of Cabinet Cooler Systems
to dependably cool and purge your electrical enclosures.
Tey convert an ordinary supply of compressed air into
clean, cold 20
F air. Tey mount in minutes through an ordinary electrical

knockout and have no moving parts to wear out. Te compressed air ltration
that is provided keeps water, oil and other contaminants out of the enclosure.
There |s oo room a|r I||ter to c|og
Ao acc0rate e|ectr|ca| thermostat cootro| m|o|m|zes compressed a|r 0se
A|| 0ab|oet 0oo|ers are 0L L|sted to 0S aod 0aoad|ao saIety staodards
They are the oo|y compressed a|r powered coo|ers that are 0 comp||aot
www.exair.com/45/440a.htm
Tese coolers are prone to
failure in dirty, industrial
environments when dust
and dirt clogs the lter.
|t takes a|most a day
to |nsta||
V|brat|on from mach|nery
causes refr|gerant |eaks
and component fa||ures
0ompressor ||fe expectancy
|s typ|ca||y 2.5 years of
cont|nuous operat|on
|t requ|res a oor dra|n
for the condensat|on
Average cost to rep|ace
a bad compressor |s $750
Te plastic box cooler from a
competitor uses an inaccurate
mechanical thermostat thats
designed for liquids. Tis
thermostat has a poor ability
to react quickly to changes in
air temperature. |t costs 0p
to 85% more to operate thao
XA|8's T0 0ab|oet 0oo|er

System w|th the same S0FN
rat|og aod 8t0lhr. o0tp0t.
F|ectron|cs can overheat
before |t turns on
|t runs far |onger than
necessary before shutt|ng off
|ncreased cyc|e t|me wastes
compressed a|r
Opening the panel door
and aiming a fan at the
circuit boards is a bad idea.
|t |s an 0SHA v|o|at|on
that presents a shock
hazard to personne|
The fan b|ows hot, hum|d,
d|rty a|r at the e|ectron|cs
The coo||ng effect |s
m|n|ma|
|t |s ||ke|y to fa|| aga|n
s|nce the env|ronment
|s st||| hot
How To Keep Your Electronics Cool
When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery
up and running again. Tere are several cooling options out there and its important to know the facts.
line up of coolers that are prone to bad behavior
If you would like to discuss
an application, contact an
Application Engineer at:
EEEEEXXXXX
EX EX EX EX
to to dd
TTT
cl cllll cle
kn kn
th h th
www.exair.com/45/44045a.htm
WATCH
THE VIDEO!
..
in in iinto to too
Reliable and maintenance free!
Scao Ior V|deo
RS# 104
E
D
I
T
O
R
S

W
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B

P
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contalnlngaserlesofcollsconnected
asthree-phasewlndlngs,themotor
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Thlsdeslgnprovldessmooth,
cogglng-freemotlonandhlghheat
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1olnuswhlleweshowyouallof
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fortheflrsthalfof20l2and
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Recordlngsofpastweblnarsare
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RS# 106
EDITORIAL
PowerPointcankill
To most engineers, the idea of using graphs or models to convey concepts
comes as second nature. In many cases, these representations get shared
through a PowerPoint presentation. You might think that a presentation
tool like PowerPoint couldnt get you into much hot water at worst, it
might inflict acute boredom on colleagues. But taking PowerPoint lightly
is particularly dangerous for engineers.
So warns Franck Frommer, who recently wrote a book (How Power-
Point Makes You Stupid) about PowerPoints downside. For instance, take
the idea of expressing concepts in a PowerPoint chart. Diagrams kill
thought! cautions one business veteran. She explains that drawings are
okay for detailing processes, circuits, and other well-defined relation-
ships. But they are a terrible way of expressing anything dynamic such as
a strategy. Her point was diagrams are prone to lull viewers into accepting
a static and oversimplified outlook on problems that are inherently mo-
bile and changing.
Bad PowerPoint even played a role in the Columbia Shuttle disaster.
After Columbia broke up reentering the atmosphere in 2003, a series of
NASA-prepared slides about the shuttle came under intense scrutiny. All
these slides were prepared using PowerPoint. Data-visualization pioneer
Edward Tufte took issue with one in particular that, he said, portrayed
a festival of bureaucratic hyperrationalism. Among the problems he
noted was that the author had used six different levels of text to arrange
and classify 11 phrases. The primary information in the slide got rel-
egated to small print several layers down.
What is troubling about the NASA example is that PowerPoint itself
encourages such problems through its built-in templates. The software
imposes what Tufte calls a summary style that can be confusing and lets
users prepare slides using letter fonts that are inappropriate for the sub-
ject at hand. In the case of the Columbia slide, for example, the author
had used a pitch-style typography that tended to belie the seriousness of
foam damaging the heat shield.
Organizations also have a tendency to let PowerPoint slide decks sub-
stitute for more-detailed forms of technical communication. Frommer
points out that the board investigating Columbia criticized NASA on this
point as well, saying that the use of PowerPoint briefing slides instead of
technical papers illustrated problematic methods of technical communi-
cation at the Agency.
Many of the problems arising from PowerPoint come from the misuse
of bullet points, especially because this practice leaves out the logical
connections that give the points meaning in the first place. Worse, bullet
points can be a screen hiding a certain intellectual laziness on the part
of users who never bothered to think out the connections, says Frommer.
There are, in fact, a few individuals who have mastered PowerPoint.
One in particular was Apples late great Steve Jobs, Frommer claims.
Youd never see cornball images, poorly formed ideas, or a font festival
in a Jobs slide deck. His slides were always simple, contained a well-
organized argument, and used analogies to make numbers in the presen-
tation memorable.
But then again, there was only one Steve Jobs.
Leland Teschler, Editor
RS#l07 1UNLl4,20l2
The engineers choice
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RS# 108
Beyond measuring angles,
Novotechniks 8erIes of
rotary position sensors can be
programmed and reprogrammed
for your applications angle, CW/CCW
direction and single or redundant output
can be selected.
8erIes sensors utilize the orientation of
a magnetic field to determine measurement
angle. An embedded microprocessor
converts the magnetic orientation to an
analog output that is repeatable to within
0.03% or 0.1 of measurement range
depending on model.
For complete R-Series information, visit www.novotechnik.com/rs
Novotechnik U.S., Inc.
155 Northboro Road Southborough, MA 01772
Telephone: 508-485-2244 Fax: 508-485-2430
Key specifications include:
Resolution: 12/14-bit
Protection class: to IP67
Measurement range:
up to 360
W
h
a
t
s
Y
o
u
r
A
n
g
l
e
?
W
h
a
t
s
Y
o
u
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A
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e
?
EDITORIAL STAFF
EDITOR
Leland E. Teschler
leland.teschler@penton.com
MANAGING EDITOR
Kenneth J. Korane
ken.korane@penton.com
SENIOR EDITORS
Leslie Gordon
leslie.gordon@penton.com
Stephen J. Mraz
stephen.mraz@penton.com
ASSOCIATE EDITOR
Robert J. Repas, Jr.
robert.repas@penton.com
INDUSTRY COVERAGE
AUTOMOTIVE, PACKAGING,
MEDICAL
Stephen J. Mraz
CAD/CAM, MANUFACTURING
Leslie Gordon
ELECTRICAL, ELECTRONICS
Robert J. Repas, Jr.
FLUID POWER, MECHANICAL
Kenneth J. Korane
EDITORIAL PRODUCTION
Denise Greco
Editorial Production Manager
Randall L. Rubenking
Art Director
l300L.9thSt.Cleveland,OH44ll4-l503
RS#ll0
RS#l09
Ever wonder how producers of extremely advanced
consumer electronics, like smart phones, manage to
keep launching new generations of these products at
such a ferocious tempo with consistently high quality?
SKF product manager Satyen Bohidar and SKFs
sales team have part of the answer SKF-SNFA high-
speed super precision bearings. They allow the machine
tools used for manufacturing key components of these
products to run awlessly and precisely at up to
60.000 rpm 365 days a year.
The result? Smart products are brought to the
market even faster. Its another great example of
knowledge engineering at work. Find out more at
www.skf.com/poke
The Power of Knowledge Engineering
Milling spindle running
at 40.000 rpm
Satyen Bohidar,
SKF Product Manager
SKF-SNFA high-speed
bearings
Producesmartphonesfaster
withhiqhspeedbearinqs
RS# 111
LETTERS
asustalnabllltystandard(Dowe
NeedaSustalnabllltyStandardI
March22).oucanbetthatthls
lsanotherwayofmaklngmoney
by thestandards freaks and a
way for the government to put
morecostburdensonmanufac-
turlng. |ts also just more buzz-
wordstoflllthelawbooksbythe
envlronmentcrowd.
Thegovernmentwlllseethls
as a way to force employers to
hlre more people to shuffle the
sustalnabllltypaperwork.Larger
companl es wl l l feel forced to
spend mllllons on thls stuff be-
cause they seek government
contracts, and the costs of the
standardwlllbepassedontothe
customer,theAmerlcantaxpay-
ers.Andsmallercompanleswlll
beforcedtodlvertresourcesfrom
lnnovatlonandbreakthroughsto
morenonproductlvepaperwork.
Asusual,Amerlcancltlzenswlll
betheonespaylngforthlsuseless
stuff.
Thanksforyourcomments.|t
wlllbelnterestlngtoseelfother
buslnesspeoplehavethecourage
tospeakagalnstthlshare-bralned
ldeaofanotherstandard.
Gerald W. Yankie
Thlslsnomorethanajob-secu-
rltyprogramforthlrd-partyqual-
lty-controlconsultantsandeco
freaks.ouwouldhavetobecrazy
toevenconslderestabllshlngthls
programlnyourcompany.Lndless,
mlndless,andnever-endlngmake
workforwant-to-bebureaucrats.
Leo V. Cranch
We can fix for the
patent office
TheU. S.patentsystemlssufferlng
fromtwobaslcproblems.|tlsbe-
slegedbysubmlttalsthatarefunda-
mentallyflawed,butlnventorsare
encouragedtopatentthembased
onexaggeratedpromlsesfromthelr
patentlawyers.Andsecond,the
PatentOfflceemploystechnlcally
weakstaffthatlsoverwhelmedby
thesheernumberofpatentappllca-
tlon.8utwecanflxthls.
Prom l977 to 2000, | was ln-
volved ln an effort to evaluate
concepts submltted to the Na-
tlonal|nstltuteofTechnology.|t
wasfundedbytheLnergyDept.
andwaseventuallycalledtheOf-
flce ofTechnology |nnovatlons.
|deas were analyzed and evalu-
atedbyexpertslnthelnventlons
subjectmatter,andnotallldeas
revolvedaroundenergygenera-
tlonorconverslons.Therewasno
chargetolnventorsforthlsservlce,
andpromlslngentrleswentonto
furtherlnvestlgatlonlnasecond
phase.|ftheysurvlvedthesecond
round,lnventorscouldrecelveup
to$200,000todevelopworklng
proof-of-conceptmodels.
|workedatN|STlnthlsOfflce
andanalyzedabout750concepts
overal2-yearperlod.About5%
ofthemlnvolvedpatents.Thevast
majorltyoftheconceptsweredls-
mlssedatflrstglancebecausethey
wereobvlouslylmpractlcalorfun-
damentallylncorrect.Therestgot
closerscrutlny,butfewwentonto
thesecondstageofevaluatlons.
|bellevethatreestabllshlngthls
OfflceofTechnology|nnovatlons
andbroadenlngltsscopetocover
allnewlyrecelvedpatentappllca-
tlonswouldsavelnventorsconsld-
erableeffortandmoney,aswell
astaklngpressureoffthepatent
offlce. Of course, the patent of-
flcewouldalsohavetohlremore
knowledgeablestaffersaswell.
Andrew Wortmang
Not another standard
ouarecorrect,wedonotneed
Crank up the
apprenticeships
|readtherecentcolumn(Dont
waltforGovernmenttoAddress
SklllsGap,March8)wlthgreatln-
terest.8ut|contendthattheSocl-
etyofMechanlcalLnglneers(SML),
togetherwlththeNatlonalToollng
&MachlnlngAssoclatlon,hasfalled
mlserablyatendlngtheshortage
ofskllledmachlnlstsandatcreat-
lngquallty,long-termmachlnlng
tralnlng.whatsneededlsamod-
ernlzedmachlnlngapprentlceshlp
runonanatlonallevel.
|nstead,herelsatyplcalexample
oftheklndofshort-termprogram
thattheNTMAputson(www.train-
ingcenters.org/ ).|tremlndsmeofa
late-nlghtlnfomerclal,areallybad
one.Afteryearsandyearsoffallure,
SMLandtheNTMAshouldnolonger
haveanythlngtodowlthmachlnlng-
apprentlceshlpprograms.
Jon Banquer
Lasers make bad
table lamps
Regardlessofhowpleasantanar-
row-bandlaserllghtmlghtbeforll-
lumlnatlon(ourNextTableLamp
Could8eaLaser,Peb.9),ltstlllls
composedofseveralnarrowbands.
Thlsmeansobjectsthatarereflec-
tlveovernarrowbandsoffrequen-
clesthatdonotmatchupwlththe
laserslllumlnatlonspectrummayof-
tenlookunnaturalundersuchllght-
lngwhencomparedtollghtlnghav-
lngablackbodyspectrumslmllar
todayllghtorlncandescentllghtlng.
Christopher James
Yes and no
Readerssaynotounlonsandanewsustalnabllltystan-
dard,aswellastouslnglaserslnlampsandllghtlngfor
houses.8uttheysayyestoapprentlceshlpsasawayto
relnvlgoratetheU. S.manufacturlngbaseandto
effortsatstreamllnlngandupgradlngtheU. S.
PatentOfflce.Andoneofmanyreaderspolnted
outthatl80-hpoutboardmotorsforboatswererareas
hensteethlnl962.
Q
Graphical Software
Q
Sensor Connectivity
Q
Signal Analysis
Q
Control Algorithms
Q
Custom Timing
Q
Custom Triggering
Q
Actuator Connectivity
Q
Embedded Storage
Q
Industrial Networks
Q
Expansion Systems
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RS# 112
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LETTERS
penswhenthependulumswlngs
toofar,unlonsbecometoopow-
erful, and unlon executlves be-
cometoogreedyI
Amerlcabecamegreatbecause
ofltsmanufacturlngpower,but
overlypowerfulunlonsnowseem
to be more of a hlndrance than
a help to economlc prosperlty.
Hugesalarlestounlonexecswho
getfullpayevenwhenworklng
unlonmembersareonstrlkewlth
measlystrlkebenefltslsnomore
falrthanwallStreetexecspulllng
downhugebonuseswhenthey
runthelrcompanleslntothered.
Do unlon leaders really rep-
resentthebestlnterestsofthelr
memberslftheykeepthemout
onlongstrlkestonegotlaterldlc-
ulousovertlmeratesthatbank-
rupt the company and throw
membersontounemploymentI
|m not so much antl-unlon as |
ampro-Amerlcanworker.
Name withheld by request
Corrections
|stherethe sllghtest posslblllty
that there l s a ml sprl nt l n the
Looklng 8ack sectlon (March
22)I|tlshardformetobelleve
that arubber boat, wlth slzes
froml0tol5ft,couldsupport
a l80-hp outboard. |n fact, go-
lngbacktol962,lfmymemory
servesme,thelargestoutboard
engl ne you coul d buy was a
l00-hp Mercury, whlch was an
ln-llneslxcyllnder.
Robert Herol
It should have read 18 hp. Leland
Teschler
|n the artlcle,How Servos and
SteppersStackUp(Peb.9),the
stepperandservoproflleswere
ml s t akenl y s wapped l n t he
graphl c tl tl edStepper versus
servoproflles.
No to the unions
Theresareasontheycall8oelng
theLazy8(TlmeforLnglneers
toThlnkAboutUnlonlzlngI1an.
l9). Theres a reason 8oelng ls
expandlng productlon lnto the
South.TheresareasonGMwent
lntobankruptcy.Theresareason
Amerlcancompanlesareshlftlng
productlon to forelgn soll. And
theresareasonunemployment
lshlgh,especlallylntradltlonally
strongunlonreglons.Andltsbe-
cause overly strong unlons are
strangllng the ablllty of Amerl-
can companles to remaln com-
petltlve, resultlng ln domestlc
l ayoffs, bankruptcl es, and l n-
creaseslntheoffshorecontentof
Amerlcanproducts.
Unlonslndlsputablyralsedour
standardofllvlngandestabllshed
falrwageslnthesweat-shopera
ofearlyAmerlca,andtheywere
responslbleforgreatlncreasesln
safetystandards.8utwhathap-
RS#ll3
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RS# 114
SCANNING FOR IDEAS
Request free information via our
Reader Service Web site at
LdltedbyStephen J. Mraz
Porashortartlcleon
anotherlnnovatlvetool,
scanthlscodeorgoto:
http://machinedesign.
com/article/nascar-team-
impacts-tool-design-0208
ThevT22Turblne
Grlndermakesllfe
easlerforworkers
bycuttlngdeeperand
removlngmorematerlalwlthless
effort,accordlngtoltsmanufacturer,
Ingersoll Rand(www.ingersollrand.
com)wlthNorthAmerlcanHQln
Davldson,N. C.|ts3-hpaxlal-turblne
alrmotorand4.6-lbwelghtreportedly
glveltthehlghestpower-to-welghtratloofany5-ln.
(l25-mm)alr-anglegrlnderonthemarket.Andthe
smallsplndleoffset(0.89ln.)letsltcutuptol.6-ln.
deep.
The5-ln.wheelsplnsatuptol2,000 rpm,wlth
agovernortomalntalnspeedunderload.Alr
consumptlonunderloadlsabout84 cfm,andlt
generates86.4 d8(A)ofnolse.Thetoolwllloperateln
temperaturesfrom32tol20P.
Porsafetyandcomfort,the5-ln.safetyguardhas
l0dlfferentposltlonsettlngs,eachl5apart.The
thumb-operatedsplndlelockletsoperatorschange
abraslvewheelsqulcklyandeaslly.Theresalsoan
optlonaltop-mountedhandleforjobswherelateral
spacelsllmlted.
RS# 401
Alr-poweredgrlnderboasts
highpower-to-welghtratlo
Two-stage,axlal-turblne
alrmotorwlth3hp
Governor
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underload
Low-proflle,self-
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Pushbutton
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wheelguard
Matchedwheel
flangesfor
grlndlngand
cuttlng
Splndleoffset
of0.89ln.
Sealedangle
headfor
bestgear
performance
andllfe
vlbratlon-dampedsldehandle
adjustsforleftorrlght-handedusers
Lxhaustdlrectloncanbe
adjustedforusercomfort
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RS# 115
How do you
select the
right sensor
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multiple types of metals?
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SCANNING FOR IDEAS
The|onAlrCannonfromExair,Clnclnnatl(www.exair.com),canneutrallze
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neutrallzlngshrlnkwrapandcontalners.
Thecannonusesarelatlvelysmallamountofcompressedalr,at
aboutl0-pslgpressure,tolnducemuchmorealrtoflowthroughthe
|oncannoncleansasltshoots
cannon.Thlsalrcanbedellvered
fromaremote,cleanerspace
throughahoselfnecessary.
Attheendofthecannon,an
emltterpoweredbya
5-kvpowersupply(not
lncluded)lonlzesthe
entlrealrstream,
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beamoflonlzed
alr.Thealrvolume
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llghtorheavy-
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Andoperatorscan
lncreasealrvelocltyby
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lnthecannon.Thecannon
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mounted,andcomeswltha
swlvelfordlrectlngthealrflow.
RS# 402
RS#ll6
Compressedalr
lntroducedlntocannon
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surroundlngs
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toflowthrough
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REPORTERS NOTEBOOK
Op-Sats, here shown in
an artists conception,
are simple spacecraft
designed solely to test
software. They will
have a volume of about
3liters but will carry off-
the-shelf components
such as three-axis
attitude-control
systems, deployable
fixed-solar arrays, GPS
receivers, and UHF-
communication systems.
It will also have state-
of-the-art components
such as S-band communications with an uplink rate four times
greater than any other ESA spacecraft and a miniaturized X-band
transmitter providing up to 50 Mbps downlink. These rates are up
to several hundreds times better than any other satellite flown
before.
Eventually ordinary
earthlings may be able to
access spacecraft from a
browser screen.
U.S. citizens tend to think of NASA when
the topic turns to space exploration. But the
European Space Agency (ESA), established
in 1975 to combine the efforts of 19 European
nations, has its own ideas for advancing space
technology. Among the most interesting efforts
with which ESA is involved is one aimed at
extending Internet connections to spacecraft.
Though its annual budget is about $5.2 billion
compared to NASAs $18 billion, ESA is making
important strides in fundamental space research.
Nanosats to test software
Engineers and technicians at ESA today control satel-
lites and space experiments using Packet Utilisation Stan-
dards, a software suite that dates to 1994. There have been
upgrades since then, but the stumbling block to moving
to newer software is that space scientists and the organi-
zations that fund them must ensure the software, includ-
ing operating systems, languages, and interfaces, is fit for
space.
No one wants to use new and possibly problematic
software on a multimillion-euro mission in space, says
Mario Merri, head of the Mission Data Systems Div. at
ESA operations center.
Unfortunately, the only real way to prove software is fit
is to take it into space and run it through its paces.
To lower the cost of validating software, and to en-
sure no missions are endangered, ESA researchers devel-
oped Operations Satellites, dubbed Op-Sats. The 30 10
10-cm satellites mission is to test and validate critical
onboard and ground software. The spacecraft is outfitted
with off-the-shelf processors that have more computing
power than a satellite usually carries. Its also designed
to recover easily and quickly from buggy software. Re-
searchers on Earth can replace the entire onboard software
suite with new and fresh code daily, letting developers
troubleshoot their work in a real, but safe, environment.
The first Op-Sats could launch next year.
Spinning an interplanetary Web
People increasingly take reliable and fast Internet ac-
cess for granted. Now space scientists want to extend the
same simplicity and reliability of the Web to astronauts on
the Moon or Mars. The first goal will be to let astronauts
communicate among themselves, with control centers on
Earth, and with spaceships and bases. But who knows;
someday top-level Internet domains may include such
names as .moon, .mars, or .sstation.
To this end, ESA, NASA, and other major space or-
ganizations and industrial partners have been working
together as part of the Consultative Committee for Space
Data Systems. They have developed standards for hard-
ware and data exchange that should pay off even in the
short term for commercial space-flight businesses, satellite
manufacturers, and space agencies.
Satellites have already been used for links between
Earth and mission spacecraft. In 2008, for example, ESAs
Mars Express acted as a data-relay node between NASA
technicians on Earth and their Phoenix Lander during de-
cent and landing on Mars, It will repeat that task in August
this year with NASAs Mars Science Laboratory.
And last December, ESAs worldwide tracking station
network handled contact between Russian controllers
and that countrys Phobos-Grunt mission to Mars. Then,
in October of this year, an astronaut on the International
Space Station will practice at remotely controlling a plan-
etary rover at ESAs operations center, simulating orbiter-
rover communication links on a planet like Mars.
Establishing technical standards and communica-
tion architectures isnt the most high-profile part of space
exploration, but its absolutely vital for ensuring that the
more-exciting efforts, like sending an astronaut to Mars,
will work when that time comes, says Nestor Peccia, the
Internet
in
Space?
ESA used its 35-m-diameter
deep-space dish antenna in
Spain to relay transmission
from a Russian Mars
mission to controller in
Russia.
The pressure sensor used in VW crash tests is based on pressure-
sensitive piezo film and consists of 50 individual sensors, each
1sq cm, and a 50-channel amplifier, all flexibly printed on a thin
and bendable circuit board.
Piezo material
suspended in a
paint was applied
to a human molar
to let scientists
measure the
force of a
toothbrush on a
tooth.
pressure data to the researchers
through the entire crash event.
The original ESA engineer
worked to convert the foil into a
strip of about 50 individual sen-
sors, each about a square centi-
meter. At the end of each strip is
a flexible printed-circuit board
with a 50-channel amplifier.
When it is attached to a fender
or bumper, it lets test engineers
know how fast that metal is
bending, as well as whether it is
bending 20 in one direction or
60 in the other.
VW has now used the sen-
sor in several crash tests and it
has contributed to changes that
make the cars safer, according to
VW managers.
A Swarm heads for space
Three identical Swarm satellites will launch from Rus-
sias Plesetsk Cosmodrome next month on a four-year mis-
sion to explore the Earths magnetic field. This is the first
person responsible for
ground software devel-
opment at ESAs Ger-
man operations center.
Tech transfer for
piezo foil
Back in the early
1990s, a German en-
gineer was developing
a new type of pressure
sensor that would coat
the wings of Hermes,
a reusable manned-
shuttle that would be
launched into space
atop an Ariane 5 rocket
and then return to
Earth on it own, much
like the Space Shuttle. The sensor had to be light and thin
so it would not add bulk or drag to the airfoil. The engi-
neer turned to piezoelectric foil to do the job. Like other
piezo materials, the thin foil (30-microns thick) converts
vibrations and pressures into electrical pulses that can be
measured and interpreted.
The foil sensors were successfully tested in a hyper-
sonic wind tunnel, but the Hermes project was cancelled.
So over the years, ESA has been looking for civilian uses
for the piezo sensors. One of the earlier applications was
converting the foil to paint and putting it on a human mo-
lar. Scientists used this instrumented tooth to measure
forces a toothbrush puts on teeth.
But just recently, Volkswagen saw the sensor demon-
strated at the Hannover Fair at a booth set up by ESAs
Technology Transfer Programme Office. They quickly de-
cided to use the piezo sensors on crash-test vehicles. Tradi-
tional sensors do well at recording pressure up to the point
of impact, then they are too often destroyed in the crash.
The foil versions, however, survive the crash, sending
Authoredby:
Stephen J. Mraz
SenlorLdltor
stephen.mraz@penton.
com
Resources:
European Space Agency,
www.esa.int
Continued on page 22
REPORTERS NOTEBOOK
RS#ll8
An astronaut on the International Space Station will
control a planetary rover, like this European Ground
Prototype (EGP) at the Mars-like terrain of Spains
Rio Tinto mines. Here the rover is working with an
astronaut in an Aouda.X spacesuit mock-up.
Heres an artists concept
of what Philae, the
Rosetta lander, will look
like when deployed on
the comet. In this view,
the arm holding a drill
is extended and taking
samples.
time a team of satellites has been deployed on a
single, dedicated mission. Two of the satellites
will travel side by side in a near-polar orbit about
305 miles above the Earth. The third Swarm or-
bits slightly higher, 330 miles, and about 40 off
axis from the other two. During the four-year
mission, this third Swarm will drift to 90 off axis
from the other two. The 1,100-lb satellites will
circle the Earth 15 times each day.
A single rocket will carry all three Swarms
into space, and it will take about three months
to get them in their final orbits and check out
all subsystems and payloads. The satellites each
measure about 30-ft long, but half that length is
taken up by a tail which will extend back from
the satellite during the check-out phase. A pair of
magnetometers mount on the tail, isolating them
magnetically from any interference from the sat-
ellites and its electronics.
For simplicity, the Swarms do not carry or
Continued from page 21
1UNLl4,20l2
RS#ll9
When in orbit,
two of the Swarms
will travel side
by side at a lower
altitude while
the third is at a
higher altitude
and offset orbit.
This gives better
coverage and
lets the satellites
triangulate more
accurately.
One of the Swarm Satellites,
with its 4-m boom deployed,
undergoes testing in a
magnetically clean environment
hence the wooden floor. The
satellites measure 5-ft wide,
2.7-ft high, and 30-ft long, which
includes the 13-ft boom.
extend solar arrays. Instead the two
sides of each triangular-hulled satel-
lite that face outer space will be cov-
ered with GaAs solar panels that de-
liver 608 W of power at the outset of
the mission. The cells will charge a
set of 48 A-hr lithium-ion batteries
for power when the satellites are not
in the sun.
The satellites will record and
transmit to Earth high-precision,
high-resolution measurements of the
Earths magnetic field strength, di-
rection, and variation. They will also
provide accurate navigation data tied
to magnetic and electric-field mea-
surements, all of which are needed to
map the geomagnetic field.
Having three satellites in two dif-
ferent orbits will improve sampling
in terms of space and time, letting
scientists distinguish between the ef-
fects of different sources of magnetism.
It is hoped the data gained will give scientists insights into the dynamics of
the Earths liquid-metal core and crust, as well as into their interactions with
Earths protective shield in the ionosphere and magnetosphere.
Catching a comet
Eight years ago, the Rosetta probe was launched on an 11-year convoluted
journey to chase down the comet 67PChuryumov-Gerasimenko. The space-
craft has already made three swingbys of Earth and one of Mars, and managed
to fly by a pair of asteroids, 2,867 Steins, and 21 Lutetia, and circle the sun four
times. Currently, its traveling at about 2,600 fps and is on schedule for a May
2014 rendezvous with Comet 67P.
Rosetta weighs in at 6,750 lb, but carries 3,200 lb of fuel. It measures 9 7
6 ft, but the twin solar panels deployed once Rosetta was in space give the space
probe a 104-ft wingspan.
Rosetta took some measurements and images when close to the aster-
oids and Mars during the trip, but for the most part, it is hibernating, with
1UNLl4,20l2
POWER DISTRIBUTION ENCLOSURES CLIMATE CONTROL
Thousands of enclosures
Hundreds of options
Designed and delivered in 10 days
REPORTERS NOTEBOOK
The Rosetta spacecraft carries a 7.2-ft steerable
communications antenna. Both of its solar arrays contain five
panels and can rotate 180 to track the sun regardless of
attitude.
On the comet, Philae will be sending data to Earth
relayed through the Rosetta orbiter. Its instruments will
detect alpha particles and X-rays to determine the comets
composition. Cameras will take high-resolution images of
the descent and surroundings of the landing area. Gas ana-
lyzers should identify organic molecules and isotropic ra-
tios of light elements. Another set of sensors be will mea-
suring the density, thermal, and mechanical properties of
the soil on the surface. And a drill will go up to 8-in. deep
to collect geological samples that will be dried onboard
Philae and examined microscopically.
The main objective of the 1-billion-Euro mission is
to make the most detailed observations of a comets icy
nucleus, surface, and tail. According to astronomers, com-
ets represent a relatively unchanged environment from
4.6billion years ago. So a close examination will give sci-
entists a snapshot of what the solar system was like when
planets were first forming. MD
most electrical systems shut
down except for thermal
control, radio receivers, and
computers.
Several challenges have
made it difficult for ESA
controllers to keep Rosetta
on track and healthy. For
example, at some points in
its journey, it has taken 100
min for signals to travel to
Rosetta and for receivers to
get a response. And com-
munications have been constrained by an 8-bps rate for
data and relatively little power available, compared to
other satellites. This is the first solar-powered spacecraft
to fly farther than 3.1astronomical units (288.3million
miles) from the sun.
Eventually, Rosetta must brake to match its speed to
the comets as they both head toward the sun. Once within
a few miles of the comet, Rosetta will begin observing it
with its onboard instruments. They include a UV spec-
trometer, ion-mass analyzer, impact analyzer and accumu-
lator, and an imaging system. These last three are designed
to examine cometary dust.
Once established in orbit above the moving comet,
Rosetta will release Philae, a 220-lb lander, and it will be-
come the first spacecraft ever to make a soft landing on a
comet. It is made mostly of carbon fiber with a hood of
solar cells.
While Philae and its suite of 10 instruments investi-
gates the comet from ground level, Rosetta will orbit and
study it for a year as it continues to its perihelion or clos-
est approach to the sun. Rosetta will then remain with the
comet for another six months as the comet heads towards
the orbit of Jupiter, ending its mission in December 2015.
SOFTWARE & SERVICES IT INFRASTRUCTURE
RS#l20
runsathlghefflclenclesandcurrent
densltles,severalfactorshlgherthan
standardLLDsthatarefabrlcatedon
forelgnmaterlals,saysKrames.wegetmanymore
lumensperwafer.Thlsbrlngsdramatlcbenefltslnlow-
erlngoverallLLDcostandlnhlgherbrlghtness.
SoraasflrstproducttouseGaNsubstrateslsanLLD
replacementfora50-whalogenthatonlyconsumes
l2w.Apolnttonotelsthatthelampusesonlypasslve
coollng.Othercompanlesthataredolngthlshave
tousetrlcksllkefanstocooltheLLDandgetenough
power,saysKrames.Ourlampsalsousejustaslngle
LLDratherthananLLDarrayfoundlncompetlngde-
vlces.Thlsletsthemproduceaslnglecleanbeamwlth
aslngleshadowratherthanamultlshadowedbeam
whlchsomeconsumersdlsllke,Kramessays.MD
Thesurestwaytomakellght-emlttlng
dlodesthatareefflclentandbrlght
lstofabrlcatethemonasubstrate
madeofthesamematerlalasthe
LLDltself.
SosaysLLDmakerSoraa Inc.
lnPremont,Callf.Thecompany
producesLLDsthatltclalmsemlt
morellghtperunltareathanany
otherLLDandhandlemoreelectrlc
currentperareathananyother
LLD.Soraagetsthlsklndofperfor-
mancebybulldlngtheLLDsona
substrateconslstlngofGaN.Thlsdlf-
fersfromtheusualpractlceofbulld-
lngLLDsontopofelthersapphlreor
SlC,materlalsthatarecheaperthan
GaNandwhlcharecompatlblewlth
lt.Theproblemwlththesesubstrateslsthattheycan
lnducelmperfectlonslntheLLDsgrownontopand
theselmperfectlonsreducetheamountofllghtthe
LLDcangenerate.
8ecauseweuseaGaNsubstrate,wedonthave
suchlssuesaswaferstraln,waferbowlngbecauseof
thestraln,and(crystal)dlslocatlondensltlesthatarlse
becauseofdlfferentsubstrates,saysSoraaCTOMlke
Krames.Thatallowsahlgher-qualltycrystalmaterlal
whlchleadstohlgher-performlngdevlces.
TheLLDsmadethlswayalsoaremoreefflclent.
wehavebeenabletoenglneerthelayersonthe
natlvesubstratetocreateanactlvelayerstackthat
Resources:
Soraa Inc.,www.soraa.com
RS# 406
Transmission
electron-microscope images show the
imperfections present in conventional
gallium-nitride material (above, right)
compared to the Soraa GaN on GaN
crystals (below, right). The first light to
use the technology is an LED bulb that
replaces an MR16 halogen light.
GaNsubstratesbrlng
brighter LEDs
O
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r

