Académique Documents
Professionnel Documents
Culture Documents
.
Its keyless hollow shaft and taper
bushings eliminate inefcient belts,
chains, and sprockets thus reducing
maintenance and energy costs while
enhancing system safety.
Its spacious air gap provides easy
mounting. Its tightening bolts provide
easy dismounting. No more tight
tolerances! No more keys!
Need retrot? No problem. TorqLOC
even mounts onto an existing shaft
that has a keyway.
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Mounting
Dismounting
RS# 101
Solve the puzzle then unscramble the letters in the yellow squares above
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ACROSS
1. Fearless stuntmans frst name
5. Everyone
8. Magentic resonance imaging
(abbr.) systems
11. ___ rly or cheap
12. Lukes sister, the Princess of
Alderaan
13. Umpires call
14. Privy to
15. North-central Utah city
16. No longer working (abbr.)
17. Avago Technologies provides
a wide range of ___
products suitable for medical
applications with its ability to
provide reinforced isolation
between power supply and
operator/patient
20. ___ Pepper, too!
21. Scatter seed
22. Avago Technologies
optocouplers can ___ power
supplies from operators
and patients in medical
applications.
26. Part of speech
29. Youll fnd one in an atlas
30. Replace the logo on
Supermans chest?
33. One-time password (abbr.)
34. Escape
36. Avago Technologies ofer
several types of motion-
control ___ solutions to
meet the needs of diferent
electrical motor systems.
38. Howard and Kobes league.
40. Charged particle
41. Avago Technologies, as explained
in 8 Across, employs ___
to manage system control/
feedback signals in high
electromagnetic- interference
environments.
46. However
47. Ready for picking
48. Of an age
50. Tempe inst. of higher learning
51. Key bakery employee
52. ___-majesty
53. Sales pro
54. Long time
55. Green-building certifcation
(abbr.)
DOWN
1. Electromagnetic interference
(abbr.).
2. Wine in Italy
3. Employee-owned co.
4. Plant with lens-shaped
seeds, often used in soup
5. Aviation prefx
6. In ___ of
7. ___ from Avago
Technologies serve as
indicators and also provide
backlighting for medical and
other applications.
8. Need for a dying fre?
9. Regretful one
10. Addams Family cousin
12. Behind todays sophisticated
device technologies are
semiconductors that sense
(or ___), illuminate, and
connect signals in order to
process digital data.
18. Bradley or Sharif
19. First name of horror movie
star.
22. International Monetary Fund
(abbr.)
23. Gal of song
24. What you do with a wrapped
present
25. Wide shoe size
27. Utah mascot
28. Commercial-free radio net.
31. Sharpshooter
tribe
37. Actor Ed
39. Hawks nest
41. Join together
42. Puerto ___.
43. Not closed.
44. Canadian tribe.
45. Manuscript encl.
46. Light-___ and ___-graph
displays for medical
Solutions for your medical application designs.
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Find the Answer to see how Avago Technologies can help you!
From motion control and ber optics to illumination and isolation...
1
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41 42 43 44 45
46
21
19
16 14
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26 27 24 25
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39 40
47 48 49
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equipment
49. Light-emitting diode (abbr.).
32. Member of ancient Gaelic
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RS# 103
DEPARTMENTS
EDITORIAL
Secret to achieving goals: Dont try too hard
EDITORIAL STAFF
LETTERS
SCANNING FOR IDEAS
Rifle lets sniper set new record
Torque limiter protects machinery
REPORTERS NOTEBOOK
LOOKING BACK
COMMENTARY
Acquihire: When companies have more money than brains
SENSOR SENSE
Pulse-ranging technology
TAVENNER ON SAFETY
Rolling equipment, fractured feet
VANTAGE POINT
Meeting and beating new-product cost targets Julie Driscoll
ORR ON ENGINEERING
The nature of design
SOFTWARE REVIEW
Direct modeler builds a better fuel tank
PRODUCT SPOTLIGHT
Mechanical slides, drives, & gears
PRODUCTS
DATA FILES
BUSINESS INDEX
AD INDEX
CLASSIFIEDS
BUSINESS STAFF
BACKTALK
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ON THE COVER
Model of a head printed on
Mcors full-color 3D printer.
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FEBRUARY 14, 2013 MACHINE DESIGN.com 4
- MateriaIs tear, |am or curI
- Webs and Ims cIing
to themseIves
- Iectronic sensors faiI,
making faIse readings
- Hazardous sparks or shocks
- Product cIings to itseIf,
roIIers, machine beds
- Dust attraction ruins
surface nishes
\hen the humiuity is low, static electricity problems will happen.
EXAIR manuIactures a complete line
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static problems. Many use our engineereu airBow
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RS# 104
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
Linear & Angular Position,
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Free 76-page catalog and technical assistance
Controls microsite
Heidenhain has launched a microsite on its TNC
machining controls at www.tnc.heidenhain.de/en. It
covers a range of controls, features, and applications,
including video and flash animation on five-axis
fundamentals. Visitors can also participate in an
online forum; download manuals, newsletters, and
communication and programming software; and
access interactive training modules.
Relays and controls
The Littelfuse Technical Center lets users download
up-to-date information on protection relays and
control products. Content includes data sheets
and manuals, details on wide-ranging applications,
and technical documentation on design, safety,
environmental compliance, and other topics. Visit
Littelfuse.com/RelaysControls.
The Model X from Tesla
At this years North American International Auto
Show, Editor Leland Teschler talks to a Tesla
Motors product planner about the new ModelX.
The electric car blends a minivan and SEV and has
unique falcon wing doors that swing up and out
of the way. With optional all-wheel drive, the Model
X sports 0 to 60-mph acceleration in under 5 sec.
Get a preview at www.engineeringtv.com/video/
The-Model-X-Complete-with-Falco;Only-Engineering-
TV-Videos.
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During this Webinar, you will learn how to:
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RS# 105
RS# 158
FEBRUARY 14, 2013 MACHINE DESIGN.com 6
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The engineers choice
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RS# 106
EDITORIAL
Secret to achieving
goals: Dont try too hard
Spring is in the air, and to many people, that means its time to pursue a
national pastime. No, not baseball: evaluating last years employee per-
formance goals and setting new ones.
I dont know what the process looks like in your company, but at
mine, it often involves going back to last years performance reviews
and changing goals that were obsolete two weeks after they were writ-
ten. Managers then write in another set of goals that pretty much reflect
what their employees actually accomplished last year.
I used to stress out over whether changing goals after the fact this
way defeated the purpose of the whole exercise. But that was before I
became aware of an increasing body of research showing that pursuing
business goals too relentlessly can be counterproductive. Among those
who have come to this conclusion is Chris Kayes, a George Washington
University professor of management science. Specifically, Kayes noticed
problems cropping up when organizations set big, audacious goals for
themselves, a tactic frequently advocated by management consultants.
Evidence often emerged that the goal was either wildly out of reach or
just unwise. But instead of abandoning the whole idea, some organiza-
tions would pour even more effort into it. This redoubling of exertion
oftentimes resulted in plans going farther off track.
Interestingly, Kayes thinks a lot of these ill-advised escapades hap-
pen because the people involved find it easier to continue investing in a
strategy that isnt working than to change course. The goal, he explains,
can become part of their identity. Uncertainty about the goal then no
longer merely threatens their plans, it threatens them as individuals.
Sticking to the plan makes them feel better by giving them a sense of
certainty about the future, even as evidence mounts that theyve got the
wrong plan.
Another management consultant who finds fault with conventional
ideas about goal setting is Stephen Shapiro, author of books such as,
Goal-free Living, and a speaker at TEDx conferences. Shapiro once
commissioned a survey that found 41% of the respondents werent any
happier after achieving goals theyd set for themselves. It also revealed
18% claimed goals had destroyed a friendship, a marriage, or another
significant relationship. Another 36% claimed adding goals on their to-
do list made them worry more, though over half of them had a goal of
reducing the amount of stress in their lives.
Shapiro now tells companies that they can get more out of their
employees by getting rid of goals. Instead, he says, its better to have a
broad sense of direction but without a precise vision for the future.
Similar themes emerge from the work of University of Virginia busi-
ness research professor Saras D. Sarasvathy. She questioned successful
entrepreneurs about the best way of bringing a new product to market.
They largely pooh-poohed the idea of devising a business plan with a
lot of specific goals. Better to just go out and try things, they said. Youll
find you what your immediate goals should be as you go along.
Which pretty much explains why we generally figure out annual em-
ployee goals only in hindsight.
Leland Teschler, Editor
RS# 107
FEBRUARY 14, 2013
Mi c r ohy dr a ul i c s .
Ma c r o c a pa bi l i t i e s .
Lee Shuttle
Valve. Shown
actual size.
Designed to
isolate the
normal from
the emergency
hydraulic sys-
tem. So small,
it ts right
into the head
of an actuator.
W e s t b r o o k G e r r a r d s C r o s s P a r i s F r a n k f u r t M i l a n
So much reliability and performance, in so little space.
