Design Apliance

July 2012
REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE
INSIDE
12 Gas Technology 15 Motors & Blowers 18 Joining 22 Heating Technology
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R R FO R FO ER FE G SF NG S IIN AN AN GN R GN R S T SII T T T DE A DE A HE HE
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INTRODUCING
UL ADVANTAGE
UL AdvantageSM is a revolutionary certication program for small appliances that provides speed, exibility and a streamlined process to get your products to market faster. The uncompromising expertise and scientic excellence you expect from UL meets the agility you need to succeed in todays market. To learn more, visit ul.com/advantage or call 1-877-UL HELPS (877-854-3577)
UL and the UL logo are trademarks of UL LLC 2012
bring ideas to life

Springboard Engineering, a UL company, specializes in providing full-service development services. The staff has a rich heritage in advancing products from concept to production for companies ranging from small to Fortune 500 suite.
Advisory Services
Mechanical Engineering
Best in class design methods involving Six Sigma, lean manufacturing, global project management and CAD modeling for manufacturing services.
Electrical Engineering
verications designed around customized test programs that produce the results customers want for a highly reliable product. Springboard Engineerings labs are ISO 17025 accredited and can provide DOE testing and EPA submission of energy results. An experienced staff of consumer scientists can conduct consumer product performance testing for bench marking and third party claim validations. Other methods include accelerated life testing, predictability and forecasting of product performance, systems/subsystems components testing, and environmental endurance reviews along UL certication and listing guidelines. Prototyping Services Prototyping and injection molding capabilities support the extensive performance and reliability testing by providing real components and product systems for user experience and validation. Springboard Engineering is positioned to be your partner, to be your one source for ensuring performance and reliability of your product programs.
Exceptional design practices in multiple disciplines around appliances, relating to embedded software engineering, immunity analysis and mitigation, electronic simulation and modeling supported by state machine logic with source code management under the CMM level 2 certication, which ensures a quality development program. Springboard Engineering can also provide advisory assistance with the implementation, conformity, security and interoperability of Smart Grid capable appliances and meters. Testing Services Performance and reliability testing at Springboard Engineering are the keystones to successful product launches, as our laboratories ensure customer centric testing that utilizes statistical process control and analysis, for product usability, competitive bench marking and efciency
For more information, were easy to reach: T: +1.641.787.8700 | E: sbe@ul.com | W: springboardengineering.com
a UL company
2012. Springboard Engineering 06/12 BDI 20606
CONTENTS JULY 2012

volume 60, no. 7
REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE
12
DEPARTMENTS
4 Editorial: See Me, Feel Me, Touch Me, Hear Me 6 Shipments/Forecasts 8 News Watch
15
25 Design Marts 30 New Products 32 Association Report: AHAM 33 Advertisers Index
FEATURES
GAS TECHNOLOGY
12 Selecting Heavy Duty Transducers for Harsh Environments: By using an in-depth checklist to select heavy duty pressure transducers, designers can make rapid and sound decisions based on true and verifiable data. By Ketan Mehta of Honeywell
22
MOTORS
15 Linear Encoders for Linear Motors: Knowing the exact position of the slide is the key to applying linear motors. New measuring devices aim to improve that accuracy. By Johannes Heidenhain
appliance DESIGN ONLINE