N
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w

S
t
a
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M
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s
2 Times More Torque
High Strength, Long Life
Quiet Operations
Same Price As
Conventional Models
V Series geared
AC motors offer
distinct advantages
over conventional
geared AC motors
and now they are
offered at the same
price as our
conventional models.
Quick & Stable
Lead Time.
Visit
www.orientalmotor.com
Technical Support Tel: 800-468-3982
7:30am- 7:00pm, CST (M-F)
Stepping Motors Servo Motors AC Motors Brushless Motors
Linear & Rotary Actuators Cooling Fans
REPORTERS NOTEBOOK
RS#l2l
Super concrete
shleldlng |ranlannukesI
Someoftheworldsexpertslnultrahlgh-performanceconcrete(UHPC)
areworklngln|ran,acountryregularlybesetbyearthquakes.Theywant
tousethematerlal,amlxofPortlandcement,slllcafume,quartzflour,flne
slllcasand,andelthersteelorplastlc-relnforclngflbers,tobullddurable
brldges,sewerplpes,dams,andotherstructures.
8utU. S.mllltaryofflclalsandothersaroundtheworldareworrledthe
|ranlanswlllusethehlgh-strengthmaterlaltoprotectnuclear-weapons
labsandtobulldothermllltarybasesandundergroundbunkers.
UHPCscompresslonstrengthlsontheorderof30,000psl,whllethat
ofnormalconcretelsjust4,000psl.AndUHPChasatensllestrengthof
l,000 psl,farabovenormalconcretes400psl.Strengthlscrltlcalforde-
fenslvestructures.Testsofal3-tonbunker-bustlngbomb,forexample,
showedltcouldpenetratel80ftofordlnaryconcrete,butonlyget
through25ftofconcretethatwastwlceasstrong.Soltsposslblethatthe
samebombmlghtonlydentUHPC,wlthltscompresslvestrengthseven
tlmesthatofnormalconcrete.
So why isnt UHPC more widely used?
|fUHPClssogreat,whylsnteverybodyuslnglttobulldroadsand
brldgesthatcouldlast75tol00yearswlthmlnlmalmalntenanceIThe
Federal Highway Administrationpolntstoflvefactors:
l.Contractorsareslowtochangecurrentlyapprovedpractlcesand
adoptnewonesuntlltheyaresureofthesafetyandbenefltsofthe
newapproach.
2.Hlghwayandlnfrastructureowners,usuallythegovernment,
areevenlessllkelytoadoptnew,potentlallyrlskytechnologles,
especlallythosethataddcosts.
3.ThedearthofdeslgncodescoverlngUHPCaddstotherlsks.And
contractorsdontwanttoconductteststoproveatechnologywlll
work.
4. NotmanyprojectsuslngUHPChavebeencompletedandthe
materlallacksalongtrackrecord.Thlsmeanstheresllmlted
experlencewlthlnspectlng,malntalnlng,andrepalrlnglt.|nfact,
newmethodsforlnspectlngUHPCwlllneedtobedevelopedbefore
ltswldelyused.
5.Customersareawareofthehlghcostsbutareunsureofthelong-
termbeneflts.
1UNLl4,20l2
B
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s
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M
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o
r

A
d
v
a
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a
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e
s
Compact, High Torque
Wide Speed Range
Continuous Duty
No Maintenance
Brushless Motors
offer all the design
exibility needed for
many different types
of applications.
Learn more about the
Brushless Motor
Advantages from
Oriental Motor.
Quick & Stable
Lead Time.
Visit
www.orientalmotor.com
Technical Support Tel: 800-468-3982
7:30am- 7:00pm, CST (M-F)
Stepping Motors Servo Motors AC Motors Brushless Motors
Linear & Rotary Actuators Cooling Fans
RS#l22
Ultrahigh performance concrete (UHPC)
was used to make these thin, curved
canopies over a train station in Calgary,
Canada. The 24 canopies are only 0.8-in.
thick, so the project used only 105 yd
3
of UHPC.
UHPCalsoreslstschemlcalssuchassaltatratesl00tlmesgreaterthan
thatofnormalconcrete.Andthesteelorpolymerflbersaddductllltyand
strength.Porexample,whenmlcrocracksstartlnthebrlttlecementmatrlx,
theflberstakeuptheloadandpreventfurthersllpplngandcracklng.|n
normalcement,thesmallcracksgrowlargerandweakenthestructure.The
flberscanalsototallyreplacetradltlonalrebarusedtorelnforceconcrete.
Slllcafume,orultraflneslllcapowder,alsoaddsseveralbenefltsto
UHPC.Onachemlcallevel,ltreactswlthcalclumhydroxldereleasedbythe
cement,turnlngtheslllcalntoastrongblnderthathelpsholdtogetherthe
UHPCmlxture.Andonaphyslcallevel,theslllcapartlcles,togetherwlth
thequartzflour,fllllnallthesmallspacesbetweencementgralnsandany
coarseraggregate.Thlstlghtpacklngkeepsoutwaterandchemlcalsthat
canseeplnanddamagetheconcrete.
U. S.mllltaryleadersworrythat|ranlansaretestlngevensmallerpar-
tlcles,nanopartlcles,asaddltlvestoUHPC.Somematerlalexpertsestlmate
thatnanopartlclescouldboostUHPCsalreadylmpresslvestrengthbya
factoroffour.
ThedownsldeofUHPClsltlscostl0tlmesthatofnormalconcrete.
|tcanalsobemoredlfflculttoworkwlth.Tomaxlmlzeltsstrength,forex-
ample,UHPCmustbesteamcured,aprocessthattakesabout48hr.MD
REPORTERS NOTEBOOK
RS#l23
GetreadyforCADln
thecloud.
Atleast,thatlswhat
graphlcschlpandsub-
systemmakerNVIDIA
Corp.,SantaClara,Ca-
llf.,sayswlllbeposslble
thankstoltsnewlyde-
velopedvGXplatform.
wlththlsscheme,asln-
gleservercarrylngone
vGXgraphlcs-proces-
sorboardcanhandle
uptol00usersdolng
heavy-dutygraphlcs.
Nv|D|Asaysservers
equlppedwlthvGX
wlllmakeltposslbleto
accessacloudserver
fromanydevlcethln
cllent,laptop,tabletor
smartphoneregard-
lessofltsoperatlng
system.
Lvencomputatlon-
lntenslveappllcatlonssuchasflrst-personshooter
vldeogamescanbevlrtuallzedthlsway,Nv|D|Asays,
wlthnodlscernabledegradatlonlnperformance.And
3Dsolldmodelsandslmulatlonsthatcharacterlzeso-
phlstlcatedenglneerlngdeslgnworkwlllworkequally
wellwhenrunfromavGX-equlppedserver.
Therehavealreadybeenattemptstomakesome
klndsofenglneerlngsoftwarecloud-based.8utre-
sponsetlmehasbeenanlssue.UsersseelngaCAD
modelcalledupfromaserver,forexample,mlght
notlceaperceptlblelagbetweenmovlngacursoron
amodelandseelngthesoftwareflnallyrespond.Thls
lagcanbejustanannoyanceorltcanbadenoughto
makereal-tlmeserverlnteractlonslmpractlcal.
Nv|D|Asayslthasellmlnatedsucheffectsby
removlngaboutl00msecfromthechalnofevents
thattransplrebetweengeneratlnganlmageona
serverandproduclngltonaremotePCortablet.
Superfast graphicsletCADgotothecloud
Game input lag
(In milliseconds)
Gaikai
powered by
NVDIA cloud-
based GPU
50 10 30 5 66
Cloud gen 1
Console + TV
100
0
66
Game pipeline
Capture/encode
Network
Decode
Display
100
100 30 75 15 66
200
300
A graph of the response time involved in multiplayer gaming applications shows why
cloud computing hasnt been able to handle such uses. A similar argument applies for CAD
applications. The first generation of cloud servers couldnt respond fast enough to generate
screen updates without inserting an input lag that players found annoying. NVIDIA says it has
reduced the delay through use of new GPU technology optimized for cloud servers. NVIDIA
demonstrated the idea on a game from Gaikai called Hawken at its recent GPU Technology
Conference.
Resources
NVDIA Corp., www.nv
com
RS# 407
RS#l24
lcspartlcularlywell.
Tosolvethlsdlf-
flculty,Nv|D|Adevlsed
ahypervlsoroptlmlzed
toworkwlthgraphlc-
processlngunlts
(GPUs).Memory-man-
agementtechnlques
theneffectlvelycreate
amlnl-dedlcatedGPU
ontheserverforeach
vlrtualuser.Durlng
lnteractlonsbetween
theserverandthere-
moteuser,graphlcdata
streamsdlrectlyout
oftheGPUframebuf-
fertotheapproprlate
networklnterfacecard
(N|C)wlthoutflrsthav-
lngtogotothemaln
CPU.
wecanpushplxels
runconcurrentlyonahostcom-
puter.|tlssonamedbecauseltls
conceptuallyonelevelhlgherthan
asupervlsoryprogram.|tletsmul-
tlplelnstancesofavarletyofop-
eratlngsystemssharevlrtuallzed
hardwareresources.Theproblem,
though,lsthathypervlsorstodate
haventbeenabletorendergraph-
Thebetterperformancecomes
thankstoseveralfundamental
patentsbyNvD|Aresearchers
thatpertalntomemorymanage-
menttechnology.
Thecompanyalsowrotea
speclalhypervlsorprogramfor
vlrtuallzedgraphlcs.Ahypervlsor
letsmultlpleoperatlngsystems
orframesdlrectlylntosystem
memory,says1eff8rown,general
manageroftheProfesslonalSolu-
tlonsGroupatNv|D|A.Theremot-
lngprotocolcangrabthedataat
thatpolnt.|cantlmaglneasce-
narlolnwhlchtherelsnoavallable
systemmemory(toslowthlngs
down)glventhetrlvlalslzeofthe
idia.
when
it matters...
(03&&MFDUSPOJD.BUFSJBMT
&OIBODFQFSGPSNBODFBOE
increase design hexibiIity
in yeur eIectrenic systems with
the Iatest MI shieIding and
kF greunding seIutiens Irem Cere.
HPSFDPNFNJ
&.*("4,&54"/%
(306/%*/(1"%4
REPORTERS NOTEBOOK
NVDIA VGX block diagram
Hypervisor
Virtual
GPU manager
Virtual machine
Guest O
Laptop
Laptop
Laptop
Laptop
Application
Citrix XenDesktop
NVDIA driver
& software
GPU
MMU
Kepler
GPU
Per-VM
channel
Remote
display
How to solve latency issues: Currently, the display of graphics from the cloud involves
passing data between the GPU, GPU RAM, through the graphics driver and graphics
API into system memory, and the CPU where its converted into a color image and
then converted into an H.264 video stream before being sent off to the end user. With
NVIDIA VGX, the data passes between the GPU, GPU RAM and immediately converts
into the H.264 video stream, bypassing the GPU driver, graphics API, system memory,
and the CPU. What makes this process possible is NVIDIAs Kepler GPU, the first such
device that can be virtualized in hardware, or shared, by many users in the cloud.
Service providers can install a few high-end NVIDIA Kepler-based VGX cards into
servers and serve multiple users and application instances.
RS#l25
framebuffer.
Nv|D|Aalsosaysdellverlng
vlrtuallzeddesktopsthlswaycan
mlnlmlzethesecurltyrlskslnher-
entlnsharlngcrltlcaldataand
lntellectualproperty.Porexample,
sourcedataforCADmodelsneed
neverleaveasecureserver,but
canbemanlpulatedbyusers
acrosstheglobelnrealtlmeuslng
thevGXscheme.
Plnally,Nv|D|Asayslntegratlng
thevGXplatformlntothecorpo-
ratenetworkalsoletsenterprlse|T
departmentshandle8ODcom-
putlng,thatls,employeesbrlnglng
thelrowncomputlngdevlceto
work.|tdellversaremotedesktop
tothesedevlces,glvlngusersthe
sameaccesstheyhaveonthelr
desktoptermlnal.
Therearethreepartstothe
Nv|D|AvGXtechnology:
vGXboardsThesecarry
Nv|D|AKeplerGPUs.Theflrst
Nv|D|AvGXboardlsconflgured
wlthfourGPUsandl6Gbytesof
memoryandfltslntothelndustry-
standardPC|Lxpresslnterfaceln
servers.LachKeplerGPUhasl92
Nv|D|ACUDAarchltecturecores
and4Gbytesofframebuffer.
vGXGPUHypervlsorThls
softwarelayerlntegrateslntocom-
merclalhypervlsors,suchasthe
CltrlxXenServer,lettlngmultlple
userssharecommonhardware
andensuresvlrtualmachlnesrun-
nlngonaslngleserverhavepro-
tectedaccesstocrltlcalresources.
Nv|D|AUserSelectableMa-
chlnesThlsoptlonletscompa-
nlesconflgurethegraphlcsthey
dellvertolndlvldualuserslnthe
network,basedonthelrdemands.
CapabllltlesrangefromPCexperl-
encestoprofesslonal3Ddeslgn
andenglneerlngexperlences. MD
1UNLl4,20l2
(03&8JSFBOE$BCMF
when reIiabiIity, durabiIity, and
perIermance can be cempremised
by harsh envirenments,
C0k
wire and CabIes

eIIer the best seIutien.

HPSFDPNFMFDUSPOJDT
8*3&"/%$"#-&
RS#l26
Prewired motor plugspeeds
servlceandrepalr
Anewmotorconnectorletsquallfledemployeesconnectordlsconnect
motors,pumps,generators,andotherelectrlcalequlpmentqulcklyand
safelybyslmplyplugglngthemln.MeltrlcDecontactorconnectorsfrom
Meltric Corp.,Pranklln,wls.,conslstsofprewlred,swltch-ratedcomblnatlon
plug/receptacledevlcesthatareULapprovedfordlsconnectswltchlng.
Replaclngelectrlcmotorshasalwayslnvolveddeenerglzlngpowerclr-
cultsandtagglngandlocklngoutthebranchtopreventaccldentalreap-
pllcatlonofpower.Thlsmeanstechnlclansmustopenthemotorservlce
boxtoexposethemotorpowerleadsanddlsconnecttheassoclatedwlr-
lng.Then,oncereplaced,thenewmotormustbeconnectedtotheelec-
trlcalservlceandpowerrestoredthroughproperprocedurestoremove
thetag/lockout.Allthesestepsaddtothemalntenancetlme.
Theplug-and-playDecontactorfeaturesadeadfront,anenclosedarc
chamber,andaswltchlngfunctlonthatensuresllveelectrlcalcontacts
aresafelydeenerglzedbeforethetechnlclanwlthdrawstheplugfromthe
receptacle.Oncewlthdrawn,theplugvlsualverlflesthatpowerlsshut-
down,ellmlnatlngtheneedforvoltagetestlng.Malntenanceworkcan
thenproceedwlthoutanyneedforhardfleldrewlrlng.Thlscutsmotor
change-outtlmesbyupto50%.
Plugsareswltchratedupto200Aand60hp,andcarryaNPPA70L
hazardrlskratlngofzero,ellmlnatlngtheneedfortechnlclanstodon
protectlvegeardurlngservlce.Typlcaluseslncludelnstallatlononwaste-
water,manufacturlng,mlnlng,foodprocesslng,andpowergeneratlon
equlpment. MD
Resources:
Meltric Corp.,
meltric.com
RS# 408
The switch-rated Meltric Decontactor plug offers simple motor power disconnection
to speed motor replacement and maintenance.
1UNLl4,20l2
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Machined Springs
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HelicalProductsCompany,Inc.anditsengineeringteamhave
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innovativeproductsforcontrollingmechanicalmovements,
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RS# 127
High-Precision Ball Screws
Precisely
The Way
You Want
Them
Get
Your
Free Catalog
Steinmeyer-USA.com/ballscrews
or call 781-273-6220
If its not in our catalog,
well build precisely
what you need.
Advanced manufacturing
technology
Experienced engineering
Innovative designs
Advanced wipers
REPORTERS NOTEBOOK
Resources:
Sandia National
Laboratory, sandia.gov
RS#l28
Lmergency-roomstaff
andLMTsroutlnelyrely
ontraumashearstocut
throughapatlentscloth-
lngandaccessawound
thatneedslmmedlate
treatment.Thesecuttlng
toolsmustsllcethrougha
wlderangeofmaterlals,ln-
cludlngdenlm,leather,and
evenbulletproofKevlar.
Mosttraumashearsare
fllmsyandpoorlyconstructed
wlthbladesthatdullqulckly.
Andtheyaretyplcallyusedonce
thenthrownaway.8uttwolnven-
torsScottPorman,anLRphysl-
clan,andMarkReece,amaterlals
englneeratSandia National
Laboratorygottogetherto
redeslgntheshears.Reecewas
abletopartlclpatethanksto
theNewMexlcoSmall8usl-
nessAsslstanceProgram,
whlchpayssclentlstsand
englneerslnsldeSandla
toworkwlthoutslde
entrepreneurs.
Theresult:apalr
oftraumashears
wlthanergo-
nomlc,am-
bldexterous
handleanda
bullt-lncara-
blner.The
carablner,a
commontool
formountaln
cllmbers,lets
physlclansand
LMTseasllyattach
thetooltoabeltloop,keeplng
ltcloseathand.Thehandlength
andhandleplvotpolntletsusers
generateconslderabletorque
andexpendlesseffortforheavy
cuttlng.Andthehlgh-carbon
stalnless-steelbladesholdan
edgelongerthanprevlousmodels
butcanalsoberesharpened.The
entlreshearscanbesterlllzedln
anautoclave.Oneofthebladesls
serrated,lettlngltcut
throughKevlar,bal-
llstlcnylons,thlck
fabrlcs,andeven
flberglass.
Theteamalso
lncorporatedsug-
gestlonsfromLMT
personnel.Sothe
shearslncludearlp-
perattachmentwlth
replaceablebladefor
qulcklysllclngthough
clothlng,abottleopener
formedlcatlons,akey
foropenlngandclos-
lngoxygentanks,and
awlndowpunch.
Theshearswlll
llkelybesold
andmarketedby
Hros,acom-
panyfounded
byPorman.The
|nnovatlvetrauma shears
makethecut
shearswlll
costfrom
$20to$60,
compared
to$5to
$l0for
typlcal
throwaway
verslons.8ut
thosewho
havetested
thepro-
totypes
say
theyare
much
better
andwell
worththe
extracost. MD
1UNLl4,20l2
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Avnet, Inc. 2011. All rights reserved. AVNET is a registered trademark of Avnet, Inc.
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RS# 129
Ultra-High-Performance Stages
Precisely
The Way
You Want
Them
Get Your
Free
Catalog
Steinmeyer-USA.com/stages
or call 781-273-6220
For your most demanding
requirements, let Steinmeyer
build precisely what you need.
100+ years of engineering
experience
Innovative designs
Compact integrated solutions
Advanced manufacturing
techniques
REPORTERS NOTEBOOK
RS#l30
Tensofthousandsofenglneersandtechnlcalmanagersfromacross
LuropegatheredlnNorthern|talylastmonthforaserlesofeventsloosely
termedTechnologyLxhlbltlonweek.TheselncludedPluldtransCom-
pomac(fluldpower),MechanlcalPowerTransmlsslonandMotlonControl,
Plast(plastlcsandplastlcs-processlngmachlnery),Xylexpo(woodworklng
machlnery)allheldlnMllanandLamlera(metal-formlngequlp-
ment),heldln8ologna.
wldespreadlnterestln|tallancomponents,machlnes,andtechnology
bellesthecountryscurrenteconomlccondltlons.|tsnosecretthat|taly
lscaughtuplntheLuropeanflnanclalcrlslsandlnarecesslon,wlth20l2
flrstquarterGDPdecllnlng0.8%.
|TAL|ANTLCHNOLOGwLLK:
Small and nimble
manufacturersare
global problemsolvers
Resources:
Assiot,www.assiot.it
Assofluid,www.assofluid.it
Cariboni,www.cariboni-italy.it
Deutsche Messe,www.hfusa.com
Federmacchine,www.
federmacchine.it
Fiera Milano,www.fieramilano.it
Saes Getters,www.saesgetters.
com
UCIMU,www.ucimu.it
etmany|taly-basedcompanlescontlnuetoprosperlnsplteofthe
downturn.ConslderdatafromFedermacchine,thefederatlonof|tallan
machlneryassoclatlons,basedlnMllan.|tsmembersmanufactureevery-
thlngfrommachlnetools,packaglngequlpment,andplastlcslnjectlon-
moldlngmachlnestohydraullcandpneumatlccomponents,robots,and
automatlonequlpment.Lastyear,productlonforthesectorrosel3.2%
andexportswereupl5.8%.|talyaccountsforl8%oftheLuropean
Unlonsmachlneryproductlon,secondonlytoGermany.
whytheongolngsuccessdespltegeneralhardtlmesIGlancarlo
Losma,PresldentofPedermacchlne,cltesseveralreasons,andtheybasl-
continued on page 36
Caribonis ultralight hydraulics for
sailing and racing yachts are half the
weight of conventional circuits.
1UNLl4,20l2
Airpel-AB
Force Without Friction
This is an air bearing cylinder?

Yes! with zero friction. And guaranteed to outlast any machine you put it in.
Airpot Corp. 800-848-7681. Airpel-AB
& Force Without Friction
are registered trademarks of Airpot Corporation.