Creating high-performance ow control on a micro scale has been
The Lee Companys exclusive focus for more than 50 years. And
its been a successful mission, as evidenced by thousands of applied
Lee Microhydraulics designs ranging from less than 0.10 in. to 1.00 in.
in diameter, and 0.1 to 68 grams, for operating pressures to 8,000 psi.
But small size and light weight are just the beginning. Theres
also absolute reliability built into every Lee component through
100
%
testing and inspection. Zero defects. Its a production benchmark
that has enabled Lee to meet demanding application needs in all
sorts of industries. Aerospace, medical instrumentation, automotive,
machine tools and oil drilling, to name a few.
The innovative problem solvers.
We dont just satisfy requirements. We also solve problems
whether by simple modication, or ground-zero design engineering.
The Lee Company is the worlds most capable and proven source
for hydraulic-component innovation. And weve documented this
claim in extensive detail with the Lee Technical Hydraulic Handbook.
An invaluable reference, the Lee handbook contains essential data
on the entire Microhydraulics product line, which includes:
Lee Shuttle Valves. Detented, spring-biased, inverse,
loose ball and zero leak shuttle valves from 50-700 Lohms.
Lee Safety Screens. Best protection for critical system
elements. 75 to 500 micron hole size. Pressures to 7,500 psid.
Lee Pri. Pressure relief valves in insert form.
50 to 400 Lohm capacity. 20 to 5,400 psid cracking pressures.
Lee Directional Flow Control. 40 to 20,000 Lohms
in metered direction. 12 to 470 Lohms in free-ow direction.
Lee Restrictors. Single and multi-orice restrictors.
200 to 2.2 million Lohms.
Lee Plugs. The best way to seal drilled holes to 32,000 psi.
No O-rings, threads or sealants required.
Lee Cheks. All-metal and zero-leak check valves.
4 to 400 Lohms.
Essential reading
for designers of
hydraulic systems.
Send for your
free copy.
The Lee Company
2 Pettipaug Rd, Westbrook CT 06498-0424
860-399-6281 Fax: 860-399-2270
1-800-LEE PLUG
www.TheLeeCo.com
Innovation in miniature.
RS# 108
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EDITORIAL STAFF
1300 E. 9th St. Cleveland, OH 44114-1503
EDITOR
Leland E. Teschler
leland.teschler@penton.com
MANAGING EDITOR
Kenneth J. Korane
ken.korane@penton.com
SENIOR EDITORS
Elisabeth Eitel
elisabeth.eitel@penton.com
Leslie Gordon
leslie.gordon@penton.com
Stephen J. Mraz
stephen.mraz@penton.com
ASSOCIATE EDITORS
Lindsey Frick
lindsey.frick@penton.com
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.
FASTENING & JOINING,
MATERIALS
Lindsey Frick
FLUID POWER
Kenneth J. Korane
MECHANICAL
Elisabeth Eitel
Lindsey Frick
Kenneth J. Korane
EDITORIAL PRODUCTION
Denise Greco
Editorial Production Manager
Randall L. Rubenking
Art Director
RS# 110
RS# 109
FEBRUARY 14, 2013 MACHINE DESIGN.com 10
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RS# 111
LETTERS
looking for those trained employ-
ees, dry your eyes and try spend-
ing a little bit of your millions to
train a few people for yourselves.
Richard Distel
Snow clones?
I read the article, Rethinking the
Snowmobile (Nov. 20), and noticed
that the Snow Runner is similar to
the Snow Hawk which has been
around since 2002. The asking price
Companies crying
crocodile tears
Your editorial is just another tearful
plea by companies for more low-
cost yet fully trained employees
(More Green cards, More H-1B
Visas, Nov. 6). If they want em-
ployees trained beyond the ability
to read, speak, think, and perform
math, I suggest they train those
employees themselves.
Over the years that I ran a tool-
and-die company, we routinely
trained apprentices at a ratio of
one for every eight journeymen.
It was a four-year program and
included almost 1,000 hr of class
time, paid at straight time, but
wages rose as the apprenticeship
progressed. The apprentice paid
tuition but got it back as a lump-
sum reward after graduation. Un-
fortunately, these new journey-
men then went to the bottom of
the seniority list and got laid off
first and soon, due to the cyclical
nature of the automotive trade.
Most of them quickly found an-
other job. About half returned and
several stayed with us over the
years, several rising to managerial
positions in our company.
I guess we trained them too
well. Many went on to manage-
ment or engineering jobs at the
big three (gasp on only a four-
year apprenticeship after high
school). The goal was that any
graduate apprentice, left alone
in the shop with a part print and
a wood model (or later a math
model and a computer) would be
able to design, build, and tryout
dies for a sheet-metal part from
a bracket to a quarter panel. We
were a small company, but we
did okay in competition with the
Henry Ford Trade School and the
GM Technical Institute. Those in-
stitutions are also gone now, of
course. No need to train people
if we can get them trained to our
specifications at public expense
from state universities either here
or in China, India, or Korea.
Hey, Microsoft, while youre
for the SR-125 ($5,550) is compara-
ble to a Ski-Doo MX Z Sport ($6,549),
which seems like a better deal.
Jim Smouse
Yes, our Snow Runner and the
Snow Hawk are both single-ski ve-
hicles, but thats where the simi-
larity ends. Look at the design re-
quirements we set out and met in
the development process com-
pl etel y di fferent than the Snow
Hawk or traditional snowmobiles.
Shortage? What shortage?
Several readers commented
on Leland Teschlers recent
blog entry (Not So Bad:
Manufacturing Skills Gap is
Local, Not National, Oct. 16).
It mentioned a study that
indicated machinists and
welders were in short sup-
ply in only five of the top 50
manufacturing cities in the
U.S. Readers, all manufac-
turers, disagreed.
Tulsa, Okla., may not be one of the top five manufacturing centers, but
we manufacture a lot of the equipment used in oil and natural-gas
production and refining. There are billboards, roadside signs, and even
a sign in a local BBQ restaurant put up by local companies looking for
CNC machinists with at least three years of experience with starting
pay of a minimum of $25/hr. Skilled welders start at $18 to $20/hr, plus
overtime. That is good money in this region with some of the lowest
housing costs and gasoline prices in the country.
Don Allen
This is the biggest load of nonsense Ive read in a long time. Manu-
facturers, including me, have a completely different experience with
trying to hire and retain good machinists and manufacturing people.
Chis Reeve
I think the studys analysis is severely flawed. In our area in central Min-
nesota, we have serious skill gaps in many areas, especially for welders
and skilled machinists. A large effort is being expended in our area to
address the skill gaps and train workers.
Lester Engel
Their statistics dont match the on-the-ground experience among
manufacturers Im networking with in the Los Angeles area. Its a bo-
gus study.
William Pratt
FEBRUARY 14, 2013 MACHINE DESIGN.com 12
RS# 112
We designed the AGR series motorized rotary stages to provide significant
improvements in speed, load capacity and long-term positioning performance over
previous generations of worm-gear-drive stages. The AGR series incorporates dual
large diameter pre-loaded angular contact bearings optimally separated to provide
excellent error motion specifications, as well as best possible load handling capability.
The large clear aperture (sizes from 50 mm to 200 mm) allows the AGR series to
address applications requiring a through-hole fixturing.
Contact our Application Engineers today for more information on the AGR series or
any of our other superior direct-drive and worm-drive rotary stages.
Benefits:
Enhanced speed and load capacity
Innovative precision worm-gear assembly for outstanding
accuracy and repeatability over an extended lifetime
Large aperture addresses a wide range of applications
Continuous 360 rotary positioning
Operation over a wide temperature range
You've Never Seen a
Rotary Stage Like This
Five models fit almost any application
AH1212C_PPG
Aer ot ec h Wor l dwi de
United States France Germany United Kingdom
China Japan Taiwan
Ph: 412-963-7470
Email: sales@aerotech.com
www.aerotech.com
Dedicated to the
Science of Motion
Add an Aerotech award-
winning single- or multi-
axis control system for a
complete motion solution.
200 mm
150 mm
100 mm
75 mm
50 mm
LETTERS
LETTERS TO THE EDITOR
Please include your name, address, and daytime
phone number. Letters may be edited for
brevity and to focus on essential points.
Mail: Letters, MACHINE DESIGN,
1300 E. 9th St., Cleveland, OH 44114-
1503, Fax: 216-621-8469
E-mail, Editorial: mdeditor@penton.com
Such projects are worth funding
early on for addition to our scien-
tific knowledge-base. However,
failing to honestly identify further
development projects as impracti-
cal nonstarters illustrates what is
wrong with how our government
decides where and how to spend
our money.
Selfish researchers, bent on
making a name for themselves,
or on creat i ng a f asci nat i ng
open-ended career-length proj-
ect, should not be permitted so
much influence over the decision-
makers. Objective experts should
have majority influence, not the
pioneering expert or the ignorant
politicians.
Mike Netbith
and fossil fuel to make this fuel
(Navy Tries Turning Seawater into
Fuel, Nov. 20,). There are many bet-
ter ways to reach this objective.