WEB EXTRAS
Thermostatic Expansion Valves in the City In 2007, the city of New York, at the direction of Mayor Michael Bloomberg, undertook PlaNYC, an impressive effort to prepare the city for one million more residents, strengthen its economy, combat climate change and enhance the quality of life for all New Yorkers. The Plan brought together more than 25 city agencies to work toward the vision of a greener, greater New York.
WEB EXTRAS
JOINING
18 New Materials, Lower Costs: The things that bind us all together have had a profound impact on the things that bind our things together. By Bob Reisel of Richco
BLOGS
Pauls European Perspective: IFA Global Press Conference 2012 Dubrovnik As IFA is originally a consumer electronics event, the white goods sector joined in five years ago, after the demise of the traditional trade-only fairs in Cologne and Paris. The combination has turned out to be a success, also because the white goods makers changed their stands to consumers taste, which roughly means more live cooking and more espresso bars.
HEATING TECHNOLOGY
22 Designing for Efficient Heat Transfer: A step-by-step procedure for optimizing the use of smaller diameter tubes in eco-friendly air conditioning designs. By Wenson Zheng and Nigel Cotton of the International Copper Association.
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COVER
Fin efficiency is determined by the pitch ratio, the longitudinal tube pitch, the transverse tube pitch, fin spacing and fin patterns as seen here. Computational fluid dynamics allow for the optimization of these features to the tube size and air flow rates.
2 applianceDESIGN July 2012
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EDITORIAL
See Me, Feel Me, Touch Me, Hear Me
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ci-fi fans of the 20th century had no problem imagining us poking at or sliding our fingers across solid surfaces, or talking to our devices and expecting them to do as told. More recent glimpses into the futurethink Iron Manhave predicted heavy use of gesture recognition, allowing our hands to manipulate 3D projections as if they were solid. When we compare science fiction interfaces with reality, no matter the technology, the road bumps become all too familiar: too much power consumed, inaccurate communications, false positives, accidental initiationsetagainst humanitys remarkable impatience at not being understood.
ten about as well as a 2-year-old. Gesture recognition, meanwhile, is now making its way into mainstream devices. GAZING AT YOU One of those companies, Omron, has put its focus on the face, with image sensing technology that can recognize users much the same way we recognize each other. From there it will find the moving parts and track meanings from mouth and eye movements. Their gesture recognition similarly focuses on universal and simple signs such as pointing (cursor), hand waving (trigger), finger twirling (page-turning), and flashing a peace sign (activate function). Thats cool on a show floor, but pragmatically gesture recognition has yet to replace anything. For the foreseeable future, gesture recognition instead seems to be finding its way to consumers as a complimentary interface. Samsung last month posted videos of various Web personalities showing off their interface-rich system introduced at CES. The remote has a microphone for voice commands, the screen hides a hand wave-activated gesture recognition system, and if you have a Samsung smartphone itll work with that too. Multiple interfaces, though conceptually onerous and redundant, are in fact exactly the way human beings are made to communicate our desires.
publishing staff
Darrell Dal Pozzo Group Publisher Seth Fisher Editor-in-Chief Daryl Delano Economics Editor Paul Roggema Kevin Henry New Media Contributors Jeff Bagwell Production Manager MaTT Britcher Art Director (847) 405-4044 dalpozzod@bnpmedia.com (248) 244-6248 fishers@bnpmedia.com (508) 746-7986 dhdelano@comcast.net
blogs@appliancedesign.com (248) 244-6481 bagwellj@bnpmedia.com (480) 334-0286 britcherm@bnpmedia.com
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Hayat Ali-Ghoneim Audience Development Specialist Alison Illes Multimedia Specialist Catherine M. Ronan Corporate Audience Audit Manager Kevin Collopy Sr. Account Manager Shawn Miller Account Manager Ann Kalb Single Copy Sales (248) 250-3096 Alih@bnpmedia (248) 244-1730 Illesa@bnpmedia.com (248) 244-8259 ronanc@bnpmedia.com (800) 223-2194 x684 kevin.collopy@infogroup.com (845) 731-3828 shawn.miller@infogroup.com (248) 244-6499 kalbr@bnpmedia.com
RIGHT BEHIND YOU, I SEE THE MILLIONS Another overlying problem for interface developers comes down to the fairly extraordinary differences between those of us doing the interfacing. Voice recognition, for example, needs to learn about 400 major languages (6,500 total) to capture most of the world market, and a million different dialects. Design for more than Tony Stark and youve exponentially increased the complexity of recognizing an input. Against such competition, the buttons binary simplicity will never die; it remains the go-to trigger for any binary function. On the other hand the same complexity that baffles advanced interfacing systems is exactly what allows humans to communicate with each other at a level of similar complexity. This is why developers are pushing so hard to free humanitys fingertips. Voice controls are into the post-release tinkering stage after consumers voiced frustration with devices that lis-
marketing
Adam Thomas Events Marketing Assistant (248) 244-6249 thomasa@bnpmedia.com
Introducing the new 2012-2013 editorial advisory board:

Joe McGuire, AHAM Andreas Schuessler, BSH Bosch and Siemens Richard Watson, Essential-Design Alberto Uggetti, UL Lighting Francis Dietz, AHRI Jill Notini, AHAM Bill Romick, DNA Group Pat Blanc, Lydall
Seth M. Fisher, Editor-in-Chief