The ne print: Just use in accordance with handling and installation guidelines.
*
I
magine positioning, tensioning, counter balancing or clamping: all
force controlled with unmatched resolution. With virtually
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We can guarantee it.
*
Visit
airpel-ab.com to
learn more.
REPORTERS NOTEBOOK
RS#l3l
callyrevolvearoundperformance,
customlzatlon,andafter-sales
support.
Plrst,successful|tallanmanu-
facturersmakemachlnesofthe
hlghestqualltyandtakeadvan-
tageofthelatesttechnologlcal
lnnovatlons,saysLosma.Produc-
tlvltyandrellabllltyneedtobe
second-to-none.Andbecause
theaveragemanufacturerlsfalrly
smallbyU. S.standards,wlthonly
about60to70employees,thls
letsthemfocusonproblemsolv-
lngandglvesthemtheflexlblllty
tocustomlzeandpersonallzethe
endproducttoexactlymatchcus-
tomerrequlrements.
|tallansarethechamplonsof
speclalmachlnes,saysLulglGald-
ablnl,vlcePresldentofUCIMU,the
|tallanmachlne-toolassoclatlon.
wearelnnovatlveandcompetl-
tlve,andweareartlsts,allttleblt.
wholssolvlngproblemsI|tlsthe
|tallans.
HenotesthatOLMsfrom
aroundtheworlddontlookto
|tallanmanufacturersforacheap
prlceonconventlonal,run-ofthe-
mlllequlpment.wewlllalways
getbeatbyChlnaand|ndlaln
termsofcosts,wlthslmplema-
chlnes.Ouralmlstobetopsln
performance,quallty,andlnnova-
tlon,Galdablnlsays.
Theexpertlseof|tallanen-
trepreneurslleslnovercomlng
technlcalhurdles,craftlngunlque
deslgns,andwrlnglngoutmore
efflclency,speed,preclslon,and
productlvltyfromamachlne.
Somemanufacturersmlghtlnvest
thousandsofenglneerlnghours
yetonlyproduceaslnglealbelt
extremelycomplexmachlnea
year,headds.
Galdablnlseeslnvestmentln
R&Dascrltlcal,butnotesmost
researchbycompanleslsdone
hand-ln-handwlththecustomer
asaprojectprogresses,creatlng
applledsolutlonstospeclflcprob-
Saes Getters
SmartFlex shape
memory alloys
are packaged into
compact, light, and
powerful actuators
that replace piezo
materials and
electric motors.
Airpot
Corp
Motion Controlled. Problem Solved.
I
n matters of motion, when your inventive vision requires unparalleled
degrees of accuracy and the kind of pigheaded force consistency that
can be almost impossible to nd, look no further than AirpotCorp. Our
problem- solving line up of instrument -quality products will keep
your project moving.
And our Accurate Force Pneumatics is the key.
With a precision glass cylinder/seal-free piston technology, coupled
with ultra-high quality pneumatics, youll nd products that give you
levels of force and motion control nearly unobtainable by any other
pneumatic means.
Whats more, many of our products can outlast any machine you
put them in. And thats something we can guarantee!
So, when your specications call for a damping, actuation, pressure
sensing, or displacement device that is optimized for exceedingly accurate
and repeatable force control and at a cost lower than other methods
providing comparable function and performance give one of our
application engineers a call.
Lets get started. Whether youre designing or improving a product
line to better serve your customers, or building specialized equipment for
research, high-level testing, or precision assembly, get AirpotCorp
involved early in your process. Call 800-848-7681.
We will move you in ways you might never have imagined.
Airpot Corp, Norwalk CT USA Learn more at Airpot.com
Airpot
& Airpel-AB
are registered trademarks of Airpot Corporation

Accurate Force Pneumatics:
et it move you. L
RS#l32
Lastyearthe|tallanmachlnery
sectorexported70%ofltsproduc-
tlon.|nsomesegmentsltwaseven
hlgher,forlnstanceabout80%of
textllemachlneswereshlpped
abroadlastyear.Pormany|tallan
manufacturers,Germanylsthe
number-onecustomer,whllema-
chlneryexportstotheU. S.were
upabout35%lastyear,accordlng
toPedermacchlne.
Anotherstrength,notesLosma,
lsmanyofthesecompanlesare
multl-generatlonal,famlly-owned
operatlonswlththelrllvellhood
onthellne.Thewaytosurvlvels
lnvestlntechnology,lnnovatlon,
andlnternatlonallzatlon,hesays.
Lxport-orlentedcompanlesthat
havelnvestedoverthelastflve
yearsarestlllgrowlngdespltethe
poordomestlcmarket.
Smart materials
CaselnpolntlsSaes Getters,a
medlum-slzemanufacturerhead-
quarteredlnLalnate.Thecompany
manufacturesarangeofwhatcan
beconslderedhlgh-techprod-
uctssuchasultrahlghvacuum
systemsforsemlconductormanu-
facturlng,organlcLLDdlsplays,
andmedlcaldevlces.|tlnvestsll
tol2%ofearnlngsonR&Dand
98%ofltssalesareoutslde|taly,
accordlngtoManaglngDlrector
flclencyandsubstantlallylower
energyandoperatlngcosts
ensurlngapractlcal,long-term
lnvestment.
Theflrmsalsostresstraln-
lngandsupportafterthesale,
bulldlnglong-termrelatlonshlps,
saysLosma.Customersneedto
understandwerelnforthelong
term.Allthesefactorsglve|tallan
manufacturersaleguplnglobal
markets,accordlngtoLosma.
Despltethecompanlesrelatlvely
smallslze,theyhavestructured
thelrlnternaloperatlonstofocus
on,andsellthelrproducts,lnfor-
elgnmarkets.
lems.|tsthellfebloodofmost
flrms,whlchonaveragecount35%
ofthelremployeesasenglneers,
technlclans,deslgners,orsoftware
developers.wetyplcallyturn
tooutsldeexpertsforspeclalty
research,forexamplelnmeasure-
mentsystemsoroptlcs,hesays.
Sustalnabllltyandenergyeffl-
clencyaregrowlnglnlmportance,
partlcularlylnmarketssuchas
GermanyandSwltzerlandand,
toacertalnextent,theU. S.8ut
lncreaslngefflclencycanralsethe
prlceofamachlne,hecautlons,
whlchoftenmakesthesalemore
dlfflcult.Thegoallstoralseef-
Newtradeshowforpower
transmlsslonandcontrol
Deutsche Messe,basedlnHannover,Germany,andMllansFiera Milano
haveannouncedajolntventure,TPA|talla,atradefalrforpowertransmls-
slonandcontrol,hydraullcs,andpneumatlcs.
|twlllbeheldeverytwoyearsandalternatewlthMDA(Motlon,Drlve&
Automatlon),DeutscheMessestradeshowforpowertransmlsslonandcon-
trolheldlnodd-numberedyearsaspartoftheHannoverPalrlnGermany.
DeutscheMesselookstoleverageltsexpertlseandextenslvenetwork
oflnternatlonalcontactstocreateastrongreglonaltradeshowln|taly,ac-
cordlngtoAndreasGruchow,amemberofthecompanysmanaglngboard.
Thlswlllglvecompanleslnthepowertransmlsslonandcontrollndustrya
hlgh-callber,well-runplatformlntheheartlandofoneofLuropesleadlng
lndustrlalnatlons,saldGruchow.
TPA|tallalsendorsedby|talysleadlngpowertransmlsslonandfluld
powerlndustryassoclatlons,lncludlngAssofluidandAssiot.Theshowwlll
lncludeanexhlbltlonandasupportlngprogramofconferencesandnet-
worklngforums.ThelnauguraleventlsslatedforMay20l4lnMllan.
LONGHORN
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RS# 133
REPORTERS NOTEBOOK
RS#l34
forsalllngandraclngyachts,and
countsamongltscustomerslead-
lngteamsfromAmerlcasCupand
thevolvoOceanRace.
Anlnnovatlonawardwlnner
atPluldtrans,Carlbonlshowcased
adeslgnthatslashesthewelght
ofatradltlonalhydraullcsystem
wlthouthurtlngperformance.Key
aspectslncludecyllndersmadeof
tltanlumandcarbon-flbercom-
poslte,wlthtltanlumflttlngs,for
controlllngthesalls,steerlng,and
otheronboardoperatlons.
Threehydraullcpumpsare
madeofalumlnum.Oneaxlal-
plstonunltrunnlngat300bar
(4,400 psl)lsforpropulslonanda
second,ratedto350bar(5,l50 psl),
operateswhatwecalllow-pres-
suresystems,suchaswlnches,
explalnscompanyspokeswoman
PaolaCarlbonl.Ahlgh-pressure,
rotary-plstonpump,at700bar
(l0,300psl),lsforthecyllndersthat
controlsalls,steerlng,andhandllng.
Llnear-posltlonsensorslnsldethe
cyllnderspermltPLCcontrol.
Theresahugedlfferencere-
placlngsteelwlthalumlnum.And
thehlgherthepressure,thesmaller
andllghterallthecomponents,
noteCarlbonl.Comparedtocon-
ventlonallndustrlalhydraullcs,our
systemwelghs50%less.
Otherwelght-savlngtechnlques
lncludearranglngpumpslnade-
centrallzedclrculttomlnlmlzethe
lengthofhosestothecyllnders,
uslngtanksofplastlc,flberglass,
orcarbonflber,dependlngonthe
pressure,andmaklngmounts,
flanges,andmanlfoldsfromaluml-
numorotherllghtwelghtmaterlals.
Rellabllltycannotbecompro-
mlsed,stressesCarlbonl,soalot
ofenglneerlngworklsneededto
mlnlmlzethewelghtandmalntaln
thestructurallntegrltyanddura-
bllltyoftheparts.Thecompanys
englneerswalkaflnellnelnbulld-
lngultrallght,hlgh-performance
componentsthatdontcompro-
mlserellablllty,sheemphaslzes,
andnodetalllslnslgnlflcant.
Grambygram,youreduceby
kllosthewelghtoftheboat,says
Carlbonl.MD
GlulloCanale.
8yleveraglngltsexpertlseln
speclalmetallurgyandhlgh-vol-
umemanufacturlng,coupledwlth
ongolngresearch,lthasdevel-
opedadlverseportfolloofshape
memoryalloy(SMA)semlflnlshed
shapesandcomponentsfortheln-
dustrlalandblomedlcalmarkets.
Thesesuperelastlcsmartmate-
rlals,basedonNltlnol(Nl-Tlalloy),
returntoapredetermlnedshape
whenheatedandcanbeeffectlvely
packagedlntocompact,llght,pow-
erful,andsllentactuatorstoreplace
plezomaterlalsandelectrlcmo-
tors.Theyrelnexpenslve,produce
dlrectllnearorangularmovement
wlthnoLM|,andtolerateharsh
envlronments.Actuatorwlres,for
example,haveamaxlmumstroke
of5.5%,forceatl50MPaloadsas
hlghas3,000 gm,andllfeexceed-
lng200,000cyclesatl50MPaand
3.5%stroke.
Thecompanysproductlon
equlpmentconvertslngotstowlre
assmallasl9mlndlameter,wlth
exactlngrepeatabllltyforhlgh-vol-
umeappllcatlons.Otherproducts
lncluderlbbons,strlps,thlnsheets,
andsprlngs.
Typlcaluseslncludesmallactua-
tors,flre-protectlonequlpment,
safetyvalves,andvlbratlon-control
devlces,aswellassurglcaltoolsand
medlcallmplants.Onepotentlally
lucratlveappllcatlononthedraw-
lngboardlsanlmage-stablllzatlon
SMAactuatorforhandhelddlgltal
cameras.Theextremelysmallde-
vlceswouldmountlnsldeacamera
andcompensateforshakyhandsto
ensurestable,well-focusedlmages
andvldeo.|tcompeteswlthsoft-
wareandplezosolutlons.Thede-
vlcelsperhapsayearfromrelease,
butpotentlalsalescouldrangeln
thehundredsofmllllonsperyear,
saysCanale.
Ultralight hydraulics
Cariboni,basedlnRonco
8rlantlno,lsa28-year-old,famlly-
ownedcompanywlthfewerthan
20employees.|tlsrecognlzedasa
worldleaderlnultrallghthydraullcs
REPORTERS NOTEBOOK
LOOK|NGBACK
10 YEARS AGO 2002
Cooling duct gives pistons lon-
ger life:Hlgh-lgnltlonpressure
andspeclflcoutputofdlrect-ln-
jectlondleselenglnesplaceheavy
mechanlcalandthermalloadson
plstons.Plstonswlthconventlonal
salt-corecoollngductsoftencannot
wlthstandthese
loads.
Mahle Inc.,Mor-
rlstown,Tenn.,has
developedaplston
wlthacooledrlngcarrlerformedby
asteelplateweldeddlrectlyonto
thecarrler.8ycoollngtheplston,
areassubjecttohlghthermalload(the
flrstgrooveandcavltyperlmeter)can
handlehlgherloads,glvlngtheplstons
alongerrunnlngllfe.
Accordlngtothecompany,com-
paratlveflnlte-elementcalculatlons
onpassengervehlclesshowthlstech-
nologylowersthetemperatureatthe
bottomoftheflrstgroovebyapproxl-
mately50C.
30 YEARS AGO 1982
Humvee prototype to Army: Theflrst
ofllprototypeHumveesproduced
byTeledyne Continental Motorshas
beendellveredtotheArmyfortestlng.
TCM,Chrysler,andAM Generalare
competlngfortheHumveecontract.
|nDecember,theArmylsexpected
tostartbuylng53,000ofthevehlcles
conflguredasweaponcarrlers,am-
bulances,andutllltyvehlcles.|nthe
TCMverslon,theenglnelsanInter-
national Harvester6.9-llterv8dlesel
ratedatl70hpat3,000rpm.|tdellvers
3l0 lb-ftoftorqueat2,000rpm.Top
speedofthevehlclels70mph,and
speedona60%grade(lowgear)ls
l0.6mph.
50 YEARS AGO 1962
Inaudible impulses, ononetrackof
atwo-trackmagnetlctape,change
plctureslnexactpredetermlnedrela-
tlontothe
soundln
thlssllde
orfllmstrlp
projector.
Durlng
playback,
thelow-
frequency
lmpulsesare
detectedbyasensltlvetranslstorlzed
relayclrcult,whlchactuatesasolenold
tochangetheplcture.The500-wSyn-
chro-Mat|vmeasuresl0l3l7ln.
andwelghs37lb.Theprojectorlsbullt
bySynchro-Mat Equipment Corp.,
1ackson,Mlch.MD
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weight, and assembly issues. Packaging many
conductors using at cables provides solutions in
high performance, tight-tting military and aerospace
applications. And Cicoils unique cable forming
capability means cables can take virtually any shape,
eliminating costly ex circuits or wiring costs.
Bring on the Heat...and Cold!
Cicoil delivers exceptional reliability under a broad
range of temperatures. Our cables retain their
electrical properties and exibility in temperatures
from -65C to +260C. They also withstand exposure
to high levels of ultraviolet, radiation and ozone
with no adverse eects.
Approved by NASA for space ight, Cicoil at cables
exceed outgassing specications for vacuum and
space use. They provide very broad temperature
capability, ranging from -65C to +260C, and also
deliver exceptional resistance to radiation and
ozone.
Certifed for Space Travel
Cicoil at cables are used extensively within a
variety of modern guided missiles and their delivery
systems. Their at prole saves space and weight,
while a seamless silicone encapsulation provides
incredible shock absorption. When one launch can
make the dierence rely on Cicoil.
Every Launch Counts - Rely on Cicoil
The Clear Choice
66l.295.l295tXXX.DJDPJM.DPN
Cicoil High Flex
Flat Cables
www.Cicoil.com
Sophisticated, Versatile,
Mission Ready...
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VTFEJOUIPVTBOETPGNJTTJPO-
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TQBDFBQQMJDBUJPOT.0VSA49l00
DFSUJFERVBMJUZTZTUFNFOTVSFTUIBU
FBDIDBCMFBTTFNCMZJTSJHPSPVTMZUFTUFEUP
QFSGPSNJOUIFUPVHIFTUQMBDFT.0VS
JO-IPVTFDBCMFQSPEVDUJPO BOE
BTTFNCMZDBQBCJMJUJFT
BMMPXVTUPSFTQPOE
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And thats just the Cicoil Cables!
The fghter is pretty cool too.
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Visit Cicoil at Booth 6646,
San Francisco, July 10-12
RS# 136
REPORTERS NOTEBOOK
COMPANNEWS
RS#l37
PERSONNEL
RobertL.Pletrafesahasjolned
Tegra Medical,Pranklln,Mass.,as
presldentandCLO.Mr.Pletrafesa
hasmorethanl6yearsofexperl-
enceasapresldentandCLOlnthe
medlcal-devlcemanufacturlng
lndustry.TegraMedlcalproduces
complexcomponentsandfln-
lsheddevlcesforleadlngsurglcal,
lnterventlonal,andorthopaedlc
companles.
DISTRIBUTOR
AGREEMENTS
Dunkermotor,Llgln,|ll.,has
enteredlntoanagreementwlth
Cymatix Inc.,Petaluma,Callf.,and
Texas-basedShepherd Controls &
Associates,todlstrlbutebothlts
llnearmotorllneandsubfractlonal
horsepowerbrushedandbrush-
lessdcmotorsandlntelllgentser-
vomotors.
NAME CHANGE
Rexnord Corp.,Mllwaukee,has
changedthenameofltslndepen-
dentlaboratoryfromRexnord
Technical Services(RTS)tothe
Rexnord Innovation Center.The
Centerhandlesconfldentlaltest-
lngandanalysesofproductslnthe
areasoffatlgueandwear,shock
andvlbratlon,falluremodeandef-
fects,andfleld-loadmeasurement.
AWARDS
Agilent Technologies Inc.,Santa
Clara,Callf.,recelvedthe20ll
GlobalProst&SulllvanAwardfor
Companyoftheearforltsperfor-
mancelntheoscllloscopemarket.
Frost & SullivannotedAgllents
concertedeffortstobecomea
marketleaderbylntroduclng
productslnallsegmentsofthe
oscllloscopemarket,aswellas
Agllentslnvolvementlnvarlous
technologystandardsgroups.
Danfoss Power Electronics,Loves
Park,|ll.,aprovlderofvLTdrlves
andpanels,hasbeennamedthe
Sllverwlnnerforthe20llGlobal
AwardsforLxcellenceln8uslness
ProcessManagement(8PM)and
workflow.Thlsawardrecognlzes
productsleadlngtoslgnlflcant
buslnessbeneflts.TheAwardsPro-
gramlsmanagedbyFuture Strat-
egies Inc.andsponsoredbyBPM.
com,Object Management Group
(OMG),andWorkflow Manage-
ment Coalition.
OMGlsanlnternatlonalnot-for-
profltcomputer-lndustryconsor-
tlumandworkflowManagement
Coalltlonlsanonproflt,lnterna-
tlonalorganlzatlonofworkflow
vendors,users,analysts,andunl-
verslty/researchgroups.
/PNO(JJ\YHJÀLYV)HJRSHZO.LHYOLHK
The OSF-./ 8u|ck Oonnect .earhead eas-
||y mounts to any servo motor yet ma|nta|ns
a|| of the benefts of /armon|c Dr|ve gear-
|ng |nc|ud|ng 1arc-m|n accuracy and aero-
back|ash. A h|gh capac|ty cross ro||er bear-
|ng |s used at the output and |s ava||ab|e w|th
e|ther a Shaft or F|ange output |nterface. The
gearhead have rated torques of 76 |n-|bs to
9,320 |n-|bs and peak torques of 343 |n-|bs
to 46,550 |n-|bs depend|ng on s|ae and rat|o.
.ear rat|os of 50, 80, 100, 120 and 160:1
are ava||ab|e.
:/-:/./VSSV^:OHM[:WLLK9LK\JLYZ
Ava||ab|e |n a w|de range of s|aes, these aero
back|ash, 1 arc-m|n accuracy /armon|c
Dr|ve gearheads enab|e des|gn eng|-
neers to pass shafts, w|res, tub|ng, or other
components d|rect|y through the center of
the gear. They |ncorporate an output fange
supported by a |arge cross ro||er bear|ng,
prov|d|ng except|ona| moment st|ffness and
|oad capac|ty. The sma||est un|t has a ho||ow
shaft 0.D. of 14 mm and an outer d|ameter
of just 64 mm. The |argest un|t of the fam||y
has a ho||ow shaft 0.D. of 80 mm and has
a rated output torque of 1236 |n-|bs, and a
peak torque of 6175 |n-|bs. .ear rat|os from
30:1 through 160:1 are ava||ab|e.
/HYTVUPJ+YP]L33*
^^^/HYTVUPJ+YP]LUL[
*:-*:.7YLJPZPVU.LHYOLHKZ
The OSF and OS. h|gh torque 7rec|s|on
.earhead Ser|es are |dea||y su|ted for robot|c
and mach|ne too| app||cat|ons. The OS. de-
||vers 30% more torque and 40% |onger ||fe
wh||e ma|nta|n|ng aero-back|ash, 1 arc-m|n
accuracy, and +/- 5 arc-sec repeatab|||ty. An
accurate, h|gh|y r|g|d cross ro||er bear|ng |s
bu||t |n to d|rect|y support the externa| |oad. A
w|de var|ety of s|aes and reduct|on rat|os are
ava||ab|e w|th max|mum peak torques rang|ng
from 450 |n-|bs. to 60,500 |n-|bs.
/PNO7YLJPZPVU4V[PVU*VU[YVS
*HSS
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7V^LY7YLJPZPVU
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KLUZP[` VM HU` HJ[\H[VY PU P[Z JSHZZ `L[ WYV]PKLZ L_JLSSLU[ WVZP[PVUPUN
HJJ\YHJ` :L]LYHS ZPaLZ HYL H]HPSHISL ^P[O V\[W\[ [VYX\LZ \W [V
PUSI ;OLZL HJ[\H[VYZ HYL PKLHSS` Z\P[LK MVY YVIV[PJZ H\[VTH[PVU
THJOPUL [VVS HUK HU[LUUH WVZP[PVUPUN HWWSPJH[PVUZ ÔLYL WLYMVYTHUJL
HUKYLSPHIPSP[`HYLLZZLU[PHS
RS# 138
ITS ALWAYS GOOD TO HAVE THE CHOICE.
IMS.techline offers the customization of
the modular standard gear drives to exactly
match your needs. Ultimate flexibility for
high volume production.
FOR EVERY PROBLEM THERE IS ONE SOLUTION.
With our standard modular system for
Pla netary Gears you have over 10,000 con -
guration possibilities to choose from.
Small and medium volume production or
prototypes? Then IMS.baseline is the fast
and reliable solution with a selection of
Standard Planetary Gears.
Germany | USA | Mexico | China
Gear Technology. Worldwide.
Unlimited
possibilities. Unique solutions.
Planetary Gears.
High quality for all volumes.
IMS Gear ofers the optimum solution and the process that you need.
From prototypes to high-volume series.
IMS Gear Planetary Gears Inc.
440 Viking Drive Suite 110
Virginia Beach, VA 23452
phone 757-227-5553 x401 www.imsgear.com
REPORTERS NOTEBOOK
COMPANNEWS
RS#l39
EXPANSION
TV SD America, Peabody,
Mass.,hasexpandedltsbattery-
testlngcapabllltlesatltsAuburn
Hllls.,Mlch.,andNewmarket,
Ontarlo,Canadalabfacllltles.TUv
SUDAmerlcalspartoftheTUv
SUDtestlng,lnspectlon,andcertl-
flcatlonorganlzatlon.
SUSTAINABILITY ROADMAP
Freudenberg-NOK Sealing Tech-
nologies(PNST),Plymouth,Mlch.,
hasdevelopedastrateglcsustaln-
abllltyroadmaptoguldeltslong-
termeffortslnreduclngenergy
usage,lowerltscarbonfootprlnt,
andproducegreener,cleaner
productsandprocesses.
PNSTspeclallzesln
sealsandvlbratlon-control
technology,nonwovens,flltratlon,
lubrlcants,andreleaseagents.
NETWORK LAUNCH
Xenon Corp.,wllmlngton,Mass.,
amakerofpulsedUv-llghttech-
nology,haslaunchedthePrinted
Electronics Test Center Network.
TheNetworkconslstsofmanufac-
turers,lntegrators,andunlversltles
thatwlllmakethelrlabsavallable
toresearchersandproductdevel-
opersfortestlngldeasandpro-
cesseslnprlntedelectronlcs.
CERTIFICATION
TheC-Lltefam-
llyofllghtwelght
marlnecablesfrom
TE Connectivity,
Harrlsburg,Pa.,has
beenawardedthe
Germanischer
Lloyd(GL)Approval
Certlflcatlon.
TLConnectlv-
lty,Harrlsburg,Pa.,
deslgnsandmanu-
facturesproducts
thatconnectandprotectpower
flowanddata.GLlsatechnlcal
supervlsoryorganlzatlonthatof-
ferscertlflcatlon,lnspectlon,and
consultlngservlces.
TECHNICAL SEMINARS
Avnet Electronics Marketing,
Phoenlx,anoperatlnggroupof
Avnet Inc.,beganltsNorthAmerl-
canlts20l2X-festtechnlcalseml-
narserles.TheX-fest20l2pro-
gramfeaturesl2technlcalcourses
basedonXlllnxsnewArtlx-7,Kln-
tex-7,andvlrtex-7PPGAs,aswell
asthenewZynq-7000Lxtenslble
ProcesslngPlatform(LPP)famlly.
Upcomlnglocatlonslnclude8al-
tlmore,Dallas,andMlnneapolls.
Pormorelnformatlon,gotowww.
em.avnet.com/xfest.Avnethascre-
atedashortvldeooftheevent.
Thevldeocanbevlewedathttp://
avnet.me/01625.MD
[ MOTOR TRUTH #7 ]
sewmotortruth.com
Can I save
energy by using
a VFD (inverter)?
The truth is that it depends on your
application. If you have a high-cycling
application, a VFD can save money by
reducing the starting current.
Or, if you have a hoisting application
(such as a storage retrieval system), a
VFD can provide energy regeneration.
Also, if your VFD has ux control, it can
maximize the motor efciency when the
motor is oversized on a small load.
Otherwise, a VFD acts as a load and
actually consumes energy, especially if
you are using a high carrier frequency.
Visit sewmotortruth.com to get the
whole story on VFDs and energy-
efcient drivetrains.
YES
NO
MAYBE
RS# 140
UPTIME, ALL THE TIME
EPIC

connectors can stop electrical failures
before they stop your packaging lines.
KEEP RUNNING WITH LAPP
EPIC
Connectors thrive in harsh