Al Nabhani
First off, you do not catalytically
combine CO
2
and H
2
to get hydro-
carbons without a lot of energy
input. Second, there is no free hy-
drogen in seawater. Any hydrogen
would have to come from breaking
down water molecules, a process
which requires more energy than
the resulting fuel can supply. And
finally, there is not a lot of carbon
in seawater. Seawater is 1.4% CO
2
.
Jim Deggit
If this is for real and is an indication
of the science in the U.S. military,
they need to start firing a lot of
people, starting with the idiot who
approved this garbage.
Brian Dermot
The concept sketches and idea for
the vehi cl e star ted i n 2001 and
sat for a while until our patented
ski was developed. The ski turned
our vehicle from a difficult-to-ride
vehicle into the fun, easy-to-ride
machine it now is. We have had
people from 10 years old to well
over 70 riding vehicles in just sev-
eral minutes of practice with no
instruction and, in some cases, do-
ing extreme maneuvers just not
possible with other vehicles.
I coul d go on and on but the
Snow Runner and Snow Hawk
fit different niches in the market
place (cost, size, weight, end user,
zero pollution electric, etc).
Good l uck and have a great
winter snow season. Jim Wade
Seawater not fit for fuel?
Why do we neglect the obvious,
cold fusion? It still takes nuclear
RS# 113
FEBRUARY 14, 2013 MACHINE DESIGN.com 14
WHAT MOVES YOUR WORLD
ITS TIME TO CHANGE
THE FUTURE OF
MOTION CONTROL.
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THE MOTION CONTROL EXPERTS AT MOOG CAN HELP YOU MAKE IT HAPPEN.
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industry youre in. For more information call 866-580-7610.
How can we improve your machine design?
Download our comprehensive white paper on electric and hydraulic
solutions in high-performance machines at http://info.moog.com/4
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RS# 114
SCANNING FOR IDEAS
Suppressor
reduces muzzle
flash and noise
Adjustable bipod
supports rifle
Magazine lets shooter rapidly
fire five rounds but is sized to not
interfere with alignment of barrel.
Adjustable cheek piece lets
shooter align his eye with the
telescopic sight
Folding stock shortens the
length of the rifle, letting it be
carried in a backpack.
Telescopic sight
magnifies targets by a
factor of up to 25.
Full-length
aluminum
chassis
Fixed butt plate
and spacers
Three-position safety
Short throw bolt
Free-floating barrel
Edited by Stephen J. Mraz
For more on new rifles
and their design, scan
this code or go to http://
machinedesign.com/
article/a-21st-century-
rifle-0112
Rifle lets sniper
set new record
The L115A3 long-range rifle was used by a British soldier to hit
and kill two Taliban targets at a distance of 8,120 ft, a record for
sniper shots. The weapon is a version of the 338 Lapua Mag-
num rifle from Accuracy International of North America Inc.
in Fredricksburg, Va. (www.accuracyinternational.us), the U.S.
headquarters of a British firm. It was modified under the British
Ministry of Defenses Sniper System Improvement Programme.
So now it fires an 8.59-mm round, which is heavier than the
original 7.62-mm round and, therefore, less likely to be af-
fected by winds during long shots. It also has a spotting
scope that magnifies by a factor of 25 instead of the
original scope which only has 12 magnification.
Muzzle velocity also increased from 838 to
936meters/sec.
The civilian version of the rifle is avail-
able to qualified buyers, but prices
are in the $9,000 range.
RS# 401
FEBRUARY 14, 2013 MACHINE DESIGN.com 16
Real parts. Really fast.
Receive
FirstQuote
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A product development team needs parts
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Call 877.479.3680 or visit www.protolabs.com
Puzzled by resin choices? Visit www.protolabs.com/parts
today and request your FREE Resin Puzzle nine of the most
common thermoplastics used in injection molding. Enter code MA13A.
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RS# 115
Friction discs
Contrinex Inc.
Old Saybrook, CT 06475
Toll free: (866) 289-2899
Fax: (860) 388-3574
E-mail: info_us@contrinex.com
www.contrinex.com
Contrinex Series 700 the worId's toughest
inductive proximity sensors
ExceptionaIIy rugged and impervious
Housings machined from a single piece of stainless steel
Mechanically and chemically very rugged and resistant to operating
pressures of up to 850 psi.
Condet
ackgrcund Supprcsscn
Mul-Pxc Array
First Precision
Servo Gearbox / SP
Founding
of alpha
Cymex
Software
High Performance
Linear System
TP+ 4000
Engineered in Germany,
Built to last!
RS# 137
VANTAGE POINT
Meeting and beating
new-product cost targets
If you are working on a new-product-development ini-
tiative (NPI), youre likely under pressure to hit specific
cost, weight, market, and quality targets under tight
time frames. Designing and making products that meet
all these criteria, particularly cost, can be extremely
challenging.
The cost implications of design decisions made dur-
ing development are often more significant than most
manufacturers realize. Cost overruns reduce profit mar-
gins. And time spent firefighting cost surprises delays
introduction. Expensive postproduction rework can
also result. At the core of these challenges is the inability
to accurately identify, assess, and manage detailed prod-
uct costs early in a products life cycle.
Best-in-class companies start managing costs at the
earliest stages of product design, letting engineering,
manufacturing, and sourcing teams collaborate on cost
analysis. As a result, the firms realize benefits, including:
Getting cost targets right the first time, before prod-
ucts or parts go into production.
Quickly evaluating the cost of design alternatives, let-
ting engineers focus more on product innovation and
less on cost analysis.
Identifying the real cost drivers behind a product
design and minimizing engineering changes later in
the release cycle where they cost more to address.
Eliminating long waits for price quotes from internal
experts and external suppliers.
Creating should-cost estimates to help select ven-
dors, validate quotes, and negotiate with suppliers.
Its not uncommon for engineering, sourcing, and
manufacturing teams to complain that product-cost-
management (PCM) activities slow them down. In fact,
the opposite is true PCM can actually speed devel-
opment. Efficiency gains often come out of faster cost
estimates from suppliers and less late-stage, expensive
rework. Cost-management operations fit naturally into
engineering and sourcing processes, and the right PCM
software complements the tools most companies al-
ready use.
There are some core requirements for effectively
managing new-product costs, including:
Early cost visibility. NPI teams must know early on
how different design alternatives impact costs. Compa-
nies should evaluate tools that let engineers determine
cost by automatically pulling geometric and feature in-
formation from CAD models. Team members who are
not cost or manufacturing experts can quickly create an
estimate and compare it against established target costs.
Also, regularly reassess costs as features and designs
change, to evaluate trade-offs and cost impacts. OEMs
should establish cost-evaluation
milestones at stage gates in the NPI
process to assess the implications
of various design ideas and alter-
natives. Sourcing managers and
manufacturing engineers should
also have early visibility into product designs and up-to-
date cost estimates, so they can comment on alternative
designs, sourcing options, and manufacturability.
Cross-functional view of product cost. Providing prod-
uct costs to cross-functional teams at each stage of de-
velopment is also important. This ensures that all par-
ties access the same information, collaborate early, and
work to prevent late-stage cost surprises. The resulting
benefits are significant. For instance, sourcing manag-
ers can consider make-versus-buy decisions earlier. This
can improve profitability and make better use of supply-
chain partners and their design and manufacturing ex-
pertise. Manufacturing engineers can regularly evaluate
designs for manufacturability and suggest changes that
reduce cost and time-to market. And cost engineers get a
broader range of information, giving them greater influ-
ence over a projects overall economics.
Integration with enterprise systems. Its important that
PCM software works with existing PLM or ERP systems.
Common requirements include loading a bill of materi-
als and carryover part costs from the enterprise system,
and storing PCM cost data in the PLM or ERP database
to create a closed-loop flow of information.
Without these core practices and tools PCM remains
highly manual and decentralized, and cost-engineering
teams have limited ability to reduce product costs. For
example, they may only focus on a portion of a prod-
uct because they do not have the resources to cost all
components. They are also forced to assess costs when
designs are nearly final, severely limiting the window
of opportunity to identify and act on potential cost sav-
ings. It also leads to inconsistent estimation methods
with static information that is difficult to update, man-
age, and share.
Best-in-class manufacturers are distancing themselves
from their competition with a systematic approach that
makes product-cost management a normal course of
responsibility and decision-making. Effective PCM pro-
grams can increase profit margins, ensure faster time to
market, and improve product quality, too. MD
aPriori (www.apriori.com) develops product-cost-management
software used in sourcing, manufacturing, and design engineering.
Edited by Kenneth Korane
Julie Driscoll
Vice President,
Strategic Marketing &
Product Management
aPriori Inc.
Concord, Mass.
FEBRUARY 14, 2013 MACHINE DESIGN.com 44
Autonics' graphic touch panels are the ideal solutions to make complicated controlling systems simple with
convenient interface. The LP/GP Series HMl's have flexible functionality coupled with a high visibility
wide screen display at a reasonable price. These exceptional features allow them to be used in many
different types of industrial applications.