environments.
U7>ì>
U-iiV
U,LiV>V>ì}
>`>viiiVV>>iViV>
v>V>}}iViVii>>>Vv`
RS# 141
Visit our Design Site at www.contrinex.com
Contrinex Inc.
Old Saybrook, CT 06475
Toll free: (866) 289-2899
Fax: (860) 388-3574
E-mail: info_us@contrinex.com
www.contrinex.com
PRESSURE-RESISTANT SWITCHES
FOR HYDRAULIC APPLICATIONS
9 Piston end-of-stroke (end-position) monitoring in hydraulic
cylinders
9 Control and monitoring of hydraulic valves switching
9 RPM monitoring and measuring of hydraulic motors
9 Control and monitoring of valve switching in gas distribution
systems (the devices are gas tight)
9 Applications in high-vacuum environments
Contrinex Pressure-Resistant Switches deIiver high
performance at pressures of 500 bar (7,250 psi)
Pressure-Resistant Switches offer sizes
for operating pressures from
1,450 to 7,250 psi.
SENSOR SENSE
Over 5,000 digital optical modules
(DOMs) like this are used in the IceCube
neutrino detector in Antarctica. Each
DOM consists of a glass bubble housing
a photomultiplier tube and associated
circuitry to detect the faint blue light of
a neutrino traveling through ice.
thelceupto2.5-kmdeep.Lach
holeholdsastrlngof60 DOMs
spacedalongthekllometer
depthoflceusedasthesens-
lngelement.Onceburledln
thelce,theDOMsareno
longeraccesslble.How-
ever,electronlcservlce
andsoftwareupgrades
arehandledremotelyus-
lngtechnologyslmllarto
thatdevelopedforspace
mlsslons.
TheDOMsrecordthedl-
rectlonandlntensltyofthe
llghtasthehlgh-energyneu-
trlnopassesthroughthelce.
Thlsletsresearchersdetermlne
wheretheneutrlnocamefrom.
whlleonlylnservlceashort
whlle,the|ceCubeobservatory
hasalreadychangedthewayscl-
entlstslookatthegeneratlonof
cosmlcraysandotherhlgh-energy
partlcles.Porexample,lthasbeen
along-heldbellefthatcosmlcrays,
amajorsourceofneutrlnos,were
emlttedfromgamma-raybursts
orGR8s.
GR8sarlsewhenamasslvestar
manytlmestheslzeofoursun
goessupernova,creatlngallght
thatshlnesmanymllllonsoftlmes
brlghterthanoursun.|nlooklngat
over300 GR8s,|ceCubefoundno
correspondlngneutrlnoemlsslons,
refutlngtheroleofGR8slnthecre-
atlonofcosmlcrays.MD
Thlsflashofllghtlsrecorded
by5,l60 dlgltaloptlcalmodules
(DOMs)burledlnthelce.Lach
DOMcontalnsaphotomultlpller
tube(PMT),adevlcethatampll-
flestheamountofllghtltrecelves,
alongwlthltsassoclatedclrcultry.
AtyplcaluseofPMTslslnnlght-
vlslongoggles.
Researchersdrllled86 holesln
Ormorepreclsely,the|ceCube
Detector,partoftheSouth Pole
Neutrino Observatorythat
searchesforoneofthemost
eluslveofthelow-mass
subatomlcpartlcles:the
neutrlno.
Neutrlnosareslmllar
tothemorefamlllarelec-
tron,wlthonecruclal
dlfference:Neutrlnos
donotcarryanelectrlc
charge.8ecauseneutrl-
nosareelectrlcallyneutral,
theyarenotaffectedby
theelectromagnetlcforces
whlchactonelectrons.And
conversely,theyhavellttleef-
fectonmatterandarecapableof
passlngthroughobjectslarger
thantheLarthwlthllttledlfflculty.
Thlsmakesdetectlngneutrlnos
extremelydlfflcult.
|ceCubelstheworldslargest
neutrlnodetector,encompasslng
acublckllometeroflce.Thetop
arrayofthedetectorlsl,400 m
(4,590 ftoralmostl mlle)beneath
Antarctlca.Thehlghpressureat
thatdepthdrlvesallgasesoutof
thewater,maklngthelceclearer
thancrystal.|tlsalsoextremely
darkasnollghtpenetratesthelce
tothatdepth.Darknesslsacrltlcal
need,asthedetectlonofneutrlnos
dependsonseelngthesmallflash
ofbluellghtemlttedwhenneutrl-
nospassthroughmoleculesoflce.
worldsbiggest sensor:anlcecubeI
LdltedbyRobert Repas
RS#l42
DOM
malnboard
Penetrator
Hvdlvlder
LLD
flasher
board
Mu-metalgrld
RTvgel
Photomultlpller
tube
Delay
board
Glasspressure
houslng
COMMENTARY
Doesmodel-based
englneerlngmakesenseI
The concept of model-based engineering (MBE) has
generated a lot of buzz lately and perhaps rightly so. As
you probably know, this approach tackles product devel-
opment using a kind of digital master model (not nec-
essarily CAD) from which all downstream activities can
be derived to build the product. The approach replaces
ambiguous documents and can eliminate the need for
physical prototypes before a particular design has been
chosen. Engineers can simulate and iterate as much as
necessary to refine the model while meeting requirements
and adhering to design constraints.
In this regards, it is helpful to distinguish
between design and engineering. Design
is merely creating the geometry. Any CAD
jockey can do design. Engineering, on the
other hand, uses physics-based rules to de-
velop functional machines and mechanisms.
A few firsthand examples of MBE came
from one of the many workshops conducted
at the recent Congress of the Future of En-
gineering Software (COFES), held annually
in Scottsdale, Ariz. Speakers there each gave
an example of how they used the approach to
build two entirely different systems. It seems
that the master model can be quite different
in scope and setup, depending on the nature
of the problem. But it must usually allow for a
certain fluidity. Why? Because product devel-
opment itself is fluid. There is also the underly-
ing assumption that it is necessary to logically
model and simulate the entire system operat-
ing in its setting to understand the systems behavior.
In one example, David Thomas, Sr. Project Leader,
of The Aerospace Corp., Los Angeles (www.aero.org),
says model-based engineering only works when design
models at the appropriate level of fidelity are integrated
across engineering discipline boundaries. His example:
A small, interdisciplinary team of engineers had higher-
fidelity models for mechanical CAD, structures, thermal,
and optics. They combined these with lower fidelity, Excel
spreadsheet models for a spacecraft bus and its associated
components. The result was an initial design for an infra-
red telescope created in less than 400 hr. In this case, engi-
neers generated initial optical, CAD, and structures mod-
els for the telescope in Comet Solutions MBE software.
First-order constraints for the telescope were determined
during an earlier predesign phase that described the orbit
and the telescope.
Integration of the CAD and structures model in the
MBE environment let the designer optimize for launch
vibration loads in only 4 hr. The resulting CAD design
for the telescope then became an input to a spreadsheet-
Leslie Gordon
SenlorLdltor
leslle.gordon
@penton.com
based conceptual design for the
mission. This design produced
additional information (orbit
details, solar array size, overall
payload geometry) needed to complete a thermal design
for the telescope. Designers completed their initial design
of the infrared telescope payload in the MBE environment
by integrating models for thermal (Thermal Desktop),
structures (MSC Nastran), and optics (Code V). The
resulting MBE let them evaluate changes to the telescope
image quality during orbit.
Integration of engineering-design
models within an MBE workspace
helps diagnose design-performance
problems as they arise. For example,
initial analysis revealed bending of the
primary mirror (optics) was degrad-
ing the telescope image. The structures
model showed the culprit to be exces-
sive clamping force at the mirror hub
mount, due in part to low temperature.
With this root cause determined, de-
signers could change designs and re-
peat the integrated analysis much more
quickly (by factors of 2 to 3) com-
pared to standard practice.
In another case, Matthew Loew, a
new-product development chief engi-
neer at Joy Global in Milwaukee (www.
joyglobal.com), is using model-based
engineering to develop mining equip-
ment that weighs millions of pounds and stands several
stories high. Again, the master model consists of multiple
domains (structures, performance, reliability, cost, as well
as product geometry) and mixed fidelity models.
For example, engineers initially investigate the struc-
tures models with closed-form calculations in a spread-
sheet. They ultimately develop a finite-element model
with fine shells and solids meshes, coarse meshes, and
beams. Loew loosely coupled the models (unlike the tele-
scope example) because, as he put it, The design process
in this case lacked a formal order. The models range
from those for nonlinear static FE, multibody dynamics,
deterministic and stochastic reliability calculations, 1D
performance simulations, and engineering-content CAD.
Typically, models need more fidelity as systems mature.
However, it is possible to actually degrade the fidelity in
some areas to concentrate on areas of continued interest
in development.
What do you think about the model-based design
approach? Write us and we might print your answers
here. MD
|ntegratlonof
englneerlng
deslgnmodels
wlthlnanM8L
workspacehelps
dlagnosedeslgn
performance
problemsas
they arlse.
GI VE YOUR BI G I DEA
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it to life with ease. Now you can have 3D printing right at your desktop
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at your fingertips, theres real l y no l i mi t to your creati vi t y. The
af fordable Mojo 3D Print Pack includes everything you need to
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3D PRINTER
RS# 143
RS#ll4
VANTAGE POINT
8enefltsofafocused
dlstrlbutorsprogram
Quality over quantity is often quoted but not often imple-
mented. The idea that more isnt better but, rather, better is
better isnt difficult to comprehend. Putting it into practice,
however, takes planning, dedication, and a focused drive
for excellence. The results can be quite rewarding.
Simrits Preferred Distributor Program is based on this
approach. That is, a small group of highly trained distribu-
tors who deeply understand our specialized products and
customer-focused solutions is much more valuable than a large group of distributors
who are just familiar with the product portfolio.
The program has been successful overseas for a number of years the
average partnership between Simrit and its international Preferred Distribu-
tors spans approximately 40 years and we recently introduced the programs
proven advantages to our North American distributor network.
Cooperation and communication with key distributors benefits everyone.
Distributors gain from access to in-depth training and ongoing communication
regarding product innovations and improvements. Distributors are better able
to consult and advise customers on the best solution for their specific needs.
Ultimately, cooperation helps customers speed delivery and maximize the value
of their end products. And this results in a more-coordinated, efficient, and
valuable business structure for Simrit as well.
Simrit has devoted substantial resources to this effort. For example, a dedi-
cated training program educates distributors on proprietary applications, ma-
terials, and products at the Freudenberg Sealing Technologies Academy (also
available online). Further, customized training can be provided at the distribu-
tors facilities.
An active sales-support program coordinates joint customer visits and tech-
nical consultation for customized products, technical alternatives, and proto-
types, particularly for complex applications.
Preferred distributors have around-the-clock access to Simrits e-commerce
platform, which provides daily updates on more than 43,000 items, including
vital details such as pricing and availability, as well as product and material data.
Internally, Simrit has put in place separate distribution-management and cus-
tomer-service teams to support the program and its participants, with a committed
focus on better understanding how to help distributors best serve their clients.
For companies interested in developing a focused distributor program, keep
in mind several notable factors:
Realize that distributors have special needs, such as for affiliate marketing
and point-of-sale support, that are different than requirements for an OEM
or major global customer.
The basics of how the company does business with distributors should
evolve over time. Identify important issues (such as the need for incentives)
and adjust to satisfy those demands.
Develop a program thats tailored to every aspect of a distributors business,
including logistics, marketing, technical support, and customer service.
Continually pursue key distributors that strategically align with your goals.
Base the partnership on trust, consistency, accountability, loyalty, transpar-
ency, and well-founded market knowledge.
With a commitment to quality over quantity, a distributor that intimately
understands a product portfolio and provides valuable and timely solutions to cus-
tomer problems can become a critical link in a companys overall success. MD
Slmrlt(www.simritna.com)lspartofFreudenberg-NOK Sealing Technologies andoffers
anextenslveportfolloofpreclslonmanufacturedproducts.
LdltedbyKenneth J. Korane
Michael A.
Baxter
SalesDlrector,
DlstrlbutlonNorth
Amerlca
Simrit
Llgln,|ll.
1UNLl4,20l2
The PPwer Pf KnPw|edqe Enqineerinq
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RS# 145
INVENTORS CORNER
Ldltedby Leslie Gordon
|nventorsCornerusuallyshow-
casesmldnlghtenglneers
thelnventorswhocomeupwlth
patentableldeaslnthelrspare
tlme,offtheclock.Here,weare
dolngsomethlngallttledlffer-
entlnfeaturlngsomeonewho
hascreatedafewlPhoneapps.
Typlcally,lPhoneappswouldbe
outsldeofthenormalscopeof
thlssectlon,butthelnventor
lsahlgh-schoolstudentandwe
feltthathlsproductsdeserveda
llttleexposure.
8llly8arbaro,ajunloratCar-
roll High School,Dayton,Ohlo,
createdappscalledSceneTlmer,
TakeTlmer,ShowTlmer,and
Pedlacenter.Theflrstthreeare
forTvandradloproductlon,wlth
SceneTlmerandTakeTlmeravall-
ableonlTunes.Accordlngto8arbaro,
ShowTlmerlslntheapprovalprocess
andwlllhopefullyjolntheother
twoshortly.Pormorelnformatlon,
seehttp://itunes.com/apps/
videoadventures
8arbarolscurrentlydeveloplng
Pedlacenterandsaysltlsthemost
ambltlousprojecthehasundertaken
yet.Theappllcatlonwaslnsplredby
hlsthree-year-oldcouslnwhowasdlag-
nosedwlthleukemlaalongwlththefact
hlsphyslcsclassrequlredhlmtoenter
thesclencefalrandhewaslooklngfora
sultableproject.
Asaresultofmedlcaltreatment,hls
couslnneedstoregularlymonltorhls
vltalslgns.Porexample,hemusttake
hlstemperatureevery4hrtomakesure
hedoesnthaveafever.Pedlacenter
provldesanentertalnlngandefflclent
waytohandlethlstask.|tgraphspatlent
temperature,date,andtlme,andalso
logsthedatalnachart.Theappprovldes
qulckandeasyaccesstothepatlents
doctorandalsodlsplayshospltalsnear
theuserwlthcontactlnformatlonand
dlrectlons.
Theblggestchallengelnthlsproject
wasbulldlngthehardware,says8arbaro.
Theflrsthurdlewassettlngupanlnterface
togetdatalntothelPhone.Theorlglnalde-
slgnwastouseeltherthelPhones30-pln
connectoror8luetooth.8otharesanctloned
byApplesMadeforlPhone(MPl)Program.8ut
8arbaroranlntosometroubletrylngtojoln
theprogram,sohelookedforanalternatlve
route.TheonlyotherportonthelPhonelsthe
headphonedevlce.
|cameacrossatechnlquecalledfre-
quency-shlftkeylng(PSK),says8arbaro.|ts
whatfaxmachlnesusedwlthallthebeeplng
andnolsestheymade.|nanutshell,ltsturn-
lngdatalntosoundthenchanglngltbackon
theotherend.Thedlgltalvaluesof0sand
lsaremodulatedlntosoundwavesoflow
(the0s)andhlgh(ls)frequencles.There-
sultlngwavelssentthroughtheheadphone
jackanddemodulateduslngllbrarlesonthe
lPhoneslde.ThlsprojectrellesonaHl1ack
boardmadebyProjectHl1ack,foundonllne
atSLLLDStudlo(www.seeedstudio.com/de-
pot).Theboardlsusedtomodulatethedata
recelvedfromthethermlstor(orwhatever
lnputyouattachtolt)lntosoundandsendlt
tothelPhone.
8arbarothenplacedathermlstorlna
voltagedlvlderclrcultandattachedlttothe
board.Theanalogvaluelstransmltteduslng
PSKtothelPhone.Thereslstancevaluegets
pluggedlntotheStelnhart-Hartequatlonto
calculatethetemperature,whlchlsthenused
throughouttheappllcatlon.Theappllcatlon
letsthechlld(oradult)playcomputergames
whlletaklnghlsorhertemperature.|twlllalso
callthedoctorlfthetemperatureexceedsa
parametersetbythedoctororparent.
Onthesoftwareslde,8arbarowroteallthe
codelnXcodeandtestedltonanlPhone.
ThecurrentverslonofPedlacenterended
upwlnnlngthecountysclencefalr.Asare-
ward,8arbarowaslnvltedtopresentatthe
|nternatlonalSclenceandLnglneerlngPalrln
Mayandcompetedagalnstotherstudentscl-
enceprojectsfrom65countrles.
Contact8arbaroat:bbarbaro@vldeoad-
venturesonllne.com.MD
Are you (or do you know) a midnight engineer
who would like to get his or her product show-
cased in MACHINE DESIGN magazine? Please con-
tact Leslie Gordon: leslie.gordon@penton.com,
(216) 931-9242
Apphelpskldsfight leukemia
www.pelicanoem.com/md
PELICAN PRODUCTS , INC.
23215 Early Avenue, Torrance, CA 90505
866.628.9890 (TOLL FREE)
Q
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these custom case solutions can provide you with the highest level of
Mission Critical condence in the eld guaranteed.
Use of the military image does not imply or
constitute Department of Defense endorsement.
RS# 146
AEROSPACE
Doom and Quake video games. The FAA examined the
plans and by the end of July granted Deville a waiver for
launch. Deville planned to launch his rocket in October at
BALLS, an annual event held at Black Rock Desert, a dry
lake bed in Nevada just north of Reno. The event draws
rocketry enthusiasts from all over the world who launch
large rockets, some with complex staging, others with
multiple motors, as well as experimental and home-built
designs. The event is sponsored by the Tripoli Rocket As-
sociation, a group that helped the Qu8k project in several
ways.
For example, Tripoli cut through a lot of red tape by
getting an FAA waiver that covered the entire BALLS
event, clearing it for rockets to fly up to 150,000 ft. Dev-
ille and other hobbyists were allowed to piggyback on this
waiver. Tripoli also assisted with the high-impulse (Class
3) flight package that had to show the FAA an analysis
of my rockets flight profile, charts of possible crash sites,
what the dispersion pattern of wreckage should be if there
Last year while working at Syntheon LLC, a Miami com-
pany that designs and develops high-tech surgical instru-
ments, Derek Deville caught wind of the Carmack 100kft
Micro Prize during the long Fourth of July weekend. The
competition offered $5,000 to the first team to build a
rocket that flew to over 100,000 ft.
Deville thought he was just the right person to take
on such a challenge. After all, he was a lifelong rocketry
hobbyist, a mechanical engineering grad from Purdue
University, and he had worked professionally in rocket de-
sign with Darpa, NASA, and the Air Force Research Lab,
not to mention building rocket engines for Burt Rutans
SpaceShipOne. Hed already built many rockets; this one
just seemed like it would take a somewhat scaled-up effort.
Planning and red tape
Deville carefully but quickly drew up plans for the
rocket, which he named Qu8k in tribute to the man spon-
soring the prize, John Carmack, developer of the popular
From
Engineer
to
Rocketman
A trained
mechanical
engineer who
seriously dabbled
in rocketry as a
hobbyist builds a
rocket that climbs
to over 100,000 ft.
Authoredby:
Stephen J. Mraz
SenlorLdltor
stephen.mraz@penton.com
Resources:
BALLS and the 2012 event, www.rimworld.
com/balls21
Derek Deville, ddeville.com/rockets.htm
Qu8k rocket and videos, ddeville.com/derek/
Qu8k.html
Tripoli Rocketry Association, www.tripoli.org
Symbiosis Foundation, symbiosis-foundation.
org
Toreadaboutanotheraward-wlnnlng
amateurrocket,scan
thlscodeorgoto:http://
machinedesign.com/
article/prize-winning-
amateur-rocket-zooms-to-
120000-ft-1117
was an accident, and prove that the risk of injury and death
were sufficiently low, say Deville.
Tripoli also made rocket hobbyists life easier when
working with one of the most-common rocket fuels,
ammonium perchlorate composite propellant (APCP).
APCP had long been classified as an explosive by the
Bureau of Alcohol, Tobacco, Firearms, and Explosives,
making it difficult to work with. For instance, you needed
a license to handle APCP, an approved storage magazine
to house it, and the magazine had to be inspected, says
Deville.
But Tripoli spent 10 years suing the ATF, trying to get
APCP reclassified. About two years ago, it won that legal
battle and ATF declassified the propellant so that a license
and permit are not required to use it.
Keeping it simple
Deville designed Qu8k with a single rocket motor
and nozzle to keep things simple. With a cluster flight,
In 2008, Derek Deville (pictured)
launched the Black Dragon,
a 26-ft-tall, 375-lb rocket. Its
engine generated 2,400 lb of
thrust for 8 sec, enough to take
the rocket to 13,000 ft.
AEROSPACE
To do this, he and his team carefully aligned the fins
when they were welded in place. In fact, they used CNC
to construct a jig from medium-density fiberboard to
hold the fins square to each other while being welded
onto a thin-walled cylinder that fit over the motor tube.
The rocket had several electrical components, in-
cluding dual timers for parachute ejection, three video
cameras, and four independent GPS units. To keep the
layout simple, Deville had separate battery packs for
each. The GPS devices, for example, drew power from
lithium power packs, which Deville was unsure would
work at altitude.
We tested the pack in a vacuum chamber at our shop
to make sure the lower pressure, nearly a vacuum at
100,000 ft, wouldnt hurt their performance, says Deville.
I expected them to swell and possibly open circuit or drop
in voltage. And although they did swell somewhat, they
or rocket with several engines on a single stage, it be-
comes challenging to get all the engines to ignite and
shut down at the same time. If they dont, the resulting
asymmetric thrust veers the rocket off its straight-line
course. With those risks, I shy away from cluster rock-
ets, though Ive built and launched many in the past,
says Deville.
Because the goal was to reach the highest altitude pos-
sible, Deville wanted his rocket to fly straight up. One way
to ensure stable, straight flight is to have the rocket spin or
roll. This evens out aerodynamic loads and tends to make
the rocket fly straighter.
But high roll rates give you horrible videos because of
the camera spinning around with the rocket, notes Dev-
ille. And one of my objectives was to get good video of the
flight. So I designed Qu8k as a low-roll rocket, one that
would spin about four to five times in 90 seconds.
About that Prize . . .
DerekDevllleeventuallyrecelvedhalftheprlze
money, $2,500, from 1ohn Carmack, the man be-
hlndtheCarmackl00kftMlcroPrlze.
|nmaklngtheaward,Carmacksald:|havede-
clded to award half the prlze value for the Qu8k
rocket.
| am not walvlng the omclal requlrement for
a GPS lock at altltude. However, | thlnk Qu8k de-
servessomethlngfortheenortandprojectreport.
Thefullprlzelsstlllavallabletotherstrocket
thathltsalltherequlrements.Thereshouldbeno
expectatlonoffuturehalf-prlzeawards.|faQu8k
2wlndsupnylngandhlttlngalltherequlrements,
lt ls stlll ellglble for the full prlze |m sure a re-
portcanbelledupwlthaddltlonalusefuldetalls.
Lveryone else that onered up addltlonal prlze
moneylslefttothelrowndlscretlon,ofcourse.
The Qu8k rocket sits in its custom-
built gantry, which was designed
in SolidWorks. The gantry had to
be easy to assemble and strong
enough to guide the rocket on a
straight course during takeoff. The
rocket and gantry contact each
other at four points; there are no
launch lugs or rail guides on the
rocket, which create drag. By not
using these parts, simulations
showed Deville was able to increase
peak altitude by over 10,000 ft.
The Qu8k rocket measured 8-in. in
diameter, 167.5-in. tall, and weighed
320 lb at liftoff. The rocket engine
exerted 4,000 lb of thrust for 8 sec,
taking it to an estimated 121,000ft,
in 92 sec. Top speed during the
ascent was 3,200 fps (almost
2,200mph). The entire flight lasted
8.5 min and the rocket landed three
miles from the launch site.
Qu8k breakdown
Radlal
bolt
retentlon
forward
andaft
closures
Aftclosure
retalnsnozzle,
extends
dlvergence,
andforms
vehlcletall
cone
Phenollccarrler
lnsulatesthroat
fromcaseand
mlnlmlzes
thlcknessof
graphltethroatto
preventcracklng
fromdlfferentlal
thermalexpanslon
|somoldedgraphltethroat
l50lbof
case-bonded
flns-on-a-
cyllnderfuel
gralnswltha
progresslve
burnproflle
Tracklng
smoke
graln
Tlmermountwlth
duelg-swltchtlmers
Pneumatlc-
cyllnder
mount
Recovery
plston
Shearplns
madeof
polystyrene
wlthstand
60lb/pln
Alumlnum
nosecone
Stalnless-
steeltlp
Anodlzed
alumlnumnose-
coneshroud
retalner
GPS
antenna
mountlng
plate
Nose-cone
shroudmadeof
radlotranslucent
flberglass
Payloadsectlon
8lack-powder-
actlvatedpneumatlc
cyllnder
Recoveryattachment
polnts(dualforged
eyebolts)
|gnlter
Plncan
madeof
welded606l
alumlnum
Plnsmadeof0.25-ln.-thlck,
CNC-proflledalumlnum
It took Deville and his
team less than three
months to go from
concept to launch.
did not lose charge and continued working.
Other electrical devices relied on N-style disposable batteries.
Taking a mechanical approach
With most amateur-built rockets, the friction-fit nose cone pops off from the
pressure generated by a timed black-powder charge. The charge goes off based
on calculations of when the rocket will reach its apogee or highest point. But
most amateur rockets dont soar to 100,000 ft.
Qu8k couldnt use this method for several reasons. First, the rocket would
run out of thrust before it got to its targeted altitude, so it would, in effect,
glide there. But when the thrust abruptly stopped and acceleration slowed, the
nose cones momentum might pull it off the rest of the rocket before the rocket
reached 100k ft. And second, if the nose cone stays on, any air trapped behind
it would remain at atmospheric pressure as the rocket climbed. Meanwhile,
outside pressure would drop and no longer push down on the nose cone. So the
trapped air would be like an inflating balloon pushing on the nose cone.
Assuming air pressure at 100,000 ft is negligible, the 15-psi air trapped in-
RS#l47
AEROSPACE
zle, a critical component that must withstand 1,000-psi
gases flowing at Mach one and 3,000F.
I used a piece of graphite for the nozzle, which is tra-
ditional, but put it in a machined phenolic carrier, says
Deville.
Deville and his team machined a nozzle with thin walls,
which reduces thermal expansion. The thin cross section
also means it heats up more evenly, so there is little dif-
ferential expansion, which creates high internal stresses
and can lead to cracks. The phenolic carrier mechanically
supports and isolates the nozzle from the motor casing,
shielding it from heat.
Payloads and problems
Qu8k also carried a couple of payloads into the at-
mosphere. A GPS unit broadcasting the rockets posi-
tion on the 70-cm ham-radio band let Deville and his
side would push on the 50-in.
2
bottom surface of the nose
cone with 750 lb of force, says Deville. So I had to vent
the small area behind the nose cone. This meant I could
not trap the pressure generated by a black-powder charge
to release the nose cone.
Deville fell back on his mechanical background and
devised an approach never used before, a piston-cylinder
actuator. Two timers (one for redundancy) were each set
to activate an electrical match, a simple device that uses an
electric current to ignite an explosive charge. The matches
were set to light a black-powder charge inside the sealed
2-in.-diameter piston. At the right time, the matches lit the
charge, and the resulting 200 psi of pressure extended the
piston and pushed off the nose cone.
We were able to ground-test this subsystems and it
worked perfectly, says Deville.
Deville also took a novel approach to building the noz-
The Qu8k team
Jorge Pinos and Angel Fernandez: Endless machining
Guy Kress: Launch tower
Greg and Rowan Mayback: Financial, moral, and physical support
Bret Ranc: Launch support
Korey Kline: Inspiration and design review
Carlos Rivera: Road tripping to Pitt
Tripoli Pittsburgh: Motor transport
Al Bychek: BRB, tracking, and launch support
Chuck Rogers: Simulation and load calculation
Miguel Hernandez: Late-night support and heavy lifting
Jim Harper: Logistics
Marc Devits: Electronics support
Ky The-Rocketman Michaelson: Parachute
Michael and Danah Kirk and Ed Ampuero: Propellant casting
Syntheon LLC: Machining and material support
Derek Deville and one
of the motors he helped
test and develop for Burt
Rutans SpaceShipOne.
The curvature
of the Earth
and blackness
of outer space
can clearly be
seen as the
Qu8k rocket
reached its
apogee. The
nose cone
has also been
popped off,
but it is held to
the rocket by
a Kevlar shock
cord.
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RS# 148
Advancing Automation
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A parachute
carried the Qu8k
to a soft landing.
team monitor rocket position, though the GPS lost positional lock as the
rocket climbed. But data resumed when the rocket began riding down under
the parachute. The GPS let us drive right to the touchdown point, notes
Deville.
The other payload was a cosmic-ray detector (Geiger counter), which
was part of the Symbiosis Foundations Ergo project. The projects goal is
to equip at least a thousand classrooms across the globe with similar detec-
tors to record and analyze high-energy cosmic rays coming from space. The
rocket carried one of their data packages, which consisted of a 5-in.-square
circuit board and some daughterboards, and it was a challenge getting it to fit
in the nose-cone area, says Deville. But apparently it detected cosmic rays
with eight times the strength of readings taken at ground level.
Qu8k carried other GPS units that also failed, a sticking point when it
comes to claiming the $5,000 Carmack Prize. It stipulated that proof the
rocket climbed to at least 100,000 ft would come from GPS, but all three
units lost positional lock during the climb. And there are two theories as to
why this happened.
The first postulates that the crystal oscillators used in the units to measure
the time between signals received from GPS satellites was disturbed by the
15-g takeoff. This altered the timing, confusing the software, and making the
GPS unit stop working.
The other theory, one Deville believes is more likely, is that the high speed
of the rocket and the resulting Doppler shift confused the GPS circuitry do-
ing periodic calculations. It couldnt accept the high speed or vast difference
in position between readings. This could probably be remedied with the
right software, but it would likely be expensive, says Deville.
Still, Deville had other proof that his rocket met the Carmack Challenge.
Experts could tell it climbed to at least 100,000 ft based on acceleration data
recorded onboard the rocket. And flight times matched simulations of it
traveling to that height. MD
AEROSPACE
RS#l49
RS# 150
SEMICONDUCTORS
Most light-emitting
diodes are made in Asia,
but future generations
of LED manufacturing
equipment could
still be marked
Made in the U. S. A.
The bad news for makers of semicon-
ductor-manufacturing equipment is that
sales of most kinds of fab gear are flat to
down. The good news is that the U. S.
could end up playing a bigger role sup-
plying manufacturing equipment for the
emerging area of solid-state lighting.
The U.S. Dept. of Energy used stimulus
funds to amplify the supply-chain strengths
of the U.S. The DOE recognized that the
U.S. would be an unlikely place for LED
fabs, so it tried to seed the development of
LED-manufacturing equipment here, ex-
plains Tom Morrow, executive vice presi-
dent, emerging markets group and chief
marketing officer for SEMI, the association
Authoredby:
Leland Teschler
Ldltor
Resources:
Intel, www.intel.com
Semicon West and Intersolar 2012, http://
semiconwest.org/
Will the U. S. be an
LED
ASSEMBLY