RS# 138
CAD
The Creatr 3D printer comes
precalibrated.
itself from other consumer printers in several regards, says company co-
founder Mathijs Kossen. First, unlike other printers, the device is made
entirely of aluminum, so it is sturdy and steady. And it also has larger,
more-reliable electronic components, he says. For example, stepper-motor
drivers in consumer printers typically break almost right away. We replaced
them with professional drivers, as well as a more-robust belt and driving
shaft. The printer, therefore, wears out less quickly.
While most printers in the Creatrs price range (approximately $1,500)
need calibration, the Creatr comes preassembled and precalibrated, so us-
ers can just start printing, out of the box. The machine targets people who
dont want to spend 20 to 40 hours building a machine and calibrating it
they just want to design immediately. This makes our printer accessible to a
broad range of people.
In addition, the 23 27 23-cm build volume is large for a consumer
printer. Whats more, the device sports an optional dual extruder. The Creatr
builds using thermoplastic extrusion. A machine with a single extruder would
It seems just about everyone
is busy printing objects in
3D. Examples range from
high-end airfoils to jew-
elry, lattice structures, and
even self-portrait figurines.
Here, we kick the tires of a
few machines, both con-
sumer and commercial.
The machines we profile
have one thing in common
a price tag of under about
$20,000. And most are much
less expensive.
LeapFrog
Aimed at the home user, the
Creatr 3D printer from LeapFrog
in the Netherlands distinguishes
Technology once deemed too
expensive for wide use has infiltrated
manufacturing and even become a hit
with consumers.
Authored by
Leslie Gordon
Senior Editor
Resources:
FormLabs, www.formlabs.com
LeapFrog, www.lpfrg.com
Mcor Technologies Ltd., www.
mcortechnologies.com
RepRap Ltd., www.reprap.org
Stratasys, www.stratasys.com
The changing face of
3D printing
The model of a
head shows the
capabilities of
Mcors full-color-
version printer.
FEBRUARY 14, 2013 MACHINE DESIGN.com 46
wecantmeet. t t
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ECONO SERIES & ACCELERA Precise. Multi-axis control. Low cost.
POCKET MOTION CONTROLLER Single-Axis. Powerful for its size.
POCKET PLC Smart. Compact. Low-Cost. Packed with I/O.
RS# 139
CAD
The relatively inexpensive Form 1 stereolithography
machine can print detailed models like this Eiffel Tower.
The Mojo can build parts such
as this medical model of a
foot, which would be used
for preoperative surgical
planning.
print ABS, for everyday design engineers who use CAD as
part of their jobs. The company first introduced its other
FDM product lines, including the Dimension in 2001 at
about one-half the price of other 3D equipment available
at that time. It has since developed numerous Dimension
products, taking the price down to about $20,000. About
five years ago, the company introduced the uPrint, which
was in the $15,000 to 20,000 price range. The Mojo came
out in April 2012. It is said to be the first professional-
grade printer to cost less than $10,000.
Whats striking about the Mojo is its shape and size,
says Cobb. The machine really mimics the form factor
of a 2D printer one might get from HP. Also, its software
lets users drag and drop from CAD files, as well as quickly
print second, third, or fourth models. The system also ar-
ranges the parts in the build envelope.
Mojo build material, which is in the form of a filament,
along with the feed head, is all part of the print cartridge.
Stratasys says users can set up the printer in about 10 to
15min.
not be able to build a bridge, for example, says Kossen.
To make the pylon, when the first layer on the road is
printed, the plastic coming out of the nozzle would fold
down into the air. But the second extruder fills in that
space with a soluble material, letting users print almost ev-
ery shape and form. When the build is complete, users can
easily wash out the water-soluble material that supports
overhangs during a build.
Building materials are in the form of a filament that
comes on reels. The machine prints ABS or PLA plastic.
PLA is a little more brittle than ABS with a lower melt
temperature, making it possible to print smoother edges.
Users might be more likely to print end models with
ABS, says Kossen. On the other hand, they may be more
likely to print display models out of PLA. PLA is also bio-
degradable. Interestingly, ABS is the material used to make
Legos.
The Creatr typically builds in 200-micron layers. But
mechanically and experimentally, its possible for the toler-
ances to go much lower, say, to 100 microns, says Kossen.
The speeds of the X and Y axes go up to 0.35 m/sec and the
extrusion speed is 200 mm/min. The machine can print an
iPhone casing in about 10 to 15 min.
FormLabs
According to FormLabs founder Maxim Lobovsky, the
Cambridge-Mass.-based company recently introduced the
Form 1, the first stereolithography (SL) machine that is
anywhere close to costing only $3,000.
We have made it easy to use the machine to tar-
get what we call pro-
sumers or designers,
engineers, and mak-
ers, he says. The
software is intuitive and
it includes tools to handle the fin-
ishing steps. The machines use a less-common ver-
sion of SL, where resin is exposed from the bottom
of the tank, rather than from the top. We didnt
invent that overall process, but we simplified it and
reduced costs. For example, new lasers on the mar-
ket make that part of the system way less expensive.
For materials, the machine uses a proprietary
photopolymer, a liquid in a bottle that costs about
$149/liter. The resin price is about half that of the
higher-resolution machines, says Lobovsky.
The machine produces layers with a minimum
thickness of 25 microns and a minimum feature
size of 300 microns. The machine prints at a typical
rate of about 15 mm of height per hour. The build
envelope is 4.9 4.9 6.5 in.
Stratasys
Stratasys Technical Director John Cobb says the
company recently introduced the Mojo 3D printer,
which uses fused-deposition modeling (FDM) to
FEBRUARY 14, 2013 MACHINE DESIGN.com 48
Non-force touch
button withstands
the demands of
manufacturing.
Banner EZ-LIGHT
.HWSLZZTH[LYPHS
\UJVTWYVTPZLK[YH]LYZL
LUKWVPU[Z
Spool integrity depends on a
good quality wind pattern and
proper tension control. For profle
materials that can't twist or tolerate
stress, accurate control of the
proper traverse wind pattern is
crucial. The SmartMotor integrated
motion control system with multi-
axis capabilities ensures accurate,
dynamically defnable traverse
points. This allows for standard or
inverse tapered patterns, as well as
step wind patterns, all within one
cost-effective integrated product.
SmartMotor frmware is custom-
tailored for the winding industry.
By using a material thickness
sensor, you'll enjoy real-time off-
sets for material width variations
without sacrifcing position
accuracy at the traverse point, and
with no gaps in material density.
FLUID POWER
(p
o
+ p)A + A(V
o
+ V)
2
p
o
A AV
o
2
= A(a V
o
)t(V/t)
p = (a V
o
)V (V
o
+ V)
2
+ V
o
2
p = aV(1 + V
o
/a) aV.
The acoustic velocity of water in Schedule 40 to 60 steel pipes is about
4,000fps. For steam or gases, calculate acoustic velocity using:
a = (144g
c
kpv)
0.5
.
The specific heat ratio, k, is 1.25 to 1.3 for steam and 1.4 for air and most
gases.
For quick full-gate closings, V = V
o
, the pressure surge and corresponding
force on the gate are, respectively:
Ap
max
S
f
(aV
o
) S
f
a
vW
A
_
,
S
f
a
W
g
c
A
_
,
S
f
a
W
g
c
A
_
,
AF
max
Ap
max
A S
f
a(W/ g
c
) (momentum equation)
A safety factor, S
f
=1.1, is generally appropriate for surge-pressure calcula-
tions. Pressure surges measured in 24-in. main steam pipes of power plants dur-
ing turbine trip tests are less than 5% above the analytical prediction using these
equations. This is a reasonable validation of this calculation method which ne-
glects friction, compressibility, and related factors.
Pressure design
Pressure design for water-hammer load must consider both rupture and
buckling failures. Overpressure may rupture the pipe from hoop-tension fail-
ure. Hoop-tension stress in a pipe wall from internal pressure is:
S
hp
= pr/h = pd
i
/2h, p = p
0
+
Longitudinal stress in pipe is half of the hoop stress. But it must be combined
with tensile and bending stresses from all concurrent loads and could dictate
the design.
Pressure wave traveling in pipe
Gate open
Gate shut
L
V
o
p wave
V
0
a V = 0
p wave
V = 0 a
p wave
a
V = 0
p wave
V = 0
a
Reservoir
t < 0
0 < t < L/a
L/a < t < 2L/a
2L/a <t < 3L/a
3L/a < t < 4L/a
Sudden gate or valve closing creates a pressure wave that travels through
the pipe. Here, V = flow velocity, V
o
= initial flow velocity, and a = acoustic
velocity.
RS# 145
FEBRUARY 14, 2013 MACHINE DESIGN.com 56
Accelerating Your Success!
3
Low-pressure, large-diameter pipes and bellows are most vulnerable to
buckling. The external pressure from underground seepage on buried pipes or
tunnel linings can be high enough to buckle pipe during water-hammer events,
when drained, or even during construction. Stiffener rings can be used instead
of thicker shells. The critical pressure per unit axial length for buckling a ring is:
q
cr
= 3EI/r
3
.