MECCA?
Though the 300-mm wafer has become the industry standard,
chipmakers are transitioning to 450-mm versions, like this example
at Innolas Semiconductor GmbH, a maker of wafer-sorting and
laser-marking systems.
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RS# 151
SEMICONDUCTORS
Worldwide spending in front-end fabs
58
48
38
28
18
8
2
12
22
Equipment
Construction
Change (%)
160
140
120
100
80
60
40
20
0
20
40
60
1
9
9
5
1
9
9
7
1
9
9
8
1
9
9
9
2
0
0
0
2
0
0
1
2
0
0
2
2
0
0
3
2
0
0
4
2
0
0
5
2
0
0
6
2
0
0
7
2
0
0
8
2
0
0
9
2
0
1
0
2
0
1
1
2
0
1
2
2
0
1
3
Change (%) In $U.S. billions
0
500
l,000
l,500
2,000
2,500
0 200 400 600 800 l,000 l,200
LED fab-equipment
spending
Total worldwide spending
36
79
60
2l
50
l32
3l
0
l25
l25
2l5
l08
l,025
925
l,l67
437
22l
260
337
62l
3l4
246
320
ll0
l90
l50
390
482
2013 2012 2011 2010
1,960
1,917
2,520
1,892
EU and
Mideast
SE Asia
Americas
China
Taiwan
Japan
S. Korea
Equipment spending (in $U.S. millions)
2013
2012
2011
2010
serving the manufacturing
supply chain for electronics
makers. Going forward, it
looks as though assembly and
automation areas, rather than
front-end LED fabs, will be a
likely focus for the U.S.
LED-manufacturing
equipment will be among the
focus areas when the upcom-
ing Semicon West show kicks
off in San Francisco July 10.
Though LED-manufacturing
equipment is a promising
area, it saw a modest drop in
sales last year. The display
market was the big engine
for LEDs, but it has declined
partly because TV sales have
cooled off, but also because
set makers are backlighting
more efficiently. Two years
ago, a 40-in. TV might con-
tain 240 LEDs for backlight-
ing. Now some TVs only use
20 or 30 because the LEDs
are brighter, and manufactur-
ers have learned how to dis-
tribute the lumens more ef-
ficiently, says Morrow.
Virtually all the recent investment
in LED-manufacturing equipment has
been for high-brightness LEDs, says
Morrow. Much of this spending has
been on MOCVD (metalorganic va-
por phase epitaxy) equipment, which
has led to overcapacity, particularly in
China. Though solid-state lighting was
the original application envisioned for
the LEDs coming off these machines,
some fabs have now switched over to
making LEDs for mid and low-power
uses, Morrow says.
Makers of high-brightness LEDs
have several technical challenges to
overcome. One is a transition from 4
to 6-in. (100 to 150 mm) wafers. LED
makers are also trying to move away
from sapphire substrates used be-
cause they are compatible with GaN
material that goes into LEDs and to-
ward silicon substrates, which are less
expensive but can have problematic
interactions with GaN.
Overall, SEMI expects sales of semi-
conductor-manufacturing equipment
to decline about 10% this year after a
boom in 2011. However, recent an-
SEMIs world-fab forecast, made in April, saw a drop in semiconductor-
manufacturing-equipment spending this year, but recent
announcements of capital-equipment spending by some big-name
chipmakers may make 2012 a flat year.
Hey big spender: China and Asia are still hotbeds of investment in fab equipment for
making LEDs, according to figures compiled by SEMI.
JUNE 14, 2012 MACHINE DESIGN.com 64
RS# 152
SEMICONDUCTORS
degrade patterns put on chips.
Another issue facing chip manufacturers this year is
the transition to 450-mm wafers from 300-mm versions.
Wafers this large need handling equipment and metrol-
ogy that is completely different than that for managing
smaller wafers. Whats worse, its likely the first 450-mm
facilities will also have to implement EUV lithography.
This puts chip fabs in the position of having to iron out
bugs in two new technologies simultaneously.
Finally, chipmakers are also transitioning away from
planar transistors toward those that employ more of a
3D structure. This helps reduce leakage current during
the off state of the device, a problem that becomes more
severe with ever-smaller dimensions characterizing chip
circuitry today. The typical approach is to locate several
gates on multiple stacked surfaces, which more effec-
tively suppresses off-state leakage current. The result
is lower power consumption and a more-compact layout
than on conventional planar transistors.
The difficulty with 3D designs is that they will only
become practical with significant advances in semicon-
ductor-manufacturing-process technology, says Morrow.
For example, Intel has been working on its 3D transis-
tor technology, which it calls a trigate architecture, since
2002. But the company only ironed out associated mass-
production issues last year. Intel factories are expected
to make upgrades this year so they can manufacture
the companys Ivy Bridge CPUs which will be built with
trigate transistors. MD
nouncements about capital-equipment purchases from
big chipmakers such as Intel, Santa Clara, Calif., suggest
that 2012 could merely turn into a flat year, Morrow says.
Booming sales of tablets, smartphones, and other mobile
platforms, as well as the growing ranks of wealthier con-
sumers in emerging markets such as China and India, are
driving the demand for consumer electronics and ICs that
power them.
Semicon West will also host discussions of several tech-
nological issues that equipment makers must overcome
to continue along the road toward higher chip densities
that Moores Law predicts. For the first time in the indus-
trys history, there are several challenges coming together
at the same time, says Morrow. One of these is extreme
ultraviolet lithography (also known as EUV or EUVL),
a next-generation lithography technology using extreme
ultraviolet wavelengths on the order of 13.5 nm. EUVL is
considered a must for making chips having features on
the order of 11 nm, but it is significantly more complicated
than the deep ultraviolet lithography used to make ICs to-
day. For one thing, EUV lithography must take place in a
vacuum. Because EUV technology requires high vacuum,
the transfer of wafers into and out of the tool chamber is
cumbersome and limits the speed at which wafers can be
processed.
Moreover, the optics typically absorb over 95% of the
available EUV light, so the EUV source must be super-
bright. And there are other difficulties associated with
shadowing, diffraction patterns, and imperfections that
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A listing of
semiconductor
fabs dedicated to
LEDs, compiled
by SEMI, shows
where the action
is. But the hope
is that the U.S.
could be a force
in manufacturing
LED-production
equipment.
RS# 153
OEM SERVICES/ MADE IN AMERICA
This huge machine puts the
chamfer on a nuclear-fuel rod.
turing. The company focuses solely on the U.S. economy
and market. It has no suppliers outside the U.S.
We dont handle maintenance, repair, and operations
(MRO) or commodity products, says CEO Frank Russo.
And that is for a specific reason: The sourcing and pro-
curement process for complex machinery is quite involved
and demands a lot of information. The company has built
an online platform to handle complex transactions.
Says Russo, We feel ours is the right model for today
as we try to bring back the U.S. manufacturing economy.
Specifically, the suppliers are relatively small companies
with diverse specialties and they are located all over the
U.S. The companies are typically so focused on specific
manufacturing processes and expertise that they do not
have a lot of marketing power, resources, or outreach.
This lack of marketing power makes it hard for buyers
to find potential suppliers that are capable and have the
No doubt, the economy is global. But there are compa-
nies in the U.S. that believe strongly in the mantra Made
in America. In fact, they base their corporate mission on
this theme. Some companies are actively trying to bring
back the manufacturing base from overseas. They want
to make money, sure. But these companies also see man-
ufacturing in the U.S. as a patriotic duty. Why? Because it
has become evident that manufacturing is really the iron
backbone of our economy and, without it, we are doomed
as a nation. The interesting questions are, is this a prof-
itable endeavor, and how did these companies remain
afloat during the recent downturn?
Complex, custom manufacturing
Completely onboard with Made in America is Fabri-
cating.com in Hoboken, N.J., a recent start-up. The online
marketplace for manufacturers targets custom manufac-
What it takes to
competitively
manufacture
in the U. S.
Authoredby:
Leslie Gordon
SenlorLdltor
Key points:
Custommanufacturlnglshot.
Offshorefacllltlesmaynotbecompetltlve
whenltcomestocomplexmachlnery.
Manufacturlnglsthelronbackboneofthe
U. S.
Resources:
Fabricating.com, www.fabricating.com
Omax Corp., www.omax.com
Salem Design & Manufacturing LLC, http://
salemndt.com
PormorelnformatlononthelssueofU. S.-
basedmanufacturlng,
scanthlscodeorgoto:
http://machinedesign.
com/article/why-it-makes-
sense-to-manufacture-in-
the-u-s-0209
Made in
America?
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www.molex.com/brad/md RS# 154
The Fabricating.com dashboard shows a buyers current
activity, a list of to-dos and a quick lookup of favorite
suppliers. This version shows the way it presents the actual
part drawing while the buyer is reviewing the RFQ.
Salem Design and Manufacturings
newest machine uses an eddy-current
probe to inspect automotive spindles for
cracks or flaws that cannot be seen by
the naked eye under a microscope.
school bus full of kids. Huge liabil-
ity. So we sell equipment whenever
a company has had a problem re-
gardless of how their business is doing.
This means that our sales dont fluctuate as
much as the others as the economy goes up
and down.
The company also serves the nuclear-en-
ergy market. It builds equipment used in the
manufacturing and inspecting of nuclear
fuel-rod tubing.
According to Warga, the company has
stayed competitive while manufacturing in
the U.S. primarily because it does not build a
product such as a small widget. We dont have
to worry much about overseas competition, he says. I
would equate us to a home contractor. For example, the
Chinese would have a hard time competing on building a
house for you. Because China is so far away, trying to meet
with companies there periodically to see how your house
is coming along would be impractical. That is probably the
biggest reason we dont have any offshore competition.
Almost paradoxically, another advantage to compa-
nies that build machine tools in the U.S. is that the dollar
is weak right now, says Warga. So Europeans are looking
here because we are a bargain compared to the Euro. If a
business such as ours were operating in Germany, lets say,
machines are going to be more expensive. Labor costs in
Germany for machinists or engineers are similar to those
in the U.S., so the big difference is which country has the
weaker currency. Plus, the world still needs power, even
specific kinds of expertise and ma-
chine capacity needed, says Russo.
This is where we fit in.
Examples of capabilities manu-
facturers might look for include
machines with a specific capacity
for making parts with unusual
diameters, says Russo. Com-
panies might also be looking
for suppliers, say, that can handle
large or unusually heavy parts.
Many machine shops typically have
weight-limited capabilities in terms
of overhead conveyors and cranes.
Fabricating.com decided to re-
strict suppliers to those from the
U.S. because it saw a good mar-
ket potential in doing so. Also,
we feel strongly about bringing
manufacturing back to the U.S. because the
strength of our country depends on it. We dont see the
market space as billions of dollars. Instead, we see it as pro-
viding great quality leads for suppliers, connecting them to
good-quality buyers.
Russo also says that people have done a great job in the
past few years of educating buyers and suppliers on the to-
tal cost of ownership. Even some of the larger companies
are beginning to see that offshored products do not neces-
sarily translate to larger profits.
Additionally, recent news has described the rising mid-
dle class in China. Labor costs there are, thus, going up,
contributing to the total cost of ownership. And it seems
there are always quality issues, says Russo. Therefore,
just the largest corporations that are currently basing their
procurement decisions only on price will continue to do
so, he says. But we think there is a large custom manufac-
turing market here in the U.S. that is vastly underserved.
Even smaller job shops have now invested in high-quality
machines and CAM equipment. So they can compete if
given the chance to find the right buyers.
Target a critical market
In another example, Salem Design and Manufactur-
ing LLC (SDM) in Salem, Ohio, designs and builds cus-
tom manufacturing equipment along with gaging, eddy-
current and ultrasonic testing machines to inspect safety-
critical parts. Says President Phillip R. Warga III, such
parts might be something like a ball joint, which if not heat
treated properly could cause a catastrophic accident. The
company remained successful even during the downturn
because manufacturers that make safety-critical parts
must invest in equipment to inspect them, to ensure they
dont have a lawsuit down the line.
Says Warga, our machines dont build parts cheaper or
make parts faster. The machines are an insurance policy.
Lets say you are making automotive spindles and one of
them is fractured, he says. It could go into a car and cause
the wheel to fall off, which could result in the car hitting a
tailored
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RS# 155
The A-Jet cutting
head accessory on
an Omax waterjet
makes angled
cuts and bevels
and automatically
corrects for the
taper normally
found in abrasive
waterjet cutting.
called UniWest, Pasco, Wash., also developed a cost-com-
petitive inspection machine designed primarily to inspect
automotive spindles for the proper heat treatment or flaws.
The machine includes two robots, one manipulates an
eddy-current probe along the surface of the spindle while
it rotates. The other robot is used to load and unload the
spindles. The probe creates eddy currents in a localized
spot, which generates a signal that can be detected should
it sense a crack or a flaw. The technology finds flaws that
are difficult to see, even under a microscope, says Warga.
The machines go in-line for the 100% inspection of auto-
motive spindles.
SDM has been in business for seven years. Of course,
there have been ups and downs like always, says Warga.
But Ive reached a point where money isnt really the main
objective I just really enjoy doing the work. And that is
true for most of our employees. I think good employees
are a huge factor in a company being successful. We are
not slave drivers, the profit just kind of came. Businesses
have to make money to survive, but we have never priced
things to make a lot of money right now. You can run your
profitability high in the short term, but that just opens the
door for competitors. So we came into the market at times,
about half of our competitors price for the same test. I
dont think our competitors will be able to make a similar
machine for the price.
A main reason for the poor economy is greed, contin-
ues Warga. As a business owner, I do not strive to make
a maximum profit every year. I would rather make less
money and be patriotic and help this country than I would
to make an extra 5 or 10% and end up hurting the country.
I think that bigger businesses should consider that going
to foreign countries in the long-term is damaging.
True, some of the components SDM uses in its ma-
though there is talks of windmills and a lot
of other methods, nuclear is not about to
go away for a long time. So that market is
increasing in size.
Another reason SDM was able to hold
its own during the downturn was because
it is fairly lean, says Warga. We reach
around 3 million a year in sales with just six
people, he says. Over the years, we have
found extremely good people some-
thing I put a lot of effort into. We shopped
around and went through a lot of individu-
als and the result is we have ended up with
an exceptional crew. We dont even have a
foreman. Everyone just knows what needs
to get done.
The machinery the company manufac-
tures is quite complex. One of our lines
uses a lot of robotics, says Warga. In gen-
eral, companies that build machines and
become profitable usually dont like to cus-
tomize its products. They will say, Here
is the machine, take it or leave it. In con-
trast, SDM always starts with a clean sheet
of paper.
Our strength is we are mostly an engineering service
and tackle difficult applications, says Warga. This ap-
proach is always risky because if we promise a company
that we can design a machine to do what the firm wants,
should we fail, we are probably bankrupt.
According to Warga, in the past few months, European
nations have been looking internally to find their weak-
nesses whether from a natural disaster or a terrorist at-
tack. One area they discovered is in nuclear-fuel-rod pro-
duction, he says. Fuel rods supply the energy for power
plants to make the steam that runs the generator. Fuel rods
last a couple of years and then need replacing. Analysts
found problems with a certain rod and came to us to see
if we could make a machine to produce them. The tubes
required an exceptionally tight, specialized chamfer on the
OD and ID. The tubes are about 15-ft long, 3/8 in. diam-
eter, with 0.020-in.-thick walls.
Cutting the chamfer is difficult because tube diameters
can vary slightly, continues Warga. So we developed a sys-
tem that uses a laser to find the centerline of the tube down
to 5 millionths of an inch. We also developed a mecha-
nism that positioned the cutter to within 10 millionths of
an inch. Integral to that, we developed the gaging system
that would do a 100% inspection after every tube was
chamfered.
Up until that time, only one European company could
make that specific kind of fuel rod. SDMs goal was to pro-
duce machined tubes that would equate to the European
tubes, however, the end result was that SDMs machine
produced tubes with accuracy exceeding those from Eu-
rope. This type of machinery costs approach 1 million dol-
lars and is quite large.
SDM, in conjunction with an eddy-current company
Generic
Motion Control
Technology by THE INNOVATORS
Perfection in Automation
www.br-automation.com
` Maximum system productivity through exceptional
performance and system synchronization
` Supports advanced manufacturing technologies by
integrating CNC, robotics and motion control with
integrated safety technology
` Easy implementation of machine options because of
software compatibility across all drive technologies
` Supports all machine topologies through the use of
centralized and decentralized drive technology
` 5educed hardware costs and simplied service
RS# 156
Machinetec
Corp. of Fairfield,
Ohio, says its
Omax waterjets
have saved costs,
increased output,
and brought
previously
outsourced work
back in-house.
our programming system automatically
takes into account.
So producing a part just involves
entering the CAD file and inputting
the part thickness, material, and qual-
ity a rough cut or a fine cut. The
machine basically then programs it-
self, says Parry. The result is great
for short runs. The sweet spot for
abrasive waterjets is one part to a cou-
ple of hundred parts, 0.040 to 4-in.
thick. Setup time is almost nothing.
We have also been successful in
manufacturing in the U.S. by always
making continuous improvements to
the technology, says Parry. Improve-
ments are more easily done because
we make parts as we need them, he says. We have ev-
erything right here instead of in a long supply chain.
Another reason Omax is continuing to be successful
is its machines also give the companys customers more
flexibility. Abrasive waterjets are kind of a new tech-
nology and take a little bit of getting used to, says Parry.
So we stand behind the product with training and sup-
port. Waterjets are not like cars where you can just hand
someone the keys and say, Here it is, go and run it.
The machines are useful in that they can cut every-
thing from superalloys to composites, coated materials,
hardened tool steel, and really soft materials that are
difficult to machine. This capability lets U.S. manufac-
turers make better-quality products, says Parry. One
example is a shop that makes elevator-control panels.
Not a really big thing, but our technology can cut the
panels after the shop has them all nice and polished.
There is no heat situation to cause problems.
According to Parry, there are abrasive waterjets that
are made in China. But they lack high quality, he says.
And, above all, the control system that lets us make
quick-turnaround parts is just not there. We have seen
people bringing over lower-cost Chinese cutting ta-
bles XY tables and adding their own controllers.
But we look at how it is being done and realize that we
can actually build high-quality waterjets competitively
priced in the U.S. simply by building them as we need
them. We keep coming back to the idea that we can do a
better job right here with our own people.
Continues Parry, The state of manufacturing in the
U.S. is encouraging. One thing I am a little distressed
about, though, is that youngsters today do not want to
get into a trade or be a manufacturing engineer because
it seems like manufacturing is all going away. But those
of us in our 50s and 60s are not seeing it going away. We
are getting smarter about how to stay competitive while
manufacturing in the U.S. We must get more young
people enthused about making stuff, so we can continue
to compete in the future. We can be smart in the way we
build and design things and use the latest technology,
which offshore manufactures cant necessarily do. MD
chines are made offshore. But that is because there is no
company in the U.S. it knows of that makes them. But
the machine base, guarding, and other components are all
made in America.
Make parts only as needed
In another case, H. Laird Parry, senior applications
engineer of Omax Corp. in Kent, Wash., says, We are a
small manufacturer that uses its own abrasive waterjets
to make parts for abrasive waterjets that we sell to other
companies. The nifty thing is we can make parts as we
need them. When companies send things offshore, they
have to order a big-enough quantity to make economic
sense. And then they dont have the flexibility needed to
make a relatively small number of machines. They must
purchase large containers of parts and often there is a
design change before the parts even arrive.
Omax is relatively small, with only about 275 em-
ployees up from 150 about two years ago and it
produces different variations on a theme, says Parry.
So as orders come in, we want to be able to make parts
for those orders rather than have a whole bunch of in-
ventory tied up on the shelves which may or may not be
used that year.
We held our own during the downturn because our
machines complement rather than compete with other
technologies such as machining, laser cutting, EDM, or
plasma, says Parry. For example, lasers cannot cut com-
posites, he says. Smaller EDM shops can use blanks cut
from waterjets then finish them off to close tolerances.
And laser shops cant cut copper or aluminum, but wa-
terjets can. In addition, waterjets are set up for a quick
turnaround. Just clamp the material down on the table
and away you go.
Omax also tries to always stay one step ahead of the
competition. One of the big technological advantages we
have although other companies are moving this way
is our control system. The challenge of a waterjet is that
the cutting jet itself is flexible. So programming the ma-
chine used to involve a lot of trial and error. Now we have
a software model that models the behavior of the jet that
Every 3.5 seconds, a Banner sensing solution is installed somewhere.
Being engineers, were trying to improve on that.
Solving automation challenges, one application at a time, for over 45 years.
For nearly half a century, when industry has an automation challenge, they turn to Banner for solutions.
And among the thousands of global sensing innovations engineered by Banner, many started as a
tailored response to a single customers needs. Challenges solved quickly. Efciently. And affordably.
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more sensors, more solutions
RS# 157
FLUIDPOWER TECHNOLOGY GUIDE
The 24-in.
model of the
Triform sheet-
hydroforming
press has a
clamp housing
enclosing the
bladder, visible
at the center of
the image. The
operator interface
supporting recipe
controls is on the
right.
Hydroforming is a process that uses fluid pressure to shape metal parts. Sheet
hydroforming, one variation, can produce formed parts that are impossible to
make using a stamping process. Also, sheet hydroforming shapes deep objects
in a single operation, whereas stamping might require multiple operations.
Another advantage of hydroforming is that the tooling typically costs much
less, as little as one-tenth the cost of that used in metal stamping. This can make
hydroforming more attractive for low-volume applications.
Hydroforming basics
The process has been used by metal fabricators for more than half a
century. Following initial interest during the aerospace boom of the 50s
and 60s, however, development of new machines and technical innova-
tion languished through the latter part of the 20th century. More recently,
hydroforming has experienced a measurable resurgence, thanks to the
Hydraulic motion controllers
enhance the precision
and repeatability of
hydroforming presses.
Authoredby:
Richard Meyerhoefer
ReglonalAppllcatlonsSpeclallst
Delta Computer Systems
8attleGround,wash.
Key points:
Hydroformlngcanmakepartsnotposslble
wlthstamplng,andthetoollngtyplcallycosts
muchless.
Hydraullcmotloncontrollersthatcontrol
toollngposltlonandfluldpressurevastly
lmprovethepreclslonandrepeatabllltyofthe
hydroformlngprocess
Resources:
Delta Computer Systems, http://deltamotion.
com
RS# 621
Pryer Technology Group,www.
pryertechgroup.com
RS# 622
Hydraulic controls
TRANSFORM
press
technology
Groschopp uses the Fast Track department to quickly build motors/gearmotors to meet customers demands. Because
Groschopp stocks components rather than nished motors/gearmotors, we can easily make modications to the motor/
gearmotor to meet your requirements. Modications include:
t Various bolt hole patterns
t Face/foot mountings with special ange
t Shaft size/diameter/shape
t Special bearings and seals
t Terminal box
t Insulation
t Keyway
t Threading
Because our Fast Track designs are based on standard product lines our experienced, on site machinists can quickly
alter bolt hole patters, create custom shafts, threadings and more.
After the entire build process is complete the Fast Track department has two rooms designated for testing the motors/
gearmotors. Computers and high tech testing equipment allow them to perform accurate tests on the hand-built motors.
From there the motors are packed with the help of a sophisticated Styrofoam packaging system.
Need a few motors quickly? Submit your application specs at www.groschopp.com/specs or call (800) 829-4135 and
ask to speeak with a regional account manager.
48 HOUR
Fast Track Gearmotors
|ntegroteoMot|on3o|ut|ons
Groschopp Inc.
420 15th St. NE
Sioux Center, IA 51250-2100 USA
(712) 722-4135 Phone
800.829.4135 Toll Free
(712) 722.1445 Fax
sales@groschopp.com Email
www.grosohopp.oom
REGISTERED
ISO 9001:2008
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(Purchase Order to Shipment)
RS# 158
The RMC151E electrohydraulic motion controller can
synchronize up to eight axes and control pressure and position
simultaneously.
model, eight axes are under closed-loop control.
Programs developed for the motion controller let oper-
ators select production recipes that contain up to 30dif-
ferent steps in a press cycle. Each step corresponds to a
target bladder pressure and punch position. Besides the
target values, motion instructions specify how the ma-
chine will reach the next target.
For example, at the beginning of a machine cycle, a
quick move instruction brings the punch cylinder to its
start position. At the same time, the bladder is precharged
to a designated pressure. Then, during the forming cycle,
the punch axis receives a position command with an accel-
eration and deceleration value for each step in the process.
Meanwhile, to control bladder pressure and coordinate its
operation with punch-axis movements, the RMC is given
a gearing command. This sets up the punch axis as master
and forces bladder pressure to follow the punch as a slave.
To smooth motions between steps, acceleration of the axes
ramps up and down gradually using an S-curve motion
command.
An intensifier cylinder pressurizes the bladder. It works
like a syringe to inject or remove oil under both position
and pressure control. A pressure transducer monitors
bladder pressure and sends the data to the motion con-
troller. The transducer can typically read between 1 and
10,000psi. The RMC also commands a directional valve
to control the position of the intensifier cylinder. A lin-
ear magnetostrictive-displacement transducer (LMDT)
mounted inside the cylinder provides position feedback.
A second LMDT monitors punch position. To ensure pre-
introduction of precision motion controls.
Case in point is a new line of sheet-hy-
droforming machines called Triform presses,
made by the Pryer Technology Group of
Tulsa, Okla. In these presses, a bladder filled
with hydraulic fluid surrounds the tool-
ing form. A hydraulic-cylinder-driven
punch presses the tooling and metal
sheet into the bladder, causing it to con-
form to the required shape.
As fluid pressure in the bladder
builds, it clamps the material and forces it
against and around the form. Simultaneously,
a hydraulic cylinder presses the form against
the bladder, bending the metal sheet to con-
form to the tooling. Its important to control
how quickly the material bends. Otherwise, it
will tear or wrinkle, according to Darrell Har-
relson, technical director with the Beckwood
Press Co. of Fenton, Mo., a design partner
with Pryer on the new Triform hydroforming
machine project.
Sheet hydroforming requires the manage-
ment of several variables to ensure quality
parts: position and speed of the punch; bladder fluid pres-
sure; lubrication of the part, which is relatively easy to con-
trol; and material variances, which can be controlled by
working with metal suppliers.
When making complex parts on traditional hydro-
forming presses, operators face differences in pressure
from cycle to cycle, causing the position of the punch
to vary, says Scott Pryer, president of Pryer Technology
Group. Historically, highly skilled and experienced ma-
chine operators were needed to deal with this variability.
And often, even that wasnt enough. Some older ma-
chines used two joysticks for control and dials to monitor
pressure in the chamber. Operators couldnt see the actual
process, resulting in poor consistency among parts made
by a single operator; and even less uniformity in parts pro-
duced by different operators.
Metal fabricators demand machines that perform
consistently, every time, so that operators can focus on
improving other process factors such as the materials and
lubrication, says Pryer.
Position and pressure control
To solve the control problem, engineers designing the
Triform presses turned to RMC electrohydraulic motion
controllers from Delta Computer Systems Inc. of Battle
Ground, Wash. They precisely control position and pres-
sure throughout the process and reduce the number of
forming steps in the manufacturing cycle.
On smaller Triform machines, the Delta RMC controls
two motion axes: the punch cylinder that pushes tool-
ing into the bladder, and the cylinder that varies bladder
pressure. On larger presses, it also controls containment
clamps and the upper chamber that closes around the
bladder and workpiece. On the largest machine, a 32-in.
RS# 159
Hydroforming operation
Intensier
cylinder
Directionalvalve
LMDT
Pressure
transducer
Proportional
valve
LMDT
Motioncontroller
Clamp
Bladder
Metal
sheet
being
formed
Tooling
Punch
cylinder
The Delta
multiaxis
motion
controller
synchronizes
operation of
the intensifier
cylinder and
punch cylinder,
providing
closed-loop
control of
the sheet-
hydroforming
process.
to close the outer shells before the pressurization cycle
begins. Closed-loop position control for this operation en-
sures smooth motion, avoiding any shocks that would cre-
ate maintenance problems over time. The controller also
monitors shell-position feedback to detect any faults or er-
rors. For example, if a wrench left in the machine prevents
the shell clamps from closing properly, a following error
(a mismatch between target motion and actual motion)
would signal a problem that needs to be fixed.
Similar controls activate the lid on a 32-in. deep-draw
press. Four cylinders, one at each corner, each with its
own proportional valve, raise the lid. The motion of these
cylinders is linked using the multiaxis synchronization ca-
pability of the Delta controller to
avoid wracking or jamming the
lid frame.
The biggest design challenge
in developing the Triform was
gearing the bladder pressure to
the punch position, says Har-
relson. Getting them to synch
requires calculating appropri-
ate ramp times in the open-loop
section. To test the design and
tune it for optimal performance,
Beckwoods engineers used Delta
Computer Systems RMCTools
software. It includes a Plot Man-
ager and pressure and position
Tuning Wizards that analyze
the system response to control
outputs and produce the proper
gains for the control-loop equa-
tion. It simplifies tuning the sys-
tem for best performance, says
Harrelson.
Results
The design goal of the Tri-
form machines was to permit
experienced operators to spend
less time controlling the machine
and more time improving the
process, while also letting inex-
perienced operators use the reci-
pes to make complex parts con-
sistently, with little training.
Precise control improves
quality and performance. On
moderately difficult forming
projects in the past, 10% of the
material would often be wasted
due to lack of precision, says
Scott Pryer. And on complex
forming operations, it could be
as high as 25%. Now, with the re-
peatable process, the scrap rate is
almost zero. MD
cise punch operation, outputs from the motion controller
drive a servo-quality proportional valve that controls the
punch hydraulics.
The trick in the hydroforming process is to avoid
wrinkling the sheet as it first bends around the corners
of the tool, notes Harrelson. To accomplish this, most of
the programmable motion steps in each press cycle oc-
cur within the first inch of punch travel. Cycle time varies,
depending on the profile of the part and the needed pres-
sure. The machines operator interface locks in all of this
information for each part by calling up a preprogrammed
recipe from the RMC. Theres no guesswork.
In some larger machines, the motion controller is used
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RS# 160
CONNECTING DEVICES.
Energy consumption is often the major contributor to overall costs of owning
and operating industrial plants and machinery. On average, energy consump-
tion accounts for between 20 and 30% of total equipment operating costs. And
in energy-intensive hydraulic applications, the share of energy costs are often far
greater. In such cases, variable-speed pump technology quickly pays for itself.
Fixed versus variable
Traditional hydraulics run continuously at a constant speed to generate the
power required to operate a machine. In these circuits, an electric motor typically
runs at its rated speed, say 1,800 rpm, and drives a fixed-speed pump. The pump,
in turn, rotates continuously and generates flow without regard to the actual power
needed by the machine at any given moment. The varying hydraulic flow a machine
demands is regulated via internal adjustment mechanisms in the pump, or by divert-
ing excess flow back to the tank.
Innovations over the years have improved the efficiency of fixed-speed pump
circuits, but applying variable-speed techniques raises potential energy savings to
a new level. Such systems use variable-speed electric drives to rotate pumps at their
most-efficient speed often less than 200 rpm while supplying only the hydrau-
lic power a process requires at any given moment. Depending on the application,
this can produce energy savings between 30 and 80%, compared to fixed-speed op-
eration, without sacrificing performance or limiting operating pressure.
In addition, lower energy consumption indirectly reduces the emission of CO
2
,
helping companies significantly reduce their carbon footprint.
Operating the pump and motor at less than full speed also means they generate
less noise. In some cases, noise emissions have been reduced by as much as 20 dB(A).
Variable-speed
pump drives
supply only the
power a process
requires, cutting
energy costs
in hydraulic
systems by up
to 80%.
Authoredby:
Neal Gigliotti
Manager,PlastlcsGroup
Jan Komsta
Manager,NewTechnologles&
Slmulatlon
Bosch Rexroth Corp.
8ethlehem,Pa.
Key points:
Tradltlonalhydraullcsrunata
constantspeedandgenerateflow
wlthoutregardtotheactualpower
neededbyamachlne.
varlable-speedelectrlcdrlves
rotatepumpsatthelrmost-efflclent
speedtosupplyonlythehydraullc
poweraprocessrequlres.
Lnglneersshouldconslderuslng
varlable-speedpumpdrlves
wheneveramachlnecyclehas
fluctuatlngflows.
Resources:
Bosch Rexroth, www.
boschrexroth-us.com
RS# 623
Energy-efficient
HYDRAULICS
slash operating costs
Variable-speed pump drives not only reduce energy
consumption, they run quieter than fixed-speed units,
generate less heat, and require less cooling.
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high voltage insulation protection or noise isolation capabilities that
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RS# 161
tion, providing high efficiency over a wide speed range.
It is can run at more than 3,000 rpm, but in partial-load
operation it reduces speed to less than 200 rpm without af-
fecting operating pressure. This also substantially reduces
noise from the hydraulic power unit.
The FcP 5000 is well suited for clamping and tensioning
operations, such as required in machine tools. Depending
on cycle characteristics, energy consumption falls by 30
to 80%, average flow is reduced over the entire machine
cycle, and the oil stays cooler.
The second line, the DFEn 5000, consists of an axial-
piston, variable-displacement pump driven by an asyn-
chronous standard motor and a frequency inverter. Its for
high-performance, high-power applications.
Digital onboard electronics calculate the best operating
speeds for the pump and motor. Destroking the variable-
displacement pump lowers the flow rate and motor load,
with optimum speed for maintaining pressure generally
between 300 and 400 rpm. During production breaks, the
software can stop the pump without affecting the operat-
ing pressure. With machines that operate on a cyclical ba-
sis, a teach-in process can be used to bring the system back
up to speed just before a needed increase in flow rate.
With noncyclical machines, sensing demand lets the
controller increase speed to the required minimum shortly
before additional flow is required, for instance in case of a
batch change. That way, the full output of the pump is
available if and when it is needed.
Finally, for high-end applications, the Sytronix SvP
7000 servopump drives offer the greatest responsiveness
and precision. They take advantage of the high dynamic
capabilities of permanently excited synchronous servomo-
tors to boost efficiency and substantially reduce energy
consumption, for example in presses and plastics-process-
ing machines.
The drives use an internal gear or axial-piston pump.
A pressure transducer senses hydraulic pressure, which is
This eliminates potential hazards to workers and the need
for personnel-protection measures. And the cost and has-
sle of secondary noise containment or damping measures
is cut accordingly. This adds to the potential savings of
variable-speed drives, helping pay off the investment in
relatively short order.
Due to lower energy consumption, another benefit
is that the hydraulic fluid does not heat up excessively.
In many cases, it is possible to eliminate heat exchang-
ers or fans to cool the power unit. This, in turn, permits
a more-compact design, which can reduce a systems
complexity and up-front costs. Commissioning becomes
easier and quicker, and it simplifies troubleshooting and
maintenance.
Finally, variable-speed pump drives can be integrated
into existing equipment without major redesigns, thus
letting them increase the energy efficiency in machines
already installed on the plant floor.
High-performance drives
A number of fluid-power and motor manufacturers
offer variable-speed pump drives, and the available com-
binations of pumps and motors seems to be growing by
the day. For example, Rexroths Sytronix product line has
more than 140 modular, variable-speed pump/drive com-
binations, covering a broad spectrum of applications for
demand-based control of hydraulic systems. The variable-
speed pump drives currently fall into three general groups:
The frequency-controlled Sytronix FcP 5000 pump
drive is the basic version. It consists of an asynchronous
standard motor and a frequency inverter driving an inter-
nal or external gear pump. This combination offers a good
price/performance ratio, especially for high-power appli-
cations. Its primarily used in constant-pressure systems.
It maintains system pressure by matching flow with de-
mand. For example, the units PGH-3x internal gear pump
has been designed specifically for variable-speed opera-
Rexroths Sytronix
SvP 7000 servo-
pump drives offer
high responsiveness
and precision. They
combine permanently
excited synchronous
servomotors with an
internal gear or axial-
piston pump. They
can be used in open
hydraulic circuits to
control pressure and
flow, and for simple
positioning. And highly
dynamic position control
is possible in closed-
loop circuits, often
eliminating the need for
control valves.
RS# 162
ciently generate the required flow. In addition, the drives
improve efficiency by eliminating throttling losses across
control lands. Required oil flow is precisely metered, and
the electric motor switched off when the press does not
need flow or pressure. When retrofitting existing presses,
they clearly improve a machines capacity while signifi-
cantly reducing energy costs and noise.
In continuous papermaking, variable-speed pump
drives can significantly improve energy efficiency. For
example, during pressure-holding functions for rolling
up paper, intelligently reducing speed directly saves up to
60% on electricity compared with power units with non-
regulated fixed displacement motors. At the same time,
variable-speed pump drives can run faster, permitting
smaller-size units with lower cooling demands. Thus,
they cut operating costs and space requirements.
In all these applications, variable-speed pump drives
maintain the reliability and power density of hydraulics,
and combine it with the flexibility of electric drives. The
extended diagnostics options of these closed-loop drives
also opens up additional options for preventing expen-
sive machine failures, thanks to condition monitoring.
And keep in mind the possibility for upgrading ex-
isting plant machinery by replacing fixed-displacement
units with variable-speed pump drives. This lets users
quickly reduce energy consumption without having to
invest in new equipment. Simulation programs are avail-
able that evaluate a machines hydraulic circuits and de-
termine possible savings for an application, before in-
vesting in hardware. And because existing hydraulic
circuits often remain unchanged, the switch can be made
with surprisingly little effort. It also opens up possibili-
ties for replacing classic, constant-speed hydraulic power
units with variable-speed pump drives. MD
controlled by software in the frequency converter. Here,
pressure control has a limiting effect on pump speed.
Closed-loop comparison of required and actual values for
pressure and flow can be sent to the higher-level machine
controller via analog signals (0 to 10 V) or fieldbus. As in
the other versions, the pumps are designed for variable
speed operations, combining low leakage and noise with
high overall efficiency.
The SvP 7000 with an internal gear pump can be used
in open hydraulic circuits to control pressure and flow, and
for simple positioning. And highly dynamic position con-
trol is possible with an axial-piston pump in a closed-loop
circuit. Precisely metered flow allows for direct control of
cylinder movements, letting the unit position an axis with-
out the need for control valves. Thus, it can considerably
simplify hydraulic systems.
And several servo-variable pump drives can be com-
bined into one cascading system. Ethernet-based, real-
time communication between several controls using Ser-
cos III lets users synchronize an almost unlimited number
of SvP 7000s to satisfy most any application demand.
Typical applications
Variable-speed pump drives arent warranted for ev-
ery hydraulic system. But engineers should consider
them whenever a machine cycle has fluctuating flows.
Intelligent servodrives sense demand and regulate
speed and, thus, power consumption of the electric mo-
tors. The more time a machine spends running under
partial-load conditions, the greater the potential energy
savings. Applications where variable-speed pump drive
offer substantial energy savings include:
Machine tools
Plastics-processing machines
Die casting
Presses
Woodworking and papermaking.
For instance, variable-speed pump drives in plastics-
processing machines reduce pressure-holding losses
during pauses and partial-load operation. High-per-
formance units, like the SvP 7000, accelerate twice as
fast as conventional variable-speed pumps, shortening
cycle times for higher productivity. Digital speed control
ensures high repeatability, and the setup compensates
for pressure-related leakage losses. With sophisticated
closed-loop pressure control, quick pressure changes are
possible while minimizing under or overshoots. Software
can even prevent cavitation when changing from high to
low pressures.
In, hot-chamber die-casting machines, closed-loop
control corrects for deviations in pressure and speed, and
compensates for leakage past the pump. It can also sim-
plify the hydraulic circuit. In one redesign, an SvP 7000
eliminated the need for separate pumps for high and low
pressure circuits, replaced some high-response control
valves, and supplied an accumulator-charging circuit for
the shot cylinder.
For press automation, variable-speed controls effi-
0
l,000
2,000
0
5,000
l0,000
5.6kw l.3kw
41.4% 2.2 kW 33.1% 8.4 kW
50-ton,
30-seccycletlme
l60-ton,
l5-seccycletlme
Energy savings
Variable-
speed
pump
Constant-
speed
pump
Comparing energy consumption
|njectlon-moldlngmachlnes
Comparisons on plastic injection-molding machines show
that replacing constant-speed, electrohydraulic variable-
displacement pumps with variable-speed pump drives
cuts energy consumption well in excess of 30%.
FOR MAINTENANCE-FREE LINEAR WAY PERFORMANCE,
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RS# 163
FLUIDPOWER PRODUCTS
Low-temperature hoses
New 472LT and 722LT hoses are engineered to work in temperatures as low
as 70F (57C). The hoses are suited for high-impulse, heavy-duty mining, drilling, and construction equipment found through-
out northern Canada and the Arctic Circle. They are also suited for snow groomers, side booms, snowmaking machinery, and
cold-storage applications. Available in -4 to -16 sizes, two-wire braided 472LT hose is rated to 5,800 psi (40 MPa). Four-wire spiral
722LT is available in sizes from -6 to -24 and rated to 4,000 psi (28 MPa). Upper temperature limit is 212F (100C).
Parker Hannifin, Hose Products Div., 30240 Lakeland Blvd., Wickliffe, OH 44092, (440) 943-5700, www.parkerhose.com
RS# 624
Air-pilot and
manual valves
The NITRA line of pneumatic prod-
ucts has been extended to include
air-pilot and manual-control valves.
The AVS-5 Series now includes
single and double-pilot directional
control air-pilot valves, offering
spring return or center-closed
operation. All are body ported
five-port (four-way) spool valves
available in 0.12 to 0.50-in. NPT port
sizes with flow coefficients from
0.67 to 2.79. Manual valves in tog-
gle-style hand lever, push-pull, and
rotary-style hand lever models have
aluminum-alloy bodies, 0.12 to
0.50-in. NPT ports, and flow coeffi-
cients from 0.78 to 5.29. Models are
available in two or three-position
detented styles.
AutomationDirect, 3505
Hutchinson Rd., Cumming, GA
30040, (800) 633-0405, www.
automationdirect.com RS# 628
Pilot-control
cartridge valves
New 09 Series cartridge valves are for
proportional and on/off pilot control of
clutches, brakes, and directional-control
valves. The hybrid units combine a 10
size cavity with an 08 size tube/coil,
providing high flow in a compact pack-
age with low-power consumption. They
include two on/off solenoid valves and
a proportional pressure-reducing valve. The solenoid valves are two position, three way or
four way, and operate to pilot pressures of 100 bar (1,450 psi) and flows to 20 lpm (5.3 gpm).
The proportional pressure-reducing /relieving valve gives pilot control of a clutch or direc-
tional valve. The valve comes with standard reduced pressure settings of 20 and 25 bar (290
and 360 psi) with flow capability exceeding 25 lpm (7 gpm).
Comatrol, 1407 Pelzer Highway, Easley, SC 29642, (864) 644-0055, www.comatrol.com
RS# 626
Diaphragm pressure regulators
Miniature diaphragm pressure regulators feature a
low-friction pressure-sensing element and a propri-
etary valve mechanism for regulation in small pack-
ages. An innovative spring system provides a range
of outlet pressures while also ensuring the lowest
installed height and lowest weight in the industry.
Single (PRD) and two-stage (PRD3/PRD2)
models are just over 1 in. in diameter. The single-
stage regulator weighs only 25 gm in stainless steel
and brass. The two-stage version weighs 66 gm in stainless steel and brass. Aluminum
versions for ultralow-weight requirements are also offered.
The regulators accurately reduce inlet pressures as high as 500 psig down to an out-
let pressure range of 0 to 30 psig. The regulators are available in 316 stainless steel, 303
stainless steel, brass, and aluminum. For applications with inlet pressures above 500 psi,
the PRD3HP three-stage regulator can reduce inlet pressures as high as 3,000 psig
down to an outlet pressure range of 0 to 30 psig.
Beswick Engineering Co. Inc., 284 Ocean Rd., Greenland, NH 03840, (800) 354-
5014, www.beswick.com RS# 625
ISO air cylinders
Extruded body, ISO 6431-compliant air cylinders have standard magnetic pistons in seven bore
sizes from 32 to 125 mm. Stroke lengths are to 1,000 mm. Adjustable air cushions at both ends
and machined male rod threads with jam nut are also standard. The hard-anodized aluminum
cylinder tube ID and OD ensures corrosion resistance and long product life, and lubrication
is not required. Optional position sensor mounting brackets fit over any of four extruded
housing rails. See Catalog #FAQR-09 for complete specs and prices.
Fabco-Air, 3716 NE 49th Ave., Gainesville, FL 32609, (352) 373-3578,
www.fabco-air.com RS# 627
Get the Original from
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RS# 164
Standard and Custom Clutch, Brake
& Power Transmission Solutions
291 Boston Turnpike Bolton, CT 06043
Phone: 860-643-1531
Reliability
inaClutch
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FLUIDPOWER PRODUCTS
Pressure sensors
The new Model IP pressure sensors are CE certi-
fied and come in common pressure ranges (5 to
10,000 psi and 0.5 to 700 bar). IP sensors include tem-
perature in its Total Error Band (TEB) configuration,
improving measurement confidence and eliminating
the need for supplementary calculations. Models
IPG1 and IPG2 offer accuracies of 0.15 % and 0.25%,
respectively. They are compatible with many liquids,
chemicals, and gases and are designed for demand-
ing industrial environments with temperature swings or
pressure spikes. Typical applications include heavy-equipment monitoring, process and
factory automation, and testing.
Honeywell Sensing and Control, 2080 Arlingate Lane, Columbus, OH 43228,
(800) 848-6564, http://sensing.honeywell.com RS# 629
ISO tie-rod cylinders
MH Series metric hydraulic tie-rod cylin-
ders meet ISO 6020/2 160-bar standards.
The products have pistons with cast-iron
rings and polyurethane U-cup seals; rod
and rod bearings with hard-chrome-
plated/high-strength steel and bronze
construction; and carbon steel tie-rods
with rolled threads. Ten different bore
diameters range from 25 to 200 mm, with working pressures to 210 bar. Multiple
mounting configurations, as well as double-rod versions, are available.
Milwaukee Cylinder, 5877 S. Pennsylvania Ave., Cudahy, WI 53110, (414) 769-9700,
www.milwaukeecylinder.com RS# 630
Check-valve assembly
A compact manifold assembly that includes a check valve and an inverted
shuttle valve is for full-power brake systems. The assembly is suited for hydrau-
lic-brake systems that must store energy in two separate accumulator circuits.
The inverted shuttle valve isolates the higher pressure of the
two circuits, while directing lower pressure to the switch
port. A check valve prevents pressure from leaking back
to the inlet port. Maximum flow capacity is 11 gpm
and operating pressure is 3,625 psi. Applications
include split systems with a pressure-compensated
pump and electrohydraulic accumulator charging
controlled by a pressure transducer at the switch
port.
MICO Inc., 1911 Lee Blvd., North Mankato, MN
56003, (507) 625-6426, www.mico.com RS# 632
Function-block library
The updated PLUS+1-compliant J1939 software function-block library supports EPA Tier
4 emissions-compliant systems and the companys related products. The library contains
30 new function blocks, including support for messages commonly used in Tier 4-com-
pliant systems, and 12 updated function blocks with protocol upgrades and new fea-
tures. These include basic PGN Receiver, PGN Transmitter, and Diagnostic function blocks.
The software supports CAN-based communications in the truck, bus, and off-highway
markets, letting OEMs quickly develop custom control systems.
Sauer-Danfoss, 2800 E. 13th St., Ames, IA 50010, (515) 239-6000,
www.sauer-danfoss.com RS# 631
RS#l65
RS# 166
SOFTWARE REVIEW
muchmaterlalremalnslnthe
machlne.|nfact,theMojowont
letyoubulldlftherelsntenough
materlaltocompletethejob.Prom
here,justhltPrlntandthemachlne
startsbulldlngtheobject.when
thejoblscomplete,anotlceap-
pearsontheControlPanel.
Theonlynlt-plckythlngthat|
cansaylsthatatadmorevlbratlon
damplngcouldbelnorder.On
veryfastmoves(e.g.,rasterflllofa
thlnwall)therelsamlnoramount
ofshaklng.|saynltplckybecause
ltdldntbothermeorlnterruptmy
work.
Somyflrstpartbullttookless
than5hr.|tcomprlsed0.007-ln.
layerswlthasolldflll.Allthede-
tallswerepresent,lncludlngthln,
0.020-ln.rlbs,walls,andhorlzon-
talsurfaces.Thepartwasgood
looklngandconslstent.Andthe
machlnelstrulyofflcefrlendly.|t
dldntthrowoffanyheat,fumes,
orodor.
Alsoexceptlonallyeasylssup-
portremoval.Aspartofthepack-
ageprlce,thecompanylncludesa
nlcesupport-removalcarafecalled
wavewash55.Agaln,ltlssmall,
compact,andslmplejusta
plug,on/offswltch,andCycleStart
button.1ustdroplntheLcoworx
tablet,thepart,andaddwater.To
acceleratesupportremoval,the
carafeheatsthewaterandagltates
ltwlthanlftymagnetlc-drlverota-
tor.Alsonlcelsthatyouneedno
plumblngconnectlons,onlyaccess
toatapanddralnnoplumblng
lsnecessary.MD
processmyflrstpart.|selecteda
Test8lockfromwlndowsLxplorer
andhadtheflrstpartreadytoprlnt
lnl5mln.
ThePrlntwlzardlnterfacefor
prlntpreparatlonlsclean,slmple,
andlntultlve,lnpartbecausethe
onlythlngauserhastodolsselect
oneofthreesupportstyles,and
orlentthepart.8othtasksarevery
easy.Therearealsotheoptlonsto
dopartscallngandmakemultlple
coples.Once|knewhowtopro-
cessapart,lttookmejust30secto
openatestSTLandmakemyselec-
tlon.|thenpressedPrlnttoprepare
andsendtheSTLtothecontrol
software.Thattookjustl9sec.
whenflnlshedlnPrlntwlzard,
usersopentheControlPanel.|t
glvesjobdetallssuchasestlmated
tlme,showsthemodel,andthe
supportmaterlal.|talsollstshow
TheMojolsanewdesktopprlnter
fromStratasys,LdenPralrle,Mlnn.,
that|reallyllke.At$9,900,lt
opensthedoortomoreusers
suchassmallshopsandsmall
teams.TheMojohasasmall
bulldvolume,butthlslsnota
problemslnceabout80%ofall
partsdeslgnerscreatefltlna5
55-ln.workenvelope.Thema-
chlneltselfls25
l82lln.
Setupwas
easy.|nfact,
wlthoutrush-
lng,95%of
userswlllbeupand
bulldlngthelrflrst
partlnlessthan45
mln.Thlslncludes
unboxlng,setup,
softwarelnstalla-
tlon,learnlngthe
software,processlng
theflrstpart,and
launchlngabulld.|n
fact,theentlrepro-
cesswasldentlcal
tothatofbrlnglng
homeanewall-ln-
oneprlnter.Clear-cutandeasy.
8aslcally,usersjustplacesMojo
wheretheywantltandremove
thepacklngmaterlal.Next,they
lnstalltheprlntenglnesbydrop-
plngthemlnandsnapplngthem
lnplace.Theprlntheadlsconsum-
able,comprlslngtheheadandthe
materlal.Assuch,ltlsaseasyas
lnstalllnganlnkjetlnkcartrldge.
Nextcomeslnstalllngthebulld
platformandplugglngMojolntoa
computervlaaUS8cordandalso
lntoawalloutletvlathepower
cord.|twaseasytoloadthePrlnt
wlzardsoftwareandControlpanel
software.|wasverypleasedthat
therelsnocallbratlonoruser-run
setuproutlnes.Allofthatlsdoneln
thebackgroundbythesystem.
Usersneednotoolsexcepta
knlfetoopenthebox.wlththe
systemreadytogo,ltwastlmeto
Professlonaldesktop
3Dprlnterlseasy to use
Authoredby:
Todd Grimm
Presldent
T. A. Grimm & Associates Inc.
Ldgewood,Ky.
LdltedbyLeslie Gordon
leslle.gordon@penton.com,Twltter@
LeslleGordon
Resources:
T. A. Grimm & Associates Inc., www.
tagrimm.com
Stratasys, www.stratasys.com
RS# 426
The Mojo is sitting on a
desktop and is hooked
to a laptop.
The printed test
part was complex
and included 0.020-in.
ribs, walls, and horizontal
surfaces.
w
w
w
.m
ach
in
ed
esig
n
.com
/rsc
R
eq
uest free inform
ation via
ou
r R
ead
er Service W
eb
site at
Accelerating the Speed of Design.
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RS# 167
SOFTWARE PRODUCTS
PowerSubD-Nurbs
formodo
PowerSubD-Nurbsformodolsaplug-lnthatlets
deslgnersautomatlcallyconvertsubdlvlslonsurface
mesheslntoNurbs-basedCADformatsthatcanbe
exporteddlrectlytostandardCADsystems.wlththls
newplug-ln,lndustrlaldeslgnerslntheearlystages
ofthedeslgnprocesscanqulcklycreateconcept
modelsthatcanbeexportedandreflnedlntheusers
CADsystem.Theplug-lnexports|GLS,SAT,STLP,and
RhlnofllesformatsforcompatlbllltywlthCADpack-
ages.Addltlonally,modomaterlalsasslgnedbythe
deslgnercanbeusedtoderlvesurfaceboundarlesln
theresultlngflleformaxlmumcontrol.
Luxology LCC,2525L.CharlestonRd.,Sultel04,
Mountalnvlew,CA94043,(650)336-l380,www.
luxology.com RS# 429
Completedle-castlng
solutlons
Thecompanynowprovldescompletealumlnumand
zlncdle-castlngsolutlonslnasfastasthreeweeks.|t
canasslstusersfromdeslgntocastlng.Thecompany
provldesmanypostprocesses,lncludlngmachlnlng,
platlng,coatlngs,salt-fogtestlng,etchlng,stamp-
lng,andanodlzlng.Partrunscanrangefroml00to
l00,000parts.AfreeDeslgnforManufacturablllty
(DPM)revlew,(valuedat$300)lsofferedtocustomers
worklngwlththecompanyondle-castlngprojects.
Quickparts.com Inc.,30lPerlmeterCenterN,Sulte
500,Atlanta,GA30346,(770)90l-3200,www.
quickparts.com RS# 430
RS#l68
motion solutions. These include an integrated controller,