A good practice is to weld the stiffener to the outside of the shell wall with
full-penetration continuous welds so that the combined moment of inertia of
the cross section exceeds the sum of the two individual moments of inertia.
The speed of pressure surge at the gate depends on valve characteristics in
terms of mass flow rate versus time. A typical nonlinear valve-characteristic
curve may be approximated by a straight line. The linear effective closing time
is about one-half to one-third of the nominal stroke time. For linear-valve char-
acteristics, surge pressure ramps up to p
max
in time, t
g
, and then remains con-
stant. This is a ramp function, p(t), defined as:
p(t) = p
max
(t/t
g
), 0 t t
g
; p(t) = p
max
, t
g
t.
The longitudinal load on a pipe section is generated by a wave front hitting
the two ends with a time lag. Consider a straight pipe section between elbows B
1
and B
2
shown in the accompanying graphic. The wave front reaches B
1
at time t
1
and arrives at B
2
at t
2
. Forces on B
1
and B
2
are time-shifted ramp functions:
F(t) = p(t)A; F
1
(t) = -F(tt
1
), F
2
(t) = F(tt
2
).
The net unbalanced force on the pipe section is a trapezoid pulse:
F
s
(t) = F
1
(t) + F
2
(t) = F(tt
1
) + F(tt
2
).
Control-volume boundary forces
Mass element
Gate shut
a V
o
p
o
+ p
V
o
+ V
A(V
o
+ V)
2
momentum
(p
o
+ p)A
a V
0
Mass element
(a V
o
)t
p
o
V
o
AV
o
2
, momentum
p
o
A
This graphic shows forces acting on a mass element (ignoring friction).
Here, A(a-V
o
)t is the mass volume and
p is the pressure surge.
RS# 147
FEBRUARY 14, 2013 MACHINE DESIGN.com 58
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For long pipe sections, defined as L
s
at
g
, F
smax
= F
max
. For short pipe sec-
tions, where L
s
< at
g
, F
smax
= F
max
(t
2
t
1
)/t
g
. Thus, short sections are subjected
to smaller forces because the wave front hits B
2
before F
1
(t) reaches the peak.
For L
s
< L
cr
= at
g
, the load on the pipe section is smaller.
sms
mx
t
t
g
g
c
s
t
g
s
g
c
t
g
s
s mx
g
c
t
g
s
cr
Tape Extension
Position Sensors
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0 ... 216.5 in.
x AnaIog, 4...20mA, SSI,
CANopen, J1939
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/ IP69K
x 1/2 axes, 180, 60
x AnaIog output,
CANopen, J1939
x Protection cIass IP67
POSITILT
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Position Sensors
xMeasurement range
0 ... 216.5 in.
x AnaIog, 4...20mA, SSI,
CANopen, J1939
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/ IP69K
x1/2 axes, 180, 60
x In MEMS technoIogy
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/ IP69K
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IncIinometers
R
ASM Sensors, Inc.
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TeI. 1-888-ASM-USA-1
Quick gate opening directly ramps up pressure to accelerate the fluid mass,
and the wave front rushes ahead at the speed of sound. A fast actuator-operated
valve that taps water from a high-pressure source could cause water hammer in
a branch line. Loose parts in a valve assembly may rattle to initiate water ham-
mer under certain conditions.
Slowing the valves closing rate reduces water-hammer loads on piping. The
wicket gates of hydraulic turbines and main steam-inlet valves of steam turbines
in power plants must close quickly to prevent turbine generators from excess
overspeeding when the unit at a high output is cut off from the power grid.
Here, the quick-closing gate causes water/steam hammer and the piping system
must be ready to bear the loads.
On the other hand, many valves close much faster than necessary simply
because theyre driven by fast actuators. If the hydraulic or pneumatic actuator
speed is not adjustable, inserting an improvised flow restrictor (tube connector
with a small flow area) on the actuator control fluid line slows the actuator with-
out impairing its force capability.
How slow is a slow valve? Pick the pressure-wave round trip time, t
r
= 2L/a,
as a benchmark. By slowing the valve to t
g
> t
r
, the p wave returns to the gate
before full gate closure to cancel further pressure surges. This proportionally
reduces the crest of the pressure surge.
Ap
g
Ap
max
t
r
t
g
, or Ap
g
(S
f
)aV
o
2L
at
g
(S
f
)
2LV
0
t
g
, p
g
p
o
By setting an acceptable pressure-surge magnitude, one can calculate a nec-
essary t
g
. Actual valve-closing time required, (2 to 3)t
g
, depends on the valve
characteristics.
Entrapped air may also cause annoying water hammer. Air gets trapped by
filling an empty pipe with liquid too quickly while impeding orderly evacua-
Calculating water-hammer loads
As an example, consider a power-plant steam turbine that draws
2.8 10
6
lb/hr saturated steam at 900 psia through a 400 ft, 24-in. Sch. 60 pipe.
Assume the turbine inlet valve closes in 50 msec to shut of the fow linearly. Assume
f
n
20 Hz for the piping system.
Here are typical calculations to determine water-hammer loads on the pipe
section.
For 24-in. Sch. 60 pipe, A = 382.35 in.
2
, d
i
= 22.064 in., and h = 0.968 in.
Saturated steam is at p = 900 psia (p
o
= 885.3 psig) and specifc volume v =
0.50091ft
3
/lb.
Specifc heat ratio k = 1.265 (Ref. Flow of Fluids Through Valves, Fittings and Pipes, Crane
Technical Paper 410).
Acoustic velocity in steam a = (144g
c
kpv)
0.5
= 1,626 fps.
Safety factor S
f
= 1.1.
Pressure surge p
max
= S
f
aW/(Agc) = 1.1 [1,626(2.8 10
6
/3,600)]/(382.35 32.2) =
1.1 102.73 = 113 psi.
Maximum internal pressure p
max
= p
o
+ p
max
= 998.3 psig.
Minimum internal pressure p
min
= p
o
p
max
=772 psig. Buckling is not an issue.
Hoop stress in pipe S
t
= (p
max
d
i
)/(2h) = 11.38 ksi.
Maximum force from the pressure surge on the gate F
max
= p
max
A = 43.2 kip.
Critical pipe length L
cr
= at
g
= 1,626 0.050 = 81.3 ft.
Dynamic load factor (DLF) = 1.3 from the chart for /T = f
n
t
g
20 0.05 = 1.
Longitudinal loads on the pipe sections are calculated as follows:
L
s
> 81.3 ft, R = F
max
DLF = 43.2 1.3 = 56.2 kips.
L
s
< 81.3 ft, R
s1
= (56.2 /81.3) = 0.691 kip/ft (load per foot of pipe length). For example,
for L
s
= 50 ft, R = R
s1
L
s
= 0.691 50 = 34.6 kip.
Pressure wave traveling frequency f = a/(4L) = 1 Hz.
Given that the minimum tensile strength of typical power-piping ASTM A106
steels is at least 48 ksi (yield stress about 30 ksi), it appears this pipe would handle
water-hammer loads.
RS# 150
p
g
, for t
g
t
r
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FLUID POWER
tion of the air. An unusually low static head at the bottom of a vertical pipe may
indicate an entrapped air column. When fluid flows, air is pushed up and down
in elevation, and pressure at particular locations fluctuates and disturbs flow and
jolts the pipes. The compressed, entrapped air expands as it approaches the exit
to atmosphere and thrusts the water slug in front at high speed. The air and water
with a huge density disparity alternately exit the pipe and the reactive momentum
AV
2
changes abruptly to jolt the pipe and shake the entire line.
Because filling operations are infrequent and can be planned, it is more cost
effective to give sufficient
time to fill or discharge the
line slowly to alleviate the
impact of air entrapment,
rather than fortify the
supports. Long and large
pipes like penstock use
a bypass valve to slowly
fill the line and evacuate
air through an air-release
valve at the highest eleva-
tion. The air-release valve
stays open when dry and
shuts while flooded. Shut-
off force come from the
buoyancy of a bulky hol-
low disk.
An engineers prior-
ity for handling water
hammer is to remove the
sources or minimize the
effects. Slowing valves and
avoiding air entrapment
can eliminate many head-
aches. But when quick
valve action is mandatory
and water hammer is in-
evitable, piping systems
must be designed to ac-
commodate the loads. MD
Nomenclature
A = Pipe flow area, in.
2
a = Acoustic velocity, fps
d
i
= Internal diameter of pipe, in.
E = Modulus of elasticity, psi
F(t), F(t), F
s
(t) = Fluid force on gate, incremental,
on pipe section, lb
f
f
n
= System natural frequency of vibration, sec
-1
g
c
= Mass-gravitational constant, (32.2 fps
2
)(lb/lb
f
)
h = Wall thickness of shell, in.
I = Moment of inertia of area, in.