Highest power density, smallest footprint, most durable.
Unrivaled power, performance and compactness comes from our T-LAM
stator design and rugged roller screw technology.
Compare and learn more at www.exlarcorp.com
Patented actuators from
Exlar utilize planetary roller
screws to outperform ball
screw actuators in life, load,
speed and acceleration.
Actuator
Motor
Amplifer
Controller
Linear or Rotary Actuator
Solutions Available
Or try our totally-integrated
electric actuator solution
Save time and development costs.
Eliminate complex engineering and achieve signicant savings with our
low-maintenance Tritex II
amplier, motor and robust roller screw actuator, all in one efcient, sealed package.
Soclal-
buslness
collaboratlon
NuageCafelsdeslgnedtobrlng
everydaypersonalsoclal-medla
practlcestotheworkplace,
provldlnganenvlronmentto
securelyshareandmanage
buslnesslntellectualproperty
whlleallowlngvlrtualteamsto
seamlesslycommunlcateand
collaborate.ThebaslcNuage
Cafesubscrlptlonlsfreetous-
ersforupto2Gbytesofspace.
Nuagelsofferlngtheflrstl,000
subscrlbers4Gbytesofspace
free.Uptol0Gbytesofspace
canbepurchasedforafeeof
$20USD.
Nuage Corp.,(855)682-4344,
www.go-nuage.com RS# 431
CAD/CAMforthe|ndlanmarket
PlcturesbyPCCAD/CAMsoftwarelntendedforthe|ndlanmarketlncludes
hybrldsolld/surfaceandmeshmodellngtechnlques,helplngdeslgners
transformthelr
conceptual
sketcheslnto
worklngproto-
types.Thead-
vancedmodellng
toolsworkwell
wlthamoldand
toolsettlng,help-
lngtostreamllne
theprocessof
creatlngpartcore
andcavltymolds.
Thesoftware
featuresaseam-
lesslntegratlon
wlthmachlnlng
andcomeswlthfreemachlnepostprocessors.Porasoftwareovervlew,vlslt
www.schott-systeme.com/index.php/en/cad-cam-videos/40-cad-software-
video-conceptual-design.html
Schott Systeme GmbH,Germany
RS#l69
SPOTLIGHT PLASTICS & ELASTOMERS
Semlrlgld
TPL
Ahlgh-lmpact,semlrlgld
gradeofthermoplastlc
elastomer(TPL)comes
lnblackpelletswltha
50 Shore Dhardness.Des-
lgnated90508X,themate-
rlalbenefltsprocessors
andenduserswlthawlde
rangeofpropertlesfortrlm
rlngsandpanelsrequlred
forelectronlcconsumer
productsandvarloustrans-
portatlonequlpmentand
lnterlorlnstrumentatlon.
TheTPLhasthelntegrlty
tobemoldedasanlntegral
partlnfastenlngsystems
thatrequlreahlghlevelof
lmpactreslstance.Thenew
TPLlssaldtoperformwell
lnpartdeslgnsthatrequlre
varlousscrewbossesand
gusset-relnforcedscrew
bossdeslgns.
Thelatex-freeTPLsdo
notrequlredrylngandare
forappllcatlonsrequlrlng
rubberllkepropertles,lm-
pactreslstance,colorablllty,
agoodsurfaceflnlsh,easy
processlblllty,andreduced
materlalusage.
Elastocon TPE Technolo-
gies,MarketlngDept.,8ox
463,Rochester,|L62563,
(888)644-8732,www.
elastocontpe.com RS# 446
8loplastlclzer
rePlexl00,afast-actlngblo-basedplastlclzer
producedfromrapldlyrenewableplant-based
feedstocks,lsanalternatlvetoconventlonal
plastlclzerssuchas88P,D8P,andbenzoates.
rePlexl00canbeblendedlntobothtradltlonal
phthalateandnewnonphthalatesystems,
provldlngaformulatlngtoolthathelpsreduce
costsbylmprovlngproductlvlty,ellmlnatlng
defects,andreduclngconsumptlon.
Tolmproveproductlvlty,rePlexl00offers
fastersetuptlmesand
reducedvlscosltyversus
tradltlonalplastlclzers.|t
helpsellmlnatedefects
throughlmprovedalr
releaseandthermalsta-
blllty.8ecauseltlsmore
efflclent,rePlexl00alsoreducestheamountofplastl-
clzerneededdurlngprocesslng.|tactslnherentlyasa
thermalstablllzeraswell,whlchmayenableprocessors
toellmlnatetheneedforstablllzerslnthelrformulas.
PolyOne Corp.,33587walkerRd.,AvonLakeOH
440l2,(866)765-9663,www.polyone.com RS# 447
Lnglneeredplastlcs
StruktolTR044wprovldesacomblnatlonofvlscosltyreductlonandmold-re-
leasecharacterlstlcsforpolycarbonatereslnsandcompounds.Thenewaddl-
tlvesglvegreaterprocesslngandperformancecapabllltlesforcompounders,
processors,andendusers.
wlthloadlnglevelsaslowas0.2%,meltflowlncreasesandallowsslgnlfl-
cantlmprovementslnmoldfllllngandrelease.|mprovedprocesslbllltyresults
lnlowermolded-lnstresslnlnjectlon-moldlngappllcatlons.
StruktolTR063A,targetedfornylon6andnylon66compounds,hasanovel
chemlstrymaklngltcompatlblewlthpolyamldesandperformbetterthanal-
ternatlvelubrlcantssuchasmontanesterwaxes.
StruktolRP28lsacompatlblllzerandblendlngaldforlncorporatlngre-
grlnd/recycledproductforawlderangeofpolymers.|tcanalsobeusedasan
alloylngagentbecauseltprovldeslmproveddlsperslonofthedlscreetphase
polymerandmechanlcalbondlngcharacterlstlcsthatresultlnbetterphyslcal
propertles.
Struktol Company of America,20lL.SteelsCornersRd.,8oxl649,Stow,OH
44224,(330)928-5l88,www.4struktol.com RS# 448
Colorandaddltlvemasterbatches
Then8alanceproductllneconslstsofcolorandaddltlvemasterbatchesthat
reducelmpactontheenvlronment.Peaturesofn8alanceproductsandser-
vlceslncludelowerenvlronmentallmpact,reducedconsumptlonofnatural
resources,andmlnlmalenergyuselnmanufacturlnganddlstrlbutlon.
OfferlngslncludedeflnedpalettesandtechnologlesforPLAandbloPTT,a
PCRrenewaladdltlveforPLT,nCorechemlcal-blowlngagentsusedtoreduce
TPLcompounds
TwonewTPLbrandsCopecandPor-TecL
offerhaptlcs,adheslonpropertles,reslstanceto
dallyuselnfluences,e.g.,handsweat,andalco-
hol,andmedla/weatherreslstance.
Copecoffersproductsatextureslmllartothat
ofvelvetandsllk.Productssuchascomputer
mlce,gamesconsolesorearplugs
arefrequentlyhandheldand
subjecttoheavyuse.Durlngde-
velopment,speclalattentlonwas
paldtohlghreslstancetosklnfats
andcleanlngagents.Copecglves
productsahlgh-qualltyflnlshthat
lsdlrtrepellentandmlnlmlzessllp-
pageonsmoothsurfaces,wlthout
astlckyfeel.TheSerlesexhlblts
excellentadheslonpropertlesln
themultlcomponentlnjectlon-
moldlngprocesswlththermoplastlcmaterlalssuchasA8S,PC,orPC/P8T.
ThePor-TecLSerleswasdevelopedforrellableadheslontosemlaromatlc
polyamldesandPA6.6.Theadheslonpropertleslnthe2Klnjectlon-moldlng
processpermlttheuseofTPL,forexamplelntheformofsealsorplug-lncon-
nectlonsformobllephonesandMP3players.Por-TecLlsusedlnconsumer
electronlcsandthepower-toolssector.
Kraiburg TPE Corp.,2625North8erkeleyLakeRd.,Sultel00,Duluth,GA
30096,(678)584-5020,www.kraiburg-tpe.com RS# 451
TPvreplacementllne
StarPrenelsallneofTPLs(thermo-
plastlcelastomers)thatmoldand
performbetterthanTPvs(thermo-
plastlcvulcanlzatesLPDMrubber
andpolypropylene).
TheadvantagesofStarPrene
TPLsoverTPvslncludeslmllarflow
characterlstlcswlththesamerheol-
ogy,hlgh-flowverslonsavallable,
bettertensllestrengthand
elongatlon,goodcolorablllty,
andnoneedtodrythemate-
rlalbeforeprocesslng.
TheTPLsarereslstantto
manyaclds,bases,aqueous
solutlons,andvarlousprocess-
lngoptlons,andareavallableln
numerousstockgrades.
Star Thermoplastics,2l2lw.
2lstSt.,8roadvlew,|L60l55,
(708)343-ll00,www.starther-
moplastics.com
RS# 452
8lo-based
resln
ThePlexlglasRnewblo-
basedreslnsaredeslgnedto
belowercarbon-footprlnt
solutlons.Thecompounds
stemfromthesynerglstlc
effectofcompoundlngtwo
completelymlsclblepoly-
mers,Plexlglasand|ngeo
blopolymer.Theresultant
alloysfeaturelowerprocess-
lngtemperatures,greater
melt-flowpropertles,and
reducedcarbonfootprlnt.
Thealloysdontcompro-
mlseoptlcs,scratchresls-
tance,coloracceptance,
andsurfaceaesthetlcs.
Altuglas International,
Arkema Inc.,l00PARoute
4l3,8rlstol,PAl9007,(800)
523-l532,www.plexiglas.
com/Rnew
RS# 449
raw-materlalusage,andnaturalfl-
berssuchasflaxusedasflllersand
forunlqueaesthetlceffects.
Americhem Inc.,2000Amerlchem
way,CuyahogaPalls,OH4422l,(800)
228-3476,www.Americhem.com
RS# 450
Copec
Por-TecL
PRODUCTS
Mobile machine display
The new PLUS+1TM-compliant DP600LX Series
Mobile Machine Displays offer off-highway
OEMs next-generation color and mono-
chrome graphical displays for in-cab and
open-air applications. The Series consists
of three displays DP600LX, DP610LX
and DP620LX that feature a more-
powerful processor, a new operat-
ing system, and enhanced industry-
leading viewability.
The high-resolution, transflective thin-film
LCDs have eight soft keys and six buttons for navi-
gation and are user programmable with PLUS+1 GUIDE
(graphical-user integrated-development environment).
A new ARM-11 processor provides greater responsiveness and faster screen
updates. A multimedia capability and 532-MHz clock speed let the processor
perform 10 times faster than previous models. The displays run on the LinuxTM
operating system.
New features of the Series include two external video inputs for providing
system overview; the capability of supporting both NTSC and PAL video feeds;
USB host support for downloading machine application log data to a USB mem-
ory stick; 9 to 70-Vdc voltage range; increased input/output functionality with
software-controlled inputs (digital, analog, frequency, current); and 16 Mbytes of
application and logging memory.
Sauer-Danfoss, 2800 E. 13th St., Ames, IA 50010, (515) 239-6222,
www.sauer-danfoss.com RS# 465
Rotary valves
Manual rotary select valves let aircraft
operators isolate hydraulic pres-
sure from specific systems to permit
ground maintenance of aircraft. De-
signed with dual or multiple ports, the
valves are qualified for aerospace
hydraulic systems up to 5,000 psi.
The Rudder isolation valve oper-
ates at 5,076-psig pressure, with
7.92-gpm flow rate at 7.25-psid max.
The lightweight, titanium
housing results in
an overall unit dry
weight of 1.050 lb.
The valve
isolates
the
rudder
actuator
from the main
hydraulic system
during maintenance, thereby prevent-
ing movement of the aircraft rudder.
Canyon Engineering Products,
28909 Avenue Williams, Valencia,
CA 91355, (661)294-0084, www.can-
yonengineering.com
RS# 467
Shims
Shims, used to achieve uniform spac-
ing or fill space between mismatched
components, are available in numer-
ous sizes and materials. The shims can
be custom made, with ODs ranging
from
0.080 to
12 in. and
in thick-
nesses
from
0.005 to
0.134 in.
Shims are
available in over 2,000 com-
monly specified and difficult-
to-find materials. Metallics
include low-carbon sheet
steel, various spring steels,
stainless steel, aluminum, brass,
copper and nickel silver. Nonmetallic
versions include ABS, acetal, polyester,
nylon, nylon MD, polycarbonate, fiber,
polyethylene and various NEMA-
grade laminates.
Bokers Inc., 3104 Snelling Ave., Min-
neapolis, MN 55406, (800) 927-4377,
www.bokers.com
RS# 466
RS#l70
Learn more at www.nexengroup.com
Call 800.843.7445
The Nexen Roller Pinion System makes the new Flow
Mach 4 Waterjet cut faster with unrivaled precision. Get the same
competitive advantage for your machines with speeds up to 36 ft/sec and accuracy to
0.00118" with zero backlash and less maintenance. This amazing system is also
extremely quiet, 99% efcient, and can be any length. Beat your competition by
overcoming the speed, accuracy, load and noise limitations of rack and pinion, ball
screw and belt drive technologies. Seeing is believingrequest a free demo today!
The Worlds Fastest, Most Accurate Waterjet.
Driven by Nexen.
RS# 171 RS# 172
RS# 173
To Get Samples and See for Yourself,
Contact The Lee Company!
2.5mm Diameter
Low Leakae
Accurate Crackin Pressure
Installs Easily in Plastics
Available in Medical Fittins
100% Performance Tested
Smallest
Check
Valve
. . . Ever!
A
N
O
T
H
E
R