4
k = Specific heat ratio (c
p
/c
v
)
L, L
s
, L
cr
= Length; general, pipe section, critical, ft
p, p
o
, p
cr
= Pressure; general, initial, critical, psi
p = Pressure surge from valve closing, psi
q
cr
= Critical buckling pressure of circular ring per
unit length of center line, lb
f
/in.
r = Internal radius of shell or pipe, in.
S
f
= Safety factor for pressure-surge calculation
S
hp
= Hoop stress of shell, psi
T = 1/f
n
natural period of vibration, sec
t
g
= Effective gate closing time, sec
t
r
= Pressure wave round trip time (t
r
= 2L/a), sec
V, V
o
= Flow velocity; general, initial, fps
W = Flow rate, lb/sec
v = Specific volume, ft
3
/lb
= Poissons ratio
= Mass density, lb/in.
3
= Characteristic time of pulse, sec
Efect of gate-closing time
Fast-closing gate: t
g
t
r
, p
g
= p
max
p
max p
g
t
r
= 2L/a
t
g
t
r
Time
Slow-closing gate: t
g
> t
r
, p
g
= p
max
(t
r
/t
g
)
p
max
p
g
t
r
t
g
Time
Slowing the valve-closing time reduces the effects of water hammer.
RS# 151
FEBRUARY 14, 2013
RS# 152
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RS# 153
INSTRUMENTATION
Authored by:
Jim Schwartz
National Instruments Corp.
Austin, Tex.
Edited by Leland Teschler
leland.teschler@penton.com
Key points:
Consider the complete system before testing begins.
Account for hardware, software, data storage and
processing, and the testing environment when
developing a test system.
ITM, www.un-yah.com/
More on this case study,
http://www.ni.com/cranetest/
National Instruments Inc., www.ni.com
Tips for
large
machinery
test
systems
Choice of strain gage
Strain gages have nearly
unlimited variations based
on qualities such as size,
sensitivity, material-temperature
coefficients, temperature ranges,
and measurement axis. Pay
attention to the strain-gage
properties and the material
it mounts on. Here, 32 strain
gages mount to each lattice
section along the entire length
of the boom, according to the
methods described in SAE J987.
Measurements of buckling
stresses in the crane boom
lattices came from single-axis
350- strain gages used in a
quarter-bridge configuration. In
total, ITM used 144 strain gages
along the length of the boom.
Lead-wire resistance and
shunt calibration
A strain measurement is
essentially a resistance
measurement, so lead-wire
resistance can cause offsets.
Quarter-bridge measurements
are inherently sensitive to the
resistance of wiring between
the sensor and measurement
device. So long wire runs on
off-highway equipment are a
problem. A method called shunt
calibration can quantify the lead-
wire resistance and nullify this
effect, either in software as data
is acquired or in postprocessing.
What to look out for when
sensors get widely dispersed
over big machines.
With data-acquisition projects, the costs of delays are
often high. Thats particularly true for heavy machinery
like cranes, mining shovels, and excavators. Examples
come from obstacles commonly faced by engineers mea-
suring strain along the length of a 300-ft crane boom
made by Manitowoc Cranes, Manitowoc, Wis. Mark
Yeager and Tim Carlier, test engineers for Integrated
Test and Measurement (ITM), Milford, Ohio, a service
provider (employed by Manitowoc Cranes) specializing
in challenging test applications, took these measure-
ments over several weeks. MD
FEBRUARY 14, 2013 MACHINE DESIGN.com 64
Visualizing test data
When testing large cranes under potentially dangerous
loading conditions, the ability to visualize and
interpret the data in real time can prevent failures and
make things less risky for personnel. This application
employed a structural test environment called
iTestSystem from ITM that included capabilities to
process the data during acquisition.
Data storage and postprocessing
Test systems for compliance with safety standards
must output data in a standard file format. Because
ITM collected data in a standard file format, Manitowoc
engineers could analyze data and verify test results
using existing in-house software.
Electromagnetic
interference
Noise sources like TV and
radio stations can affect
measurements, necessitating
data filters to ensure
accuracy. For example,
the NI CompactDAQ data-
acquisition platform from
National Instruments
includes integrated signal
conditioning such as filtering,
amplification, and excitation.
Quarter-bridge
measurements
Instrumentation options
are limitless. You need to
chose hardware that can be
optimized for the application.
ITM engineers used NI
CSeries modules with the
NI CompactDAQ platform.
Each module includes
built-in bridge completion,
excitation, amplification, and
filtering required for making
quarter-bridge strain-gage
measurements.
Shielding from the elements
Most large equipment wont fit in a test lab. Its
usually exposed to the elements. Each piece of
instrumentation should sit in rugged, sealed
enclosures. In ITMs case, NEMA-4X enclosures
protected instruments.
Safety standards
Engineers at ITM had to pay close attention to
SAE J987, which outlines the methods for testing
static loads on a lattice-boom crane. This let them
supply Manitowoc with the test results to show
compliance. SAE J987 dictates this particular test,
but nearly every large piece of machinery has
certain standards and codes.
Instrumentation and documentation
The safety standard usually includes the required
instrumentation accuracy, calibration procedures,
and documentation steps for the final report. But
different manufacturers may have more detailed
or stringent requirements. Failure to understand
them can cost hours of test time.
FEBRUARY 14, 2013 MACHINE DESIGN.com 65
FASTENING/JOINING
Inserts like this let engineers use
screws to attach components to
plastic parts. Manufacturers can use
heat or ultrasonics to install inserts
in thermoplastics, and each has its
advantages and disadvantages.
Authored by:
Christopher G. Jeznach
Application Engineer
Spirol International Corp.
Danielson, Conn.
Edited by Stephen J. Mraz
stephen.mraz@penton.com
Resources:
Spirol International Corp.,
www.spirol.com
method. Engineers should
consider the advantages and
disadvantages of both meth-
ods before purchasing instal-
lation equipment or finaliz-
ing manufacturing plans.
Ultrasonic installation
During ultrasonic installa-
tion, a relatively small down-
ward force, typically gener-
ated by a pneumatic cylinder,
presses the insert into a pre-
drilled or molded hole while
an ultrasonic horn converts
electric power into high-frequency vibrations. Those vibra-
tions get delivered to the insert-plastic interface through
direct contact with the insert. The vibrations generate
enough heat to melt the plastic around the insert. Equip-
ment needed for ultrasonic installation includes an elec-
tronic power supply, cycle controlling timers, an electrical
or mechanical energy transducer, and an ultrasonic horn.
Here are some of the advantages of ultrasonic
installation:
It is generally fast for inserts under 0.250-in. OD,
leading to short cycle times. These times increase with
insert size.
The machines can be changed to accommodate dif-
ferent sized and shaped inserts.
Ultrasonic-installation machines can also be used for
plastic-to-plastic welding and other processes.
There are two primary
ways of putting
threaded inserts into
thermoplastics. Here are
the pros and cons of each.
Plastic parts and assemblies are becoming
more common as engineers work to reduce
costs and weight in their designs. But plas-
tics often arent strong enough to support fas-
teners such as screws or bolts. Using screws to
attach parts to plastic housings, for example,
often ends with stripped threads, failed hous-
ings, and assemblies that fall apart.
To get around this limitation, engineers first
install threaded metal inserts into plastic parts.
They give screws and bolts stronger metal
threads to mate with, letting plastic parts be
easily assembled, taken apart, and repeatedly
reassembled.
Two of the most common methods for in-
stalling inserts into thermoplastic parts are heat
and ultrasonics. (Thermoplastics can be remelted a num-
ber of times. Thermosets, on the other hand, have a one-
time reaction and cannot be remelted, making them un-
suitable for heat or ultrasonics.)
Insert basics
With both heat and ultrasonic installation, remelted
plastic firmly holds inserts in molded or drilled holes by
conforming tightly to the knurls, barbs, and undercuts
around the outside of the inserts. But the installation pro-
cess must create enough remelted plastic to entirely fill
these external patterns to get maximum performance,
including pullout and torque resistance, when the plastic
solidifies.
Both heat and ultrasonic installation depend on melting
the plastic around the inserts, but results can vary with each
Putting inserts in plastic parts:
ULTRASONIC
or
HEAT?
FEBRUARY 14, 2013 MACHINE DESIGN.com 66
RS# 155
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RS# 156
RS# 157
FASTENING/JOINING
Inserts can be installed using an
ultrasonic machine (left) or a heat
machine (right). Each melts plastic
around the insert, where it can
solidify and keep the insert in place.
When the plastic is properly heated, either by direct heat or ultrasonics,
it flows in and around the patterned features on the insert (left). When
the insert is not heated, the plastic does not flow around the patterned
knurls (right), which means the insert will not be as firmly seated in the
plastic and could fail under load.
Now heres a look at the downside of
ultrasonic installation:
Insufficient melt, or not enough plastic
being melted, can result in inserts being
reamed into solid plastic. This so-called
cold pressing can damage inserts and
the plastic parts. Cold pressing can be
caused by several factors. For example,
bad fixturing/clamping of the plastic
part can dissipate vibrations, pre-
venting enough heat from being gener-
ated around the insert. Slight size varia-
tions of inserts or holes can also lead to
cold pressing. And if inserts are driven
too quickly, the plastic does not have
time to fully melt, creating high stresses
and poor retention in the plastic. This
can lead to part failure during installa-
tion or, even worse, in the field.
Although sophisticated controls can
prevent cold pressing, the cost of such
controls nearly doubles the price of an al-
ready expensive ultrasonic installation
machine.
Here are some of the other downsides
of ultrasonic installation:
Ultrasonic vibrations can chip metal
particulates and flakes off of
inserts. These flakes could
prevent t he i ns er t f rom
seating properly, thus weak-
ening the plastic-to-insert
connection. The flakes are
also unsightly.
Ul t r as oni c i ns t a l l at i on
machines are loud due to
the metal-on-metal contact
between the insert and ultra-
sonic horn. And the bigger
the insert, the louder the
noise.
It is difficult and costly, if not
impossible, to install mul-
tiple inserts simultaneously,
depending on the design.
Using the wrong vibrational
frequencies or downward
force damages inserts.
Extra caution needs to be
taken when using non-
headed inserts to ensure
proper contact is made
between insert and the horn.
Otherwise, it is likely that
the inserts internal threads
will be damaged.
Ultrasonic horns are expen-
sive. They are also subject
to wear and often need to be replaced. It is
common for them cost over $1,000.
Heat installation
Machines that rely on heat to install inserts
use one of two approaches. In some, a metal
tip transfers heat to the insert. In the others, in-
serts are preheated and pneumatically pressed
into predrilled holes in the plastic. In both ap-
proaches, inserts are pushed into the plastic
by a controlled force, usually less than 50 lb.
Heat installation also requires the entire in-
sert be heated, not just the metal-plastic inter-
face. So for proper installation, inserts should
have enough thermal conductivity so that plas-
tic around the insert quickly heats and melts.
Thats why two of the most common insert
materials are brass and aluminum. Once the
plastic melts, it fills the inserts retention
features, then solidifies while inducing
minimal stresses.
Good thermal conductivity also lets
inserts cool quickly after installation.
Here are some of the advantages of heat
installation
Reliability and consistency. Lower instal-
lation forces let inserts be installed into
thin-walled parts which would be destroyed
by ultrasonic equipment. With stable and
FEBRUARY 14, 2013 MACHINE DESIGN.com 68
Gearing
lntegrated Brake
17 Bit Absolute Encoder
H|ghTorqueDens|ty
1 arc-min Accuracy
5 arc-sec Repeatability
High Capacity Output
Bearing
ThenewSHAser|esofHo||owShaftActuatorshastheh|ghesttorque
dens|tyofanyactuator|n|tsc|ass,yetprov|desexce||entpos|t|on|ng
accuracy. Several sizes are available with output torques up to 30,000
in-lb. These actuators are ideally suited for robotics, automation,
machine tool, and antenna positioning applications where performance
and reliability are essential.
RS# 173
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an initial implementation phase at
Amsterdam Airport Schiphol is now
underway. At existing installations,
baggage jams and blockages on
conveyor belts have been reduced by
40% and lost luggage instances have
been signifcantly minimized. MD
explains Naber. Line rates up to
4,000 Hz require 125-sec control
cycles so the camera is linked
with the PC via 1-Gbit Ethernet.
Other PLC and soft PLC systems
fail to deliver suffciently short
cycle times, but Beckhoffs Ether-
CAT feldbus components combined
with TwinCAT NC PTP software do
the job with fast and accurate data
communication.
The Panel PC also delivers on
data capacity, integrating controls
with an SQL database that stores all
scanned-luggage image data. The
information is used to evaluate Bag-
check decisions against jam occur-
rences, allowing adaptive learning
to improve future sorting decisions.
Items missing their labels can also
be identifed: Here, Bagcheck
matches scanned luggage images
with those of the untagged item to
trace the luggage to its owner.
Finally, Bagcheck software al-
lows virtual separation of luggage
that is stacked or snagged together.
In traditional systems, stacked
luggage often causes conveyors to
stop or, even worse for travelers,
mistakenly direct both bags to the
same aircraft.
Five Bagchecks are in use at
London Heathrow Airport with
additional systems on order, and
technical director. Luggage unsuit-
able for the standard conveyor can
then be fltered out within 1 or 2sec.
The camera scans passing lug-
gage at 4,000 1-mm contours/sec. A
CP6502 Panel PC with a 19-in. TFT
display from Beckhoff Automation,
Burnsville, Minn., leverages feed-
back from high-resolution encoders
to synchronize the camera, lighting,
and conveyor belts.
The design relies on high-
resolution images, so the line-scan
cameras and LED lights must be
synchronized very accurately with
the conveyor velocity and position,
A new luggage-scanning system
called Bagcheck employs a Beckhoff
Panel PC to reliably sort bags to the
correct destinations. The control
panel shown here indicates which
luggage items can pass through
normal transport routes and which
items have problematic shapes or
features.
The Bagcheck camera scans passing
luggage at 4,000 contours/sec to
generate 3D bag images. Unusually
shaped luggage is then separated
from the main luggage stream
reducing jams by 40%.
Resources:
For more information, visit type22.aero,
vanderlande.com, and beckhoff.com.
RS# 175
FEBRUARY 14, 2013 MACHINE DESIGN.com 81
Actuatorline has all the
precision you need and
wont keep you waiting
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MOTIONCONTROL TECHNOLOGY GUIDE
This collapsible sound barrier is
easily moved and transported to
reduce sound levels from noisy
machinery.
Nonmetallic
roll-up covers
can contain
corrosive fumes
while allowing
tank access.
guideways located in a pit below foor level. Production workers must access
workpieces as theyre produced, necessitating pit covers during production,
yet also requiring a way to remove the covers for repairs and adjustments.
Grating is time consuming to move, and slats require complex support struc-
tures that complicate maintenance tasks.
Instead, the aircraft manufacturer uses rugged walk-on metal pit covers
with extruded aluminum stiffening ribs bonded to stainless-steel sheets; there
are no hinges to collect debris. These roll up onto steel rollers equipped with
take-up mechanisms.
Roll-up covers can also be used to enclose chemical tanks and other vessels
to contain fumes or prevent injury. These covers are not designed to support
the weight of workers, so they are made of lighter materials such as polypro-
pylene to withstand corrosive fumes. Wiper strips can keep the cover under
tension and remove debris before retraction; electric motors and gear drives
are employed in the take-up mechanisms.
Protecting against welding ash and spatter
Portable screens protect workers eyesight against welding fash and UV
radiation, and confne weld spatter. Basic weld curtains on stands can be
moved around the factory foor to provide shielding where needed. Freestand-
ing curtain modules simplify work-cell assembly.
Motorized weld curtains take it a step further in custom-engineered frames
suitable for robotic-welding areas and
automated equipment. Some incor-
porate gearless direct-drive motors
that can be programmed to open to
various widths at speeds to 2 m/sec.
Reducing equipment
noise levels
The noise levels of some equip-
ment, such as that on construction
sites, are diffcult to reduce. Howev-
er, portable sound barriers can be set
up to suppress sound. Some designs
retract into compact wheeled cases
for easy transport. Unlike traditional
sound curtains consisting of basic
frame-mounted material, these use
multilayer materials incorporated
into a pleated accordion design that
Continued from page 78
Continued on page 84
RS# 176
FEBRUARY 14, 2013 MACHINE DESIGN.com 82
RS# 177
Standard and Custom Clutch, Brake
& Power Transmission Solutions
291 Boston Turnpike Bolton, CT 06043
Phone: 860-643-1531
Reliability
inaClutch
...a clutch, brake or power
transmission part for that
matter. Since 1903 Carlyle
Johnson has solved some of
historys toughest motion
control challenges its what
we love to do. Our precision
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hydraulic power transmission
products consistently prove
reliable and dependable in
every application. Underwater,
on the ground and in the air,
CJM is everywhere.
www.cjmco.com
MOTIONCONTROL TECHNOLOGY GUIDE
2013 FIRST Robotics
Competition now underway
Last month, inventor Dean Kamen commenced the 2013 FIRST
Robotics Competition (FRC) season with the kickoff of a new game
called Ultimate Ascent. Nearly 51,000 high-school students in 81
cities around the world joined the 2013 kickoff event via live NASA-TV
broadcast and Webcast.
There is no stimulus package that will have as much return as stimulating
a bunch of kids to become the workforce of the future, the problem solvers, the
creators of the future, says Kamen.
The 2013 game will be played between two alliances of three teams each.
Each alliance competes by trying to score as many fying discs into their
goals as possible during a short match. Discs scored in higher goals score
more points. The match ends with student-designed robots trying to climb up
pyramids located near the middle of the feld. FRC teams receive a parts kit
of motors, batteries, a
control system, PC, and
a mix of automation
components with no
instructions. Working
with mentors, students
have six weeks to
design, build, program,
and test their robots
to meet the seasons
engineering challenge.
Teams then participate
in regional and dis-
trict competitions. For
more information, visit
usfrst.org. MD
increases sound mitigation and simplifes setup. For excessively hot operations,
screens can also double as heat shields when suitable materials are used.