L
E
E

I
N
N
O
V
A
T
I
O
N
The Lee Company
2 Pettipau Road
Westbrook, CT 06498 USA
Tel: 860-399-6281
shanleyg@theleeco.com
www.leeimh.com
Innovation in Miniature

Make RETROFITS easy as 1,2,3.
1. Connect efficiently to transducers and fieldbuses.
Simulate to speed setup and testing.
2. Control electric, hydraulic and pneumatic closed-loop
motion smoothly and precisely.
3. Optimize swiftly with motion wizards and graphs for
more throughput and machine life.
Squeeze more
from existing machines.
1-2 Axis Multi-axis
RMC75 and RMC150
Motion Controllers
4
1, 2, or up to 8 axes
4
User programs control
position and pressure/
force
4
Wizards for quick, easy
setup and tuning
4
EtherNet/IP, PROFINET
and PROFIBUS
connectivity
Call 1-360-254-8688 or
choose your controller
at deltamotion.com
2012 Newport Corporation
Precise 10 mm vertical and continuous 360 degree angular motion
Low mass, high natural frequency (rapid step-and-settle applications)
Simplied vacuum chuck and utilities management
Single location for electrical and vacuum connections
Three-point bottom adjustable interface for stable mounting
Newports new ZVR-PP and ZVR-PC are integrated Z-vertical and
Theta-rotation positioning stages designed to precisely focus and
rotate up to 300 mm diameter wafer chucks. Our unique balanced
approach rigidly supports and drives the payload at three points, a
perfect fit for applications that have slight to extreme unbalanced
loading such as wafer probing. Angular deflections due to these
off-center loads are minimized and binding of the vertical motion
is eliminated.
Discover Newports motion solutions to better wafer positioning. Visit
www.newport.com/ZVR-10 or call us at 800-222-6440.
The Perfect Fit
G
U
A
R
ANT
E
E
D
S
P
E
C
I FI CAT
I
O
N
S
PRODUCTS
Stepper-motor driver IC
The A4979 flexible microstep-
ping motor driver with built-in
translator is designed to operate
bipolar stepper motors in full,
half, quarter, and sixteenth-step
modes, at up to 50 V and 1.5 A.
The unit is controlled by simple step and direction inputs,
or through the SPI-compatible serial interface. Many
features, as well as diagnostic feedback, are programmed
through the serial port.
The current regulator can be programmed to oper-
ate in fixed off-time or fixed frequency PWM, with several
decay modes to reduce audible motor noise and increase
step accuracy. Phase-current tables are programmed via
the serial interface to create unique microstep current pro-
files to improve motor performance.
Circuit protection includes cross-conduction when
switching between high side and low-side drives. Out-
puts are protected from short circuits. Mixed decay, a key feature
in the device, improves low load-current accuracy. Other protec-
tion measures include stall detection and hot and cold thermal
warnings, overtemperature shutdown, and undervoltage lockout.
Allegro MicroSystems Inc., 115 Northeast Cutoff, Worcester, MA
01606, (508) 853-5000, www.allegromicro.com
RS# 468
Analyzer
The new DeviceNet Analyzer checks, commissions,
monitors, and maintains DeviceNet/CANbus instal-
lations. The device lets users analyze signal square-
wave quality; monitor overall network health by
node; detect locations of cable breaks and short
circuits; and locate weak points such as incor-
rect cable types,
lengths, and faulty
plug connections.
The Analyzer
helps with day-to-
day maintenance
of DeviceNet instal-
lations by identify-
ing trouble nodes
on the network,
and over time, can
see trends in net-
work health. The device also checks the cable quality
(or field-wireable connections) and, during downtime
troubleshooting, can help root out the zone where
the trouble is occurring.
Balluff Inc., 8125 Holton Dr., Florence, KY 41042,
(859) 727-2200, www.balluff.com
RS# 469
RS#l74
Recipe for Perfect Fluid Control
Step 1: Choose Step 2: Customize Step 3: Win
Choose from the largest range of uid
sensors and controls
Partner with us to customize our standard
products to your exact requirements.
Win with Gems: more performance, lower
cost, quicker to market.
PRESSURE VALVES FLOW LEVEL
RS# 175
RS# 176
RS# 177
Linear Velocity
Transducers
for Velocity
Measurement & Control
No Excitation High Sensitivity
Voltage Required High Frequency Response
Strokes from 1/2 to 36 inches
Instantaneous Reading
Perfect for machine control, R&D and testing, includ-
ing injection molding ram rate; glass pulling rate; shock
absorber proling; et al.
800/828-3964 www.lvdtsensor.net
Free 76-page catalog... Also includes LVDT Position,
Angular Displacement & Gaging Transducers
344 Kaplar Drlvc rscy 07004 , Falrncld, Ncw [cr
76.1515 Tcl: 973.276.0500 - Fax: 973.27
www.sabcable.com ablc.con - lrfoCsabca
Nortn Amori oa Nortn Amori oa

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PRODUCTS
E-Stop button with
illuminated base
A 30-mm emergency-stop (E-Stop)
button combines status indication and
safety in one. When the pushbutton
is armed and the machine is in the
Run position or is running, its bright,
highly visible yellow
illuminated base
provides users with
enhanced safety.
In the event of an
emergency, users
push the button to
change the yellow illumination to a
flashing-red indica-
tor. Users can reset
only the pushed
button or buttons,
minimizing down-
time. The yellow
illumination also
turns to a steady-red indicator when a
Stop condition exists by applying an
external signal via the M12 QD con-
nector. The E-Stops are available with
two-color yellow and red lighting, red
lighting, or a nonilluminated black
base. For applications requiring a series
of E-Stops, multiple buttons can be
interfaced and series connected with
CSS Series Hookup Cordsets.
Banner Engineering Corp., 9714
Tenth Ave. N, Minneapolis, MN 55441,
(888) 373-6767, www.bannerengineer-
ing.com RS# 470
Body adapters and
sanitary inserts
The MPC and MPX quick-connect
lines now include back-to-back body
adapters and sanitary inserts. Available
in polycarbonate and polysulfone, the
adapters let end users connect off-the-
shelf single-use systems that feature
male coupling inserts on both parts.
Being able to combine differing inserts
provides a reducing option when us-
ers need to transition between tubing
with diameters ranging from / to in.
The MPC and MPX and 1-in.
sanitary inserts allow connections to
equipment or single-use systems that
feature sanitary fittings.
Colder Products Co., 1001 Westgate
Dr., St. Paul, MN 55114, (800) 444-2474,
www.colder.com RS# 471
RS#l78
OUR APPEARANCE HAS CHANGED
Were not the same company we were yesterday.
And we wont be the same tomorrow. We adapt
with the times and with our customers. We
are still present in many different markets,
however, we are now focused completely
on industrial technology.
www.itt.com | 1-800-852-8508
but our ability to meet all of your high expectations by providing
you with the most innovative technology has not changed at all.
RS# 179
RS# 180
RS# 181
www.nipponpulse.com | info@nipponpulse.com | 1-540-633-1677
RELIABLE. ACCURATE.
NPM
Nippon Pulse
Your Partner in Motion Control
Nippon Pulse has been designing and
manufacturing stepper motors for the last
60 years, ensuring you get the most
reliable product available.
SIXTY YEARS OF RELIABILITY
ECONOMICAL.
Easily integrated into any system, our
stepper motors offer a cost effective and
accurate motion control solution.
COST EFFECTIVE, ACCURATE
When you choose a Nippon Pulse stepper,
youll also get one-on-one product support
unmatched in the industry. If you have
questions about integrating, prototyping,
customizing, we have the answers.
UNMATCHED PRODUCT SUPPORT
STEPPER MOTORS
Tin-can
Gearhead
Linear
Hybrid,
Synchronous
Advanced Antivibration Components
zIerichoIurnpi|e
New|ae|ar|,N\+
j. .1z.1z r l. .1z.11
www.vi|rationmounts.com
AAC Takes the Vibration
Out of Your Operation
ed Antivibration Components
Iurnpi|e
ar|,N\+
z r l. .1z.11
ationmounts com
Soft silicone gel absorbs
vibrations not eliminated by
other materials.
Engineering Expertise
Years of experience & customer
specications has led to an
extensive & varied product line.
Excellent Durability
Unique gel material performs in
any weather, -40F to +392F, and
is ozone, UV & chemical resistant.
Shock Absorption &
Vibration Damping
Call with your latest application
or visit our Web site.
PRODUCTS
is available as a one, two, or three-
convolution bellows in dimensions
of 80 mm/Type 22 up to
435 mm/Type 816. Without a
piston rod, strokes of more than
400 mm are possible. Lifting force
ranges from 0.5 to 80 KN.
ContiTech North America Inc., 136
Pneumatic air actuator
The D-type Series of air actuators are
designed so its components can be
quickly and easily replaced. The actua-
tors connecting plates, in diameters
of up to 175 mm, are made from alu-
minum. The D-type actuators come
in eight different sizes, each of which
Summit Ave., Montvale, NJ 07645,
(800) 654-0974, www.contitech-usa.
com; www.contitech.de/iap
RS# 472
Air and filter regulators
The Type 330/340 Series
of instrument air-filter
regulators and air regulators
withstand the harshest envi-
ronments while providing accurate
pressure regulation and filtration.
The Type 330 instrument air-filter
regulator has been expanded to in-
clude a regulator-only version, larger
porting sizes, and an automatic drain.
Designed for systems that require
clean, accurate, instrument air, the
330 provides pressure regulation and
filtration. It is now available in -in. NPT
porting for normal operation and -in.
NPT porting for high-flow require-
ments. The automatic drain option
prevents moisture from being retained
in the unit and carried downstream.
The new Type-340 regulator provides
accurate, constant control under vari-
able flow rates and supply pressures.
The Series come in three output
ranges for control up to 120 psig
(8 bar). Maximum supply pressure is
250 psig (17 bar). Two 1/4 NPT gauge
ports are included.
ControlAir Inc., 8 Columbia Dr., Am-
herst, NH 03031, (800) 216-3636, www.
controlair.com RS# 473
RS#l82
'
RS# 183
RS# 184
RS# 185
...your best source for Specialty AC/DC Electric:
RELIABLE, HIGH PERFORMANCE
MOTORS SERVING:
DC Servo Motors
Explosion Proof Motors
Hermetic AC Motors
Military/Defense Motors
And MORE!
Commercial Industries/Centrifugal Pumps
Material Handling/Motion Control
Military/Defense Applications
Nuclear, Specialty, Custom Design and OEM
www.peerlesselectric.com ) www.hbdindustries.com
800/676-3651
sales@peerlesselectric.com
) DC Servo Motors
) Explosion Proof Motors
) Hermetic AC Motors
) Military/Defense Motors
) And MORE!
) Commercial Industries/Centrifugal Pumps
) Material Handling/Motion Control
) Military/Defense Applications
) Nuclear, Specialty, Custom Design and OEM
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www.mort|nsprocket.com 817-258-3000
"The ONE You Rely On!"
Martin offers the industry's broadest
product range with fast delivery from stock,
same day / next day rebores and alterations,
fast turnaround times on Made-to-Orders.
Our broad selection continues to grow with
complete inventories in 30 North American
branch locations.
PRODUCTS
in length from 120 to 88 mm
(4.7 to 3.5 in.), while the
length of the more-powerful
BG45x30SI was reduced from
135 to 103 mm (5.3 to 4.0 in.).
The new BG45SI motors
feature digital control and
power electronics and the
45-mm brushless motors
Two new iBLDC (intelligent brushless
dc) motors with four-quadrant speed
controls in the 45-mm frame size,
have been reduced in size by 25%,
while maintaining the same power
and torque capabilities.
The new BG45x15SI was reduced
motor connector
has been updated for
space saving and con-
venience in mounting
and connection.
With a 12 or 24-V
power source,
at a nominal
speed of 3,000 rpm,
the BG45x30SI is con-
tinuous-duty rated for 80 W (/-hp)
power output. The motors can
achieve peak powers of four times the
continuous duty rating and, therefore,
a starting torque of up to 100 N-cm
(142 oz-in.) is possible.
The motor target speed can be set
using an analog 10-Vdc input signal
or be selected via digital inputs using
simple start-up software.
The drive has four digital inputs
two for selecting the four operating
conditions: rotation clockwise/coun-
terclockwise, stop with free running,
and stop with holding torque. The
other two are for selecting the motor
speed with acceleration and decelera-
tion ramps.
Dunkermotor USA Inc., A div. of
Dunkermotoren GmbH, 2511 Tech-
nology Dr., Suite 105, Elgin, IL 60124,
(224) 293-1300, www.dunkermotor.
com RS# 474
Dual-output switching
power supplies
The new VGD Series of enclosed
dual-output internal-switching power
supplies comes in 30 and 60-W
configurations.
The Series offers a universal input
(85 to 264 Vac) and dual output volt-
ages of either 5 V/12 V or 5 V/24 Vdc.
Protections include short circuit,
overload, and overvoltage. All models
include an EMI filter.
CUI Inc., 20050 S.W. 112th Ave., Tuala-
tin, OR 97062, (800) 275-4899, www.
cui.com RS# 475
RS#l86
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RS# 188
RS# 189
Paper Tube Company
1033 S. Noel Ave., Wheeling, IL 60090
COIL WINDING BOBBINS
Fabricated or molded, hi-dielectric,
hi-temp, choice of 12 electrical insulating
materials,extra strong, w/or w/o tie-offs, low
cost, 75 years experience, Made in USA!
Full PDF info: www.pptube.com
Fhona. B476874Z60 Fax. B476876777 LMaII. saIas@ppIuba.ro
More Than 75 Years - The Original
RS# 187
Distributed by Amacoil, Inc.
PO Box 2228, Aston PA, 19014
Phone: (610) 485-8300
Zero backlash. Jam-proof design.
For positioning & reciprocating motion applications
Smooth movement; ultra-low maintenance
Uhing
Rolling Ring linear drives have zero play when the shaft
is rotated even during reversal. The threadless shaft won't
clog or jam. If the system is somehow overloaded, the shaft
simply slips instead of churning and grinding.
Example applications: material handling machines, winding
equipment, test and measurement devices, packaging &
converting equipment.
Uhing Drives are available separately or
on shaft in custom assembly.
Wide range of sizes for varying linear
speeds & axial thrust requirements.
Simple set-up & operation
Some models feature mechanical control
over speed and travel direction without
programming or electronics.
equesta8rorhureor6M
1 (800) 252-2645
LmaII. amacoil@amacoil.com
www.amacoil.com
ManuaIIysIIdedrIve
usIngreIeaseIever
Rolling Ring
linear drives
PRODUCTS
Features of the hourmeter include
low operating current, wide operat-
ing voltage and temperature range,
interlock input, and a locking 10-pin
connector harness. Users can preset
total hours and replace a failed meter
without losing total elapsed time. A
key lock prevents unauthorized access
Hourmeter
The Series PT12 hourmeter features
two 6-digit, 7-segment LCDs. A ser-
vice LED indicates when the preset
setting is reached. Accumulated hours
are stored on powerless, nonvolatile
memory (no battery) using CMOS EE-
PROM technology..
to reset and programming functions.
ENM Co., 5617 Northwest Highway,
Chicago, IL 60646, (888) 372-0465,
www.enmco.com
RS# 476
Draw-wire linear
position sensors
Positals MDW draw-wire linear posi-
tion sensors, with analog voltage or
current output, are for use in low-cost
analog-control systems. Program-
ming operating parameters, including
range and sensitivity, is through a
pushbutton and LED interface.
The sensors are an alternative to
conventional multiturn potentiom-
eters. Based on a noncontacting mag-
netic-measurement technology, they
are not susceptible to the wear or
corrosion that degrades a potentiom-
eters accuracy. The sensors provide
instantaneous measurement of linear
displacement over a 0 to 16-ft
(0 to 5-m) range.
The encoders rugged enclosures,
seals, and bearings protect internal
components for operation in harsh
conditions. The sensors heavy-duty
spools are rated for over 1 million
draw/rewind cycles.
Fraba Inc., 1800 E. State St., Suite 148,
Hamilton, NJ 08609, (609) 750-8705,
www.fraba.com
RS# 477
RS#l90
PRODUCTS
Rotary stage
CCS Series rotary stages, with in-
tegrated captured collet chucks,
provide automated material han-
dling for a wide range of materials
and applications. The units collet
chucks accept C, D, or Levin-style
collets that are available from machine-tool
component suppliers in sizes that support 0.1 to 27-mm
tube diameters. The collets provide run-out characteristics for applica-
tions requiring high-precision gripping of tubular material.
The collet-chuck design allows workpiece advance without manual realign-
ment to compensate for axial tube motion during clamp/unclamp cycles. By
moving the taper around the collet instead of drawing the collet into the taper,
axial motion of the workpiece is reduced, eliminating the need for part reregistra-
tion after tube advancement, thereby increasing system throughput.
Mounting features on the units housing support customer-supplied wet-
cutting accessories. The stage also tolerates moderate fluid leakage into the ap-
erture, which is inevitable during wet-cutting operations. These features prevent
encoder contamination and collet-chuck failure, minimizing machine downtime.
The CCS Series uses direct-drive brushless motor technology to maximize po-
sitioning performance. Direct drive provides quicker acceleration and higher top
speeds than gear or belt-driven mechanisms, for higher total overall throughput.
Aerotech Inc., 101 Zeta Dr., Pittsburgh, PA 15238, (412) 963-7470, www.aerotech.
com RS# 478
RS#l92
RS#l9l
1UNLl4,20l2
WL LkCLL A1 1nCSL
Cear hobbing and gear grinding from 1 - 60 (ACVA 15)
lnternal gear grinding from 10 - 60
CNC gear inspection up to 60
Cear shaping to J6 in diameter, 9.0 face width
0esign and Analysis (excellentsoftware.com)
Peverse engineering service
Wind turbine gear box, high speed spindles, gimbal heads
and gear boxes
NEE0 CEAPS 1 - 60
WITH UALITY TD AChA 15!
(;&(L*($5IN&
WL Lk
W
A TDTAL SEPVICE CDhPANY
ISD001-2008 APPPDVE0
Phone: (815) 62J J414
quotations@ExcelCear.Com
www.ExceICear.com
PRODUCTS
Silicone solar
cables
Silicone solar cables,
rated for voltages up
to 42,000 Vdc, provide
absolute reliability in
solar-panel intercon-
nection and photovol-
taic applications. The
halogen-free cables
are flame retardant,
highly flexible, and perform well when exposed to severe heat and cold (65
to 260C).
The cables crystal-clear silicone encapsulation resists tearing, and will
not deform, break, or wear during its 10 million cycles+ lifetime, even under
tight bending radius and constant flexing conditions. The silicone self-
heals from small punctures and cable jacket damage can easily be repaired
in the field. The silicone-extruded cables do not require external armor or
conduit for protection, and are unaffected when exposed to UV-radiation,
sunlight, ozone, abrasion, salt, coarse sand, submersion, acid rain, ice, vi-
bration, shock, humidity, mechanical stress, many chemicals, and difficult
weather conditions.
The 30 to 4-awg cables are available in continuous lengths, cut to order, or
as assemblies.
Cicoil Corp., 24960 Avenue Tibbitts, Valencia, CA 91355, (661) 295-1295,
www.cicoil.com RS# 480
Safety air guns with
chip shields
Safety air guns are now available
with polycarbonate chip shields
to protect workers from chips
blown off machined parts. The
shields also keep coolant from
splashing during drying opera-
tions and help businesses com-
ply with OSHA standards. Chip
Shields can be used on safety air
guns with or without an exten-
sion pipe.
The guns use air nozzles that
maximize entrainment of room
air while minimizing compressed-
air consumption.
Exair Corp., 11510 Goldcoast Dr.,
Cincinnati, OH 45249, (800) 903-
9247, www.exair.com/cs.htm
RS# 479
Angular-style grippers
The FKHW Series of 180 angular-style pneumatic
grippers handle small parts in confined areas. The
grippers rack and pinion synchronizes finger mo-
tion. Features include heat-treated fingers,
sealed bearings, magnetic pistons, and a
hard-coated aluminum body with slots to ac-
commodate optional sensors.
Fabco-Air Inc., 3716 N.E. 49th Ave., Gaines-
ville, FL 32609, (352) 373-3578, www.fabco-air.
com
RS# 481
RS#l93
When il comes lo cable and hose carriers, nobody gives you more
opIions lhan U.5. T5UAKI and KAEL5CHLEPP. Choose lrom
micro-sized lo super-duly sleel, plaslic, and hybrid carriers. Available
in a wide range ol open, lube, and special problem solving designs.
kabeIschIepp.com or call 800-443-4216
NLW! RequesI a FRLL 2012
CaIalog & 1echhical Cuide
Over 600+
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H MORE OPTION5
RIGHT 5OLUTION !or your cabIe & hose carrier appIicaIion!
NASA Low Outgassing
Approved Epoxy
154 Hobart Street, Hackensack, NJ 07601 USA
+1.201.343.8983main@masterbond.com
www.masterbond.com
EP29LPSP Two Part
Adhesive/Sealant
Optically clear
Chemically resistant
Cryogenically serviceable
Non-stick
Chemical
resistance
Low
coefficient
of friction
We coat both small and large parts to close tolerances in
quantities from 1 to 1,000,000. Call Donwell for custom
TEFLON
coating services to meet your specifications.

www.donwell.com
TEFLON
COATINGS
To enhance product
performance
Donwell Company is a licensed
DuPont applicator for all TEFLON
Coatings. These coatings can

improve the performance of your
parts by providing them with one
or more beneficial properties.
P.O. Box 906, 130 Sheldon Rd.
Manchester, CT 06040
Tel: (860) 649-5374
Fax: (860) 647-0074
1-800-864-2702
TEFLON
is a registered trademark of the DuPont Co.