Other equipment may be muffed directly with specially designed jacketing.
Pavement breakers, commonly called jackhammers, produce 120 to 125-dB
sound levels at the ear of the operator and approximately 90 dB at a distance
of 50 ft. A light jacket reduces these levels by around 9 dB, which cuts the
breakers perceived loudness by half. The jacketing can reduce sound intensi-
ty, which leads to hearing loss, by 88% because most of the noise is produced
by the breakers internal components.
The 2-lb jacket, made of three layers of material sewn together, is wrapped
around the breaker and fastened with industrial Velcro. It covers the lower
housing from just below the handle bar and encloses the opening at the bottom
that allows the tool bit to travel. A suspender strap over the handlebar keeps it
from blowing off due to air pressure.
In addition to reducing noise levels, the jacket protects the worker from
the exhaust air of these pneumatic units and the oil that often spews onto the
workers legs. Finally, refective strips make it visible at night for improved
operator safety. MD
Continued from page 82
RS# 178
FEBRUARY 14, 2013 MACHINE DESIGN.com 84
FABCO-AIR www.fabco-air.com phone 1-352-373-3578
Multi-Power
Air Cylinders
Ho w t o ge t hyd r au l i c c yl i nder f or c e s f r om c ompr e s s ed a i r
Multi-Power
Air Cylinders
w w w. f a b c o - a i r . c o m
. . . deliver forces equivalent
to low pressure hydraulics
using only shop air pressure.
Forces from under a hundred
pounds to over 22 tons !
. . . are easy to install having
only two port connections and
a variety of mounting styles.
. . . cost far less and are
cleaner than hydraulics.
. . . conserve energy by using
only one piston for retract stroke.
. . . produce forces up to four
times that of a conventional,
single piston air cylinder.
Get orders lled in 2 days
5 body styles.
Bores 1/2 to 12.
Strokes 1/8 to 12.
Fabco-Air attaches multiple pistons
to a common shaft and provides
internal air passages through the
shaft to all pistons.
Supply air applied to the extend
port energizes all pistons simul-
taneously enabling tremendous
thrusts to be obtained.
What these cylinders do How they work
Specifications:
4" bore x 5" stroke, Magnetic Piston, Shock and Speed Control.
High force in a small footprint
for an automotive application
Multi-Power
option enables
precision adjustment of the extend stroke.
Specials like this amount to almost half of our business.
We can design, prototype and deliver custom samples
within 72 hours! FABCO-AIR solves problems. Let us help !
Cutaway view of a 4-piston model in extend mode
2-piston Multi-Power
cylinder with clevis mount
Retract port
Extend port
Air vent slot in
bafe plate
Male rod
extension
Air
Vent
Air
Vent
Air
Vent
Exhaust
from
Retract Port
RS# 179
MOTIONCONTROL TECHNOLOGY GUIDE
Headlines in Motion
NEW BOOK FOR YOUNG
AUTOMATION PROFESSIONALS
A new book from the International
Society of Automation (ISA) is designed
to help the next generation of automation
engineers steer clear of common career
obstacles. 101 Tips for a Successful
Automation Career by Gregory K.
McMillan and P. Hunter Vegas offers
guidance on technical issues as well as
interpersonal and workplace situations.
ISO STANDARDS ON ELEVATOR
AND ESCALATOR COMFORT
An updated ISO standard aims to
improve passenger experience when
using elevators, escalators, and moving
walkways. The new standard aims to
determine ride quality by specifying the
defnition, measurement, processing,
and expression of vibration and noise
signals that affect user experience.
NIST EXPERIMENTS CHALLENGE
THEORY OF ELECTROMAGNETISM
A cornerstone of physics may
require some revision if fndings at the
National Institute of Standards and
Technology (NIST) are confrmed.
Recent experiments suggest that the
current theory of electromagnetism
one of the four fundamental forces in the
universe may not accurately account
for the behavior of atoms in exotic, highly
charged states. MD
Precision geared products market decelerates
According to a new report from IMS Research, Aus-
tin, shipments of precision geared products (gearboxes
and geared motors with backlash ratings of less than
20arc-min) were nearly 80% higher in 2012 compared
to 2009. However, uncertainty about the Eurozone econ-
omy and Chinas slower economic growth are leading
factors in the more than 1% decline expected for pre-
cision geared product shipments in 2013. Nevertheless,
this markets value is projected to reach nearly $1.7bil-
lion with more than 1.8million units shipped in 2013.
Precision gearbox shipments, which accounted for
more than 95% of the precision geared products mar-
ket in 2012, increased by more
than 70% from 2009 levels due to
pent-up demand for servo-driven
machinery and increased access to
capital. The new report, The World
Market for Precision Gearboxes
and Geared Motors, indicates
shipments will exceed 2 million
units by 2016 despite decelerat-
ing growth. For more information,
visit imsresearch.com. MD
FEBRUARY 14, 2013 MACHINE DESIGN.com 86
SAFFiR (Shipboard Autonomous FireFighting Robotj
- Dr. Dennis Hong, Professor of Mechanical Engineering and Director
of RoMeLa (Robots & Mechanisms Laboratoryj at virginia Tech
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KLJKWRUTXHDFWXDWRUV7KHRQO\
VROXWLRQLVPD[RQq
What drives Dr. Dennis Hong is
his quest to create truly humanoid
robots that can do useful work.
What drives his robots are maxon
motors and controllers. Where
precision, consistency, and easy
integration are critical, maxon pro-
vides the intelligent drive systems
to bring tomorrow's designs to life.
Learn how we can help you keep
your projects moving. visit us at
maxonmotorusa.com.
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Cross-referenced to metal
cam followers for
easy replacement
OnOyourpatentpendingiCamFoOOowers
offeraOOtheseadvantages:pOastictireeOimi-
natesraiOwear;noOubricationisrequiredin
thebearingorontheraiO;reducenoiseup
to10dB;absorbshocNandvibration;high
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(-40F).ForOoadratingsandsizesgoto
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IntechCorp.,250HerbertAve.,COoster,N-
07624.(201)767-8066;Fax:(201)767-7797.
www.intechpower.com
RS# 251
RS# 260
RS# 263
RS# 254
RS# 259
RS# 262
Free design guide
to servo-hydraulic
motion control
www.deltamotion.com
Popular, practical 64-page guide
with 16 topics by Peter Nachtwey:
s#LOSEDLOOP#ONTROL
s3IZING#YLINDERSAND6ALVES
s3ELECTING!CCUMULATORS
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s4UNINGFOR/PTIMAL0ERFORMANCE
Fabco-Air.com
Gainesville, Florida
Air Table Slides
Dual pistons double thrust.
Repeatable workpiece
mounting via dowel hole &
slot on table surface.
Magnetic pistons are
standard. 3 ways to mount
body. Bores 8 to 25mm
Strokes 10 to 150mm
DATA FILE LITERATURE ADVERTISING
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Access our Reader Service
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RS# 257
RS# 264
RS# 253
belts are
manufactured to our customers specifications
and are of the highest quality with exceptional
abrasion resistance and durability.
Pyramid Inc.
522 N. 9th Ave. E. Newton, IA 50208
Phone: 641-792-2405 Fax: 641-792-2478
E-mail: sales@pyramidbelts.com
Website: www.pyramidbelts.com
RS# 270
RS# 267
Nomex
is a calendered, aramid
insulation paper that, when wound
into an insulating tube with appro-
priate binders, offers superior high
temperature resistance and high
dielectric strength in insulating
tubing and bobbins Nomex also
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Precision Paper Tube Co., Inc
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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-
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Specials manufactured with
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Trim-Lok Inc., Buena Park, CA
Vinyl & Rubber Extrusions
Trim-Lok Inc. releases a brand new
FREE Catalog 500 featuring How
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FREE samples may be requested.
Latest additions include our Flap
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- Stepping Motors
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- Linear & Rotary Actuators
- Cooling Fans
RS# 274 RS# 273
RS# 276 RS# 275
RS# 265
RS# 268
users can
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From tutorials
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At
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visit us at
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FEBRUARY 14, 2013 MACHINE DESIGN.com 99
ME C H A N I C A L S L I P C L U T C H E S
BACKTALK
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energy when designing four self-propelled devices that
would collectively compete in a relay race. Each device
had to contain an onboard energy source to trigger the
subsequent device.
For the 2013 competition, the challenge is to design a
Remote Inspection Device. Following the tragedy at the
Fukushima nuclear facility after the Tohoku earthquake
and tsunami in March 2011, the nuclear industry issued a
Request for Proposal to design and build a small, remotely
controlled inspection vehicle that could determine the
level of radioactivity at specified locations and inspect for
damage, protecting humans from absorbing high doses
of radioactive contamination. Participants must design a
vehicle to negotiate around obstacles, both in getting to
the inspection points and bringing the sensor to the desig-
nated return area. MD
RS# 196
FEBRUARY 14, 2013 MACHINE DESIGN.com 104
The First Name in
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