RS# 194
RS# 195
RS# 196
PRODUCTS
Utility-scale inverter for
wind and solar
The Series 6001 energy storage-
grid-connect inverter provides
improved power stability for wind
and solar-energy users. The unit
provides high-performance conver-
sion for wind, solar, and other heavy
industrial applications by creating a
link between the power source and
battery. Downtime is reduced and
faults are cleared faster by staying
on-line during fault conditions. True
low-voltage ride through (LVRT)
let the inverter run near-zero line
voltage for extended periods, while
maintaining line synchronization.
High-voltage ride through (HVRT)
is attained through conservatively
rated components.
Designed for utility-scale grid-
connect battery applications, the
inverter lets users achieve full bat-
tery storage because of a large
direct-current operating-voltage
window.
Features of the Series 6001
include a seismic zone-4-rated en-
closure; indoor and outdoor rating;
a dusttight section that protects
the liquid-cooled inverter and elec-
tronics-control components from
harsh and dusty environments; and
a vented section that houses air-
cooled magnetics.
Rated for 500, 1,000, and
1,500-kW applications, the inverter
has conservatively rated magnetics
and liquid-cooled power modules
with over 7 million hours mean time
between failure.
Eaton Corp., Electrical Sector,
1000 Cherrington Pkwy., Moon
Township, PA 15108, (412) 893-3300,
www.eaton.com
RS# 482
RS#l97
Can work dry or |n o|| [goarbox)
H|gh torquo |n common dos|gn
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Lxco||ont hoat d|ss|pat|on
[whon usod |n o||)
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|rom tho wor|d's |argost
manutacturor ot wor|d-c|ass
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and brakos
|ectromagoet|c c|0tches & brakes
Ior v|rt0a||y every app||cat|oo
100 |onoo.ph |ooo 3omerset, NJ 0BB73
|hone. 732g271g7361 |o:. 732g271g7IB0
vebs|te. http:ogura-c|utch.com,mu|t|p|o
cmo|.. |nlouogurogo.utoh.oom
Multiple Disk
Clutches and
Brakes
Multiple Disk
Clutches and
Brakes
RS#l98
PRODUCTS
Metrology DROs
Quadra-Chek Models ND 1100 and ND 1200 and Gage-
Chek Model ND 2100 metrology digital readouts (DROs)
have been upgraded with new LED screens.
The DROs offer numerous functions for acquiring and
statistically evaluating measured data. The Quadra-Cheks
support up to four axes, and are used for simple metrologi-
cal positioning tasks and for 2D geometries. The Gage-
Chek is for multipoint inspection apparatuses.
Heidenhain Corp., 333 E. State Pkwy., Schaumburg, IL
60173, (847) 490-1191, www.heidenhain.us RS# 483
RS#l99
RS#200
Unmatched Precision. Unmatched AffordabiIity.
The planetary gear reducer that sets a new
industry standard for performance at an
exceptional price point.... Shimpo's ABLE
Speed Reducers.
Contact us today about your servo motor
application, and let us help you build a better,
more cost effective piece of equipment for
your customer. Make it a Shimpo!
PRODUCTS
Control cables
The flame-retardant, self-extinguishing JZ 603 and JZ 603-CY control cables are suitable for me-
dium mechanical stresses with free movements in dry, damp, or wet indoor environments. The
PVC cables have oil-resistant outer sheaths and operate in temperatures from 5 to 90C (flexing)
and 40 to 90C (fixed installation). The cables are UL (U. S.), HAR (Europe), CSA (Canada), CCC
(China), and GOST-R (Russia) certified.
Helukabel USA, 1355 Bowes Rd., Unit C, Elgin, IL 60123, (847) 930-5118, www.helukabel.com
RS# 484
Motorized microscope
stage
Fully integrated, miniaturized ce-
ramic linear drives works with the
M-687 motorized microscope XY
stage for inverted microscopes. The
complete system includes a control-
ler, joystick, and software.
The self-clamping ceramic/ce-
ramic linear motors in the positioner
are more compact than electromag-
netic motors and provide higher
positional stability once in place,
no energy is consumed to hold posi-
tion (no heat dissipation). Integrated,
100-nm resolution linear encoders
provide direct position feedback to
the controller, allowing closed-loop
operation with high accuracy.
The device features constant ve-
locity at low speeds to 10 microns/
sec; travel range up to 135 85 mm;
suitable for long exposure imaging,
image stitching, etc.; speeds up to
120 mm/sec; and its design allows
for free rotation of the turret for in-
verted microscopes.
Physik Instrumente (PI) L.P.,
16 Albert St., Auburn, MA 01501,
(508) 832-3456, www.physikin-
strumente.com/en/news/fullnews.
php?newsid=177&onl_pr
RS# 485
RS#20l
Faced with gaps, crevices, close tolerances,
misaligned parts and awkward equipment
designs a custom elastomeric seal
can be your solution to provide a
leak-proof closure.
These seals are not simple
rubber extrusions. They are
engineered, built and
molded to fit your applica-
tion and to meet strict
performance, safety and
environmental standards.
Fabric-reinforced for strength and
structural integrity for optimum
inflation/deflating operations, they
are not subject to the compression
set of ordinary seals.
Strong, versatile and flexible,
Seal Master seals have been solving
troublesome problems
for industry since 1974.
SOLVE DIFFICULT SEALING PROBLEMS
CUSTOM
Seal Master
Inflatable Seals
TYPICAL INFLATABLE
SEAL OPERATION
When inflated it expands to the striking surface creating a positive
seal. When deflated it returns to its original configuration allowing
free movement of one or both surfaces.
Inflatable seals and other custom rubber products
SEAL MASTER CORPORATION
368 MARTINEL DRIVE, KENT, OH 44240-4368 USA
800.477.8436 330.673.8410 FAX 330.673.8242
E-mail: info@sealmaster.com www.sealmaster.com
Design assistance offered
2010 Seal Master Corporation
DEFLATED INFLATED
maxon motor control
Maintaining
control has never
been easier.
maxon motor is the worlds leading supplier of high-preci-
sion drives and systems of up to 500 watts power output.
Rely on the quality of the highly specialized solutions which
we develop with and for you. www.maxonmotorusa.com
If decentralized drive intelligence is called for, maxon motor
control provides the answer: All speed and positioning con-
trollers are designed to match with DC motors up to 700 watts
power. The EPOS2 positioning controller can be used with
CANopen and Interpolated Position Mode.
RS# 202
RS# 203 RS# 204
Farmington Hills, Ml 48335
tel: 800-521-3320 / fax: 248-476-2470
e-mail: shocks@acecontrols.com
www.acecontroIs.com
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Solid, Long Life Construction
Push & Pull Type Designs
Fixed Force or Adjustable Models
Stainless Steel Models Available
Expert Application Sizing
ACE Controls Gas
Springs provide
counterbalance motion
control for lifting and
lowering lids, hoods, hatches,
machine guards, panels and
more. Offered in a wide range of
body sizes, stroke lengths and forces.
Aerospace, Defense, Transportation,
RV, Medical, Furniture, Packaging,
Printing, Amusement and More
WELL DO THE
LIFTING
& LOWERING
PRODUCTS
Tilt-float switches
An expanded line of tilt-float switches
for large-volume liquid-level applica-
tions feature a watertight rubber float
with a three-conductor cable.
Available in three different
configurations, each float is made
from EPDM for long service life and
resistance to heat, oxidation, ozone,
and aging due to weather. EPDM
offers good electrical resistivity and
resistance to solvents such as water,
acids, alkalies, phosphate esters,
and many ketones and alcohols.
The switches contain an 8-A
(250-Vac) microswitch on an antivi-
bration mount. The SPDT switch el-
ement can be used for either open
or closed contact configurations
and measures both increasing and
decreasing fluid levels. The resulting
signal can be used to start or stop a
pump, open or close a valve, or actu-
ate indicator alarms.
Madison Co., 27 Business Park Dr.,
Branford, CT 06405, (800) 466-5383,
www.madisonco.com
RS# 486
Linear-shaft motor
The S605 linear-shaft motor offers up
to 3,100 N of acceleration force, and
a continuous force of 780 N, making
it suitable for applications requiring
high force, high precision,
energy efficiency, and high
precision. The motor can hit
submicron resolution.
Three types of windings
are available double, triple,
quadruple. The S605s ac-
celeration current is between
34 and 35 A and acceleration
force and current can be main-
tained for up to 40 sec. The
motor has a 60.5-mm shaft diameter,
is available with strokes between 200
and 2,000 mm, a 1.75-mm noncritical
air gap, and a rated voltage of 240 V.
The motor is available in 18 different
sizes, ranging from 4 to 60.5 mm.
Nippon Pulse America Inc., 4 Cor-
porate Dr., Radford, VA 24141, (540)
633-1677, www.nipponpulse.com
RS# 487
Miniature diaphragm pump
The 1410 Series dc diaphragm pump measures
3.3 1.2 2.1 in. and is designed to work with a
range of motor options and several design con-
figurations, depending on the life requirements
and specifications of the application. The pump
features a low sound level, weighs 0.4 lb (180 gm),
and is EMC suppression qualified to EN55011-B
on some designs. Maximum flow is 4.3 lpm, with
a maximum pressure of 27.5 psig/1.9 bar, and a
maximum vacuum of 22.0-in. Hg.
Thomas Div., a Gardner-Denver Co., 1419 Illinois Ave., Sheboy-
gan, WI 53081, (920) 457-491, www.gd-thomas.com/productlist.
aspx?id=21044&tp=v
RS# 488
RS#205
RS# 206
RS# 207
RS# 208
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PRODUCTS
16-mm
spindle drive
The GP16 16-mm spindle drive con-
verts rotary motion into linear mo-
tion by combining the spindle drive
with a dc motor. Gearheads, motors,
encoders, and controllers drive the
spindles. The drive, available in a self-
locking metric M6 spindle or a 5-mm
ball screw, offers high efficiency and
load capacity. The axial bearing with-
stands the high tractive and com-
pressive forces of the spindle.
For the planetary gearhead, 14 dif-
ferent reduction ratios are available,
from 4.4 to 850:1. Depending on the
reduction ratio and spindle type, feed
forces between 35 and 370 N, and
even up to 400 N for short durations,
are possible.
Nine different brushed and brush-
less motors can drive the system. For
precise positioning, the motors may
also be equipped with compatible
sensors (encoders).
maxon motor usa, 101 Waldron Rd.,
Fall River, MA 02720, (508) 677-0520,
www.maxonmotorusa.com
RS# 489
Ultrasonic sensors
The F77 Series ultrasonic sensors are
an alternative to background-sup-
pression photoelectric sensors in dirty
and dusty applications or where color
variations or
transparent
targets are
the norm.
Highly im-
mune to
acoustic
interference,
the sensors
have mini-
mal dead-
band, which
is important
when the
devices mount on machinery that
uses numerous pneumatic cylinders.
The sensors are compact and pro-
vide up to 50-Hz switching frequency
for fast response times. They come in
diffuse (up to 400-mm sensing range),
retroreflective (up to 400-mm sensing
range), and thru-beam models (up to
800-mm sensing range).
Pepperl+Fuchs, 1600 Enterprise
Pkwy., Twinsburg, OH 44087, (330)
486-0001, www.pepperl-fuchs.us
RS# 490
Intelligent power
module
Semistack_RE is an intelligent
power module (IPM) targeting
synchronous and double-fed
induction generators (DFIG) in
wind turbines, and central solar
PV inverters.
The water-cooled three-
phase converter comes in
B6CI two-quadrant or 2 B6CI
four-quadrant configurations
in a bookcase-type mechanical
design.
The previous version of Semistack-RE based on the three-bay version of SKiiP 3
has a current capability of 1,200 /module. The bigger, four-bay SKiiP 4 version has
a current rating of between 1,000 and 1,400 A.
SKiiP 4s new digital gate driver provides a safe electrical isolation between
primary and secondary side for all switching or control signals and for the tem-
perature signal. The SKiiP driver features a CANopen setup and diagnosis channel,
giving access to an error memory so errors in SKiiP 4 can be quickly identified and
saved for later diagnosis.
Semikron Inc., 11 Executive Dr., Hudson, NH 03051, (603) 883-8102,
www.semikron.com RS# 491
RS#209
RCP4
ROBO Cylinder Series
PCON-CA
Power Controller
IAI America, Inc. California: 800-736-1712 Illinois: 800-944-0333 Georgia: 888-354-9470
www.IntelligentActuator.com/RCP4
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RS# 210 RS# 211
RS# 212
Kep-O-seal
Adjustable Relief
Valves
Available as in-line or cartridge insert
types, these valves feature the industry
proven Flexible Seal Seat design which
provides dependable control of liquid or
gas. Direct operating and spring loaded,
they are designed for applications requir-
ing fast acting relief performance and
tamper-proof pressure adjustment. Fully
adjustable 50 to 2000 psi.
For details visit: www.kepner.com
Cont rol Sol ut i ons That Act ual l y Gi ve You
. . . CONTROL!
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s Integrator!
Phone: (336) 589-6920 viccontroIs.com
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AryanZandiebatI312!92-188crazandiebbfusa.ccm.
Partner: 0rganizedby:
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InternaticnaITrade5bcwfcrFactcry,Prccessand
BuiIdingAutcmaticn5ystemsand5cIuticns
5eptember10-15, 2012 - HCc-)ik P(ae, Cbiagc, I((inci.
INDUSTRIAL AUTOMATION
NORTH AMERICA at IMTS 2012
Bekbcff A0tc)aticn provides advanced,
open automation products based upon
proven industrial technologies. Manufacturers
and machine builders can implement high
performance Beckhoff control systems
more efciently and at a lower overall cost
than traditional PLC and motion control
systems. Visit them at booth E-4271
or www.beckhoff.com.
Static
Control
800.787.7325
e-mail: industrial@sealeze.com
www.sealeze.com
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Sealezes line of brushes for
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PRODUCTS
Mini actuator
A new miniature actuator de-
signed for the miniature robot-
ics and life-science markets,
consists of a small dc servomo-
tor coupled to a ball screw.
Included in the assembly is a
high-precision miniature 8-mm-
diameter ball screw, a Faulhaber
dc motor with graphite commu-
tation, rotary encoder, and gear-
less coupling for high-speed,
backlash-free positioning with
high dynamic performance. This
product is ideal for applications
in miniature robotics and preci-
sion dispensing systems. The
actuator comes in travels rang-
ing from 10 to 300 mm, with
resolution of 1 micron, speeds
up to 120 mm/sec, and capable
of peak axial loads to 800 N.
Steinmeyer Inc., 56 Middlesex
Turnpike, Suite 200, Burlington
MA 01803, (781) 273 6220 (781)
273-6220, www.steinmeyer.com
RS# 492
Rugged circular connector
The new Circular High Density (HD) connec-
tor line is a low-cost alternative to 38999 and
other circular connectors for rugged non-Mil
Spec applications. The connectors offer ease
of push-to-latch/pull-to-unlatch mating as
well as the advantage of blind
mating into small spaces that nor-
mally requires clearance for hand
tightening to mate.
Other features include scoop-
proof, blind mating; operating
range of 65 to 125C; durability of 1,000
mating cycles; five shell bodies ranging from
14 to 27-mm diameter; panel-mount recep-
tacles; IP68 rated with potted, solder cup or
PCB termination; 96-hr salt-spray exposure;
withstand 37 gs of vibration and 50 gs of
shock; cable-attached plugs and receptacles;
up to 40 signal contacts; and up to 20-A cur-
rent rating.
TE Connectivity, 1050 Westlakes Dr., Ber-
wyn, PA 19312, (800) 522-6752, www.te.com
RS# 493
Switching power supplies
A new family of 24-V power supplies converts ac to dc and provides safety ex-
tralow voltage (SELV).
With a wide input range between 90 and 260 Vac the supplies can be
used in diverse supply networks. An onboard potentiometer adjusts output voltage
from 22.5 to 28.5 Vdc, and styles are available with an output current strength of 2.5,
5, 10, or 20 A. This highly-
efficient power supply can
be run in parallel for applica-
tions requiring redundancy
and includes up to 150%
overload protection.
A power relay guaran-
tees a reliable functional
check, monitoring itself for
voltage, eliminating potential wire breakage or system malfunction. The device
can automatically bypass power failures, which lets the ac input disappear for up
to 30 msec without any effect on the output.
Turck Inc., 3000 Campus Dr., Minneapolis, MN 55441, (800) 544-7769, www.turck.us
RS# 494
RS#2l3
JUNE 14, 2012 MACHINE Design.com 122
RS# 255
Digital Pressure
Gauge
AP60 digital pressure
gauge is CR2032 battery
powered, offers wide
viewing angle and provides
an accurate readout. They
are rated for pressures up
to 1.0MPa (145 psi) with
user-programmable display pressure units for MPa, kgf/cm
2
,
bar and psi. Suitable for fltered air and non-combustible and
non-corrosive gases; excellent repeatability of +0.2% F.S. +1
digit or better.
Adsens Technology Inc.
City of Industry, CA
Brushless DC and Intelligent Servo Motors
Dunkermotor releases its 2012
Low Voltage Brushless DC and
Intelligent Servo Motors catalog.
Expanded catalog includes
specifcations on custom confg-
urable BLDC motors, controls,
gearheads, brakes, encoders
and accessories. Available for
complimentary download at
Dunkermotor website or email
request for hard copy.
Dunkermotor
Email: info@dunkermotor.com
Web: www.dunkermotor.com/2012_BLDC_catalog
New tutorials and podcasts on Learn Web site
What is a PLC plus many more
topics on industrial control prod-
ucts including new videos and
podcasts on AutomationDirects
free self-service learning site.
Visit http://learn.automationdirect.com
to watch these and other tutorials
on a range of industry topics.
Rotary Dampers
Minimize noise, shock, and
safety hazards. Soft and
smooth motion enhances
functionality and provides
that touch of quality. Use on
computer hardware, fip top
phones, lids, access panels
and more.

19 new series introduced.
ACE Controls Inc.
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Fax (248) 476-2470
e-mail: shocks@acecontrols.com
www.acecontrols.com
RS# 261
Galil Motion Control
Galils 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.
B&B Electronics is a global source
for rugged, reliable wired and wire-
less data connectivity systems.
Backed by strong technical
support, B&Bs Ethernet, USB,
Wireless and Serial solutions are
known for being easy to order,
install and use.
For more info, please contact:
B&B Electronics
Phone: 888-948-2248
Email: orders@bb-elec.com
URL: http://www.bb-elec.com
Download B&Bs latest white papers:
http://bb-elec.com/technical_library.asp
UL TC-ER listed TOPSERV
Motor /Servo/VFD Cables

HELUKABEL
USAs new motor and

servo cables are suitable for fxed
and continuous fexing applications
in harsh industrial conditions. These
high-quality, Oil Resistance I & II
cables are tested for multimillion
cycles in cable tracks and ambient
temperatures ranging from -30C up
to +90C. The cables have multiple
global approvals, including UL
(USA), CSA (Canada), VDE
(Germany), CE (Europe) and
GOST-R (Russia), and are available
in stock.
HELUKABEL
USA Inc.
1355 Bowes Rd, unit C, Elgin, IL 60123
(847) 930-5118, www.helukabel.com
Free design guide
to servo-hydraulic
motion control
www.da|tamot|on.com
Popular, practical 64-page guide
with 16 topics by Patar hachtway:
s#LOSEDLOOP#ONTROL
s3IZING#YLINDERSAND6ALVES
s3ELECTING!CCUMULATORS
s4RANSDUCERSAND2ESOLUTION
s4UNINGFOR/PTIMAL0ERFORMANCE
Pancake
II Cylinder
Has interchanges with
better performance. Tough
composite barrel is self-
lubricating & impact
resistant. Composite rod
bearing, captive in head,
has higher load capacity,
lower friction, zero slip-stick.
We solve problems. Let
us help!
FABCO-AIR, Inc.
Gainesville, Florida
Helical Products Co., Inc.
COUPLINGS, U-JOINTS
and MACHINED SPRINGS
Helicals 28-page catalog
features miniature fexible
couplings, u-joints, power
transmission couplings and
machine springs. Quick-
reference, product summary
chart highlights features and
technical data. Easy-to-use part
number builders make ordering
easy.
Visit: www.heli-cal.com
Avago Technologies San Jose, Ca.
The power inverter - from sunlight to power grid
This video discusses
performance
advantages of optical
isolation technology
based isolators and
optocouplers, in terms
of common mode
rejection, EMI
immunity, radiated
emissions and part
degradation over time
in renewable energy
applications.
RS# 251
RS# 260
RS# 263
RS# 254
RS# 256
RS# 259
RS# 262
DATA FILE LITERATURE ADVERTISING
Access our Reader Service
Website to quickly find and
request information on the
products and services found
in the pages of MACHINE DESIGN.
RS# 257
RS# 250
RS# 264
RS# 252
RS# 258
RS# 253
MACHINE Design.com 123
Smalley Steel Ring Company
New Smalley Engineering
& Parts Catalog
Smalleys new catalog combines
existing Spirolox Retaining Ring
and Smalley Wave Spring selec-
tions with series recently released
from Smalley. Now a single catalog
includes new: Hoopster Rings, Met-
ric Wave Springs, Constant Sec-
tion Rings and more. Over 10,000
standard parts in carbon and stain-
less steel; free samples available.
Specials manufactured with
No-Tooling-Costs from .200-120.
info@smalleZcomXXXsmalleZcomgetcatalog
www.masterbond.com
Resists up to 500F Thermally conductive
One Part B-Stage Epoxy EP36AO One Part B-Stage Epoxy EP36AO
Available in cookies
Over 15,000 products +
everything you need to know
about
Order your free copy today at: www.orientalmotor.com
- Stepping Motors
- Servo Motors
- AC Motors
- Brushless Motors /
AC Speed Control Motors
- Linear & Rotary Actuators
- Cooling Fans
RS# 272
RS# 274
814-894-2461 www.symmco.com
Discover Symmcos Parts
Conversion Opportunities
Your Key To Quality & Savings
Design Support (for Simple to Complex Parts)
Gears
Assembly Solutions
Materials Options
Dont Cast &
Machine Save
Time & Money
with Powder
Metallurgy (P/M)
JUNE 14, 2012
MAINTENANCE AND TROUBLESHOOTING
GUIDE NOW AVAILABLE!
A newly revised brochure by Martin
Sprocket & Gear, Inc. provides helpful
tips for routine maintenance as well
as insight for troubleshooting common
problems and corrective action on power
transmission and material handling prod-
ucts. Individual sections on chain drives,
gear drives, chain couplings, elastomeric
couplings, synchronous drives, v-belt
drives and screw & drag conveyors as
well as heavy duty conveyor pulleys
is included.
For additional information including which
of Martins 31 North American plants
are located nearest you please contact
Martin Sprocket & Gear, Inc. at 817-258-
3000. Or visit our web site at
www.martinsprocket.com.
RS# 266
RS# 270
RS# 268
High- Performance
Magnets
New catal og features hi gh
performance magnet materials
such as NdFeB and SmCo,
molded magnets, ceramic and
al ni co magnets. MCE offers
magnet ci rcui t desi gn,
custom fabrication, assembly,
and advanced coati ngs.
Complete traceability is offered.
P h o n e : ( 3 1 0 ) 7 8 4 - 3 1 0 0 ,
Fax:(310)784-3192; mcesales@mceproducts.com;
www.mceproducts.com
MagnetIr6omponentLngIneerIng
RS# 275
RS# 273
RS# 271
RS# 269
RS# 265
Trim-Lok Inc., Buena Park, CA
Vinyl & Rubber Extrusions
Trim-Lok Inc. releases a brand new
FREE Catalog 500 featuring How
to Order steps for the frst time
customer, along with an expanded
line of complete trims and seals.
FREE samples may be requested.
Latest additions include our Flap
Seal, Fire Retardanct Trim, adn
Hatch Seal. Contact us toll fee at
1-888-874-6565, e-mail us at info@
trimlok.com or visit us on-line at
www.trimlok.com
Seal Master Corp., Kent, OH
SEALS, ACTUATORS,
GRIPPERS AND BAGS
Solve difficult closure prob-
lems with custom-built, fab-
ric-reinforced, fully molded
elastomeric Seal Master
infatable seals. With close
tolerance capability and re-
sistance to compression,
theyre ideal for imaginative production and processing
applications too. Engineered specialties include fabric-
reinforced bags, bladders, plugs and other custom rubber
products. Design assistance offered.
Pelican Products
Pelican Products
Protects Sensitive
Instruments
The global leader in the design
and manufacture of both
high-performance protective
case solutions and advanced
portable lighting systems.
Sales Contact: Mark Rolfes
www.pelican.com/contact
Website: www.pelicanoem.com
23215 Early Avenue
Torrance, CA 90505
Phone: 310-326-4700
Toll Free: 800-473-5422
Fax: 310-326-3311
Brad Power Products
Brad power products replace machine hard wiring
with easy-to-install, modular, quick-connect systems
comprised of crush resistant, prewired cordsets
and factory-molded connectors. They do not require
special tools or labor.
Molex
www.molex.com
800.225.7724
Omega introduces its PSW14 series
of electronic pressure switches which
can feature either a single switch with
adjustable hysteresis or a dual switch
with xed hysteresis.This CE compli-
ant product has an easy to program
on/off set point and its compact
construction makes it ideal for OEM applications in hydraulic and pneumatic
systems, the automobile industry, lubricant monitoring and industrial control.
Price Starts at $135
Electronic Pressure Switch PSW14
Omega | Stamford, CT USA | www.omega.com/psw14
Email: info@omega.com | Twitter: @OmegaEng
Facebook: http://www.facebook.com/pages/Omega-Engineering/121219014465
Phone: 1-800-TC-OMEGA or 203-359-1660
RS# 267
RS# 276
users can
browse video
libraries using
technology-
based
navigation
to focus
on specific
technology
topics. They
can also
browse by
company
brand, trade
show, or by
publication-
specific video
playlists.
From tutorials
to trade-show
coverage,
Engineering TV
is the video
site for design-
engineering
professionals.
At
EngineeringTV.com
visit us at
EngineeringTV.com
ADVERTISER INDEX
RS# . . . . . . COMPANY. . . . . . . . . . . . . . . . . . . . . . .PAGE
205........AceControls..........................ll6
l79........AdvancedAntlvlbratlonComponentsl03
ll3........Aerotech,|nc............................l4
l3l........AlrpotCorp/Alrpel ......................36
l32........AlrpotCorp/Alrpel ......................37
2l6........AllMetrlcSmallParts.................l27
l90........Amacoll,|nc...........................l08
2l4........AnlmatlcsCorporatlon................l24
l53........AssoclatedSprlng/Raymond...........67
l03........Automatlondlrect.com.................. 3
l05........Automatlondlrect.com.................. 6
l6l........AvagoTechnologlesU.S.|nc............83
l64........AvagoTechnologlesU.S.|nc............89
l29........Avnet...................................34
l67........Avnet...................................93
l60........8&8Llectronlcs........................8l
l56........8&R|ndustrlalAutomatlon .............73
l57........8annerLnglneerlngCo.................75
l47........8elden|nc. ..............................57
l97........8ellowstech,LLC......................ll2
2l7........8eswlckLnglneerlngCompany,|nc...l27
220........8lmbaManufacturlngCompany ...... 8C
l62........8lsonGear&Lnglneerlng...............85
l65........Carlyle1ohnsonMachlneCo............90
l36........ClcollCorp..............................4l
l06........Cllppard|nstrumentLaboratory,|nc. .... 7
l55........ContlnentalHydraullcs .................7l
l42........Contrlnex|nc ...........................47
l92........Craftech|ndustrles|nc................l09
l7l........DeltaComputerSystems|nc............99
l95........DonwellCo...........................lll
2l8........Dunkermotor.........................l28
l08........L8M-Papst............................... 9
l04........LxalrCorporatlon........................ 5
l93........LxcelGear,|nc.........................ll0
l69........LxlarCorporatlon.......................95
l48........PabcoAlr,|nc............................59
l49........PestoCorporatlon ......................60
l99........Ployd8ell .............................ll3
203........PorestCltyGear.......................ll5
l66........GalllMotlonControl|nc.................9l
l33........Gates ...................................38
l77........GemsSensors.........................l0l
l58........Groschopp..............................77
l38........HarmonlcDrlveLLC.....................43
l27........HellcalProductsCompany,|nc..........32
2l2........|A|Amerlca|nc........................ll9
206........|garashlMotorSales..................ll7
l34........|gus,|nc.................................39
l63........|KO|nternatlonal|nc....................87
l39........|MSGear ................................44
l70........|ntechCorporatlon .....................98
ll8........|ntelllgentMotlonSystems,|nc..........22
ll9........|ntelllgentMotlonSystems,|nc..........23
l8l........|TT-Lnldlne|nc.......................l03
l96........KabelschleppOfAmerlca.............lll
2ll........KepnerProducts......................ll9
l4l........LappUSA...............................46
l72........LeeCompany...........................99
209........LlnxTechnologles.....................ll8
ll0........MagnetlcComponent
Lnglneerlng,|nc. ......................ll0
l86........MartlnSprocket&Gear ...............l06
While every effort has been made to ensure the
accuracy of this index, the publisher cannot be
held responsible for any errors or omissions.
l94........Master8ond,|nc. .....................lll
204........MaxonMotorUSA....................ll5
l44........MlnalexCorp ...........................50
ll7........MlnnesotaRubber......................l9
l9l........M|TRPAK..............................l09
l54........Molex...................................69
2l5........NammoComposlteSolutlonsLlc.....l25
ll2........Natlonal|nstrumentsCorporatlon......l3
ll5........Newark/Llementl4....................l7
l74........NewportCorporatlon.................l00
l73........NexenGroup|nc........................99
l80........NlpponPulseAmerlca|nc ............l03
l09........NovotechnlkU.S.,|nc. ...................l0
l5l........NumatlcsLxpress.......................63
l98........Ogura|ndustrlalCorp.................ll3
l02........OmegaLnglneerlng|nc ................. l
............Ondrlves.us .............................40
l2l........OrlentalMotorUSACorp...............26
l22........OrlentalMotorUSACorp...............27
l84........PeerlessLlectrlc.......................l05
l46........PellcanProducts ........................53
l50........Plttman.................................6l
l87........PreclslonPaperTubeCompany.......l07
2l9........ProtoLabs,|nc..........................|8C
l89........Pyramld|nc...........................l07
207........Quallty8earlngs&Components......ll7
200........QualltyTransmlsslonComponents...ll3
l82........R+wCoupllngs......................l04
l20........Rlttal ................................24-23
208........RotorCllpCompany..................ll7
l78........SA8AssoclatedwlreProducts........l02
l68........SantestCoLtd..........................94
l0l........SchmersalLLC......................... |PC
202........SealMasterCorporatlon..............ll5
2l3........SealezeCorp..........................l2l
l88........Servometer'.........................l07
l40........SLwLurodrlve..........................45
20l........Shlmpo...............................ll4
l45........SKP......................................5l
lll........SKPGroupHeadquarters...............ll
l37........SmalleySteelRlngCompany...........42
l07........Splrol|nternatlonalCorporatlon......... 8
l28........Stelnmeyer,|nc. .........................33
l30........Stelnmeyer,|nc. .........................35
l83........StockDrlveProducts..................l05
l43........Stratasys................................49
l52........TDK-LambdaAmerlcas|nc..............65
l75........Techno|nc ............................l0l
l76........Trans-Tek|nc..........................l0l
l85........Trlm-LokCompany...................l05
ll6........Turck|ncorporated .....................l8
2l0........v|CControls...........................ll9
l23........veljanHydralrLtd. ......................28
l24........veljanHydralrLtd. ......................29
l25........w.L.Gore&Assoclates|nc ..............30
l26........w.L.Gore&Assoclates|nc ..............3l
l59........wlttensteln.............................79
ll4........ZLRO-MAX.............................l5
RS# 214
BUSINESS INDEX
Thlslndexlncludesallslgnlflcant
referencestoparentcompanles
mentlonedlnfeatureedltorlalmaterlal
wlthlnthlslssueofMACHINEDESIGN.|t
doesntcltecompanlesllstedsolely
lntheProductsandLltSectlon.Page
numbersllstedrefertothepageswhere
theartlclesbegln.
MeltrlcCorp................... 3l
M|CO|nc....................... 90
MllwaukeeCyllnder............ 90
NASA.................... 8,20,54
Nv|D|ACorp. .................. 28
NuageCorp. ................... 95
ObjectManagementGroup.... 42
ParkerHannlfln,HoseProducts
Dlv......................... 88
PlttmanMotors..................6
PolyOneCorp. ................. 96
PrlntedLlectronlcsTestCenter
Network.................... 44
PryerTechnologyGroup ....... 78
PurdueUnlverslty............. 54
Qulckparts.com|nc............ 94
RexnordCorp. ................. 42
Rexnord|nnovatlonCenter.... 42
RexnordTechnlcalServlces
(RTS)....................... 42
SLM| .......................... 62
SaesGetters ................... 37
SalemDeslgnand
ManufacturlngLLC......... 70
SandlaNatlonalLaboratory.... 33
Sauer-Danfoss................. 90
SchottSystemsGmbH......... 95
ShepherdControls&Assoclates 42
Slmrlt......................... 50
Soraa|nc....................... 25
SouthPoleNeutrlno
Observatory................ 47
StarThermoplastlcs............ 97
Stratasys ...................... 92
StruktolCompanyofAmerlca.. 96
SymbloslsPoundatlon......... 60
Synchro-MatLqulpmentCorp.. 40
SyntheonLLC................. 54
T.A.Grlmm&Assoclates|nc..... 92
TLConnectlvlty................ 44
TvSDAmerlca.............. 44
TegraMedlcal................. 42
TeledyneContlnentalMotors.. 40
TrlpollRocketAssoclatlon...... 54
U.S.Dept.ofLnergy........... 62
UC|MU........................ 36
workflowManagement
Coalltlon ................... 42
XenonCorp. ................... 44
AMGeneral................... 40
AMD............................6
AerospaceCorp.,The.......... 48
AgllentTechnologles|nc....... 42
AlrPorceResearchLab......... 54
Altuglas|nternatlonal,
Arkema|nc.................. 97
Amerlchem|nc................. 97
Ansys...........................6
Asslot......................... 37
Assofluld...................... 37
AutomatlonDlrect...............6
AutomatlonDlrect............. 88
AvnetLlectronlcsMarketlng... 44
Avnet|nc...................... 44
BPM.com...................... 42
8eswlckLnglneerlngCo.|nc.... 88
8oschRexroth................. 82
8ureauofAlcohol,Tobacco,
Plrearms,andLxploslves .... 55
Carlbonl....................... 39
CarrollHlghSchool............ 52
Chrysler ....................... 40
Comatrol ...................... 88
CongressofthePutureof
LnglneerlngSoftware....... 48
Cymatlx|nc.................... 42
DanfossPowerLlectronlcs ..... 42
Darpa ......................... 54
Delcam.........................6
DeltaComputerSystems|nc. ... 76
DeutscheMesse ............... 37
Dunkermotor................ 6,42
LlastoconTPLTechnologles .... 96
LuropeanSpaceAgency....... 20
Lxalr.......................... l8
PAA........................... 54
Pabco-Alr...................... 88
Fabricating.com . . . . . . . . . . . . . . . . .68
PederalHlghwayAdmlnlstratlon26
Pedermacchlne................ 35
PleraMllano ................... 37
PreudenbergSeallngTechnologles
Academy ................... 50
Preudenberg-NOKSeallng
Technologles............44,50
Prost&Sulllvan ................ 42
PutureStrategles|nc........... 42
GatesCorp. ......................6
GermanlscherLloyd........... 44
HoneywellSenslngandControl 90
|ngersollRand................. l6
|nternatlonalHarvester........ 40
1oyGlobal ..................... 48
KralburgTPLCorp. ............. 97
LuxologyLLC.................. 94
MSCNastran.................. 48
Mahle|nc. ..................... 40
RS#2l5
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June 14, 2012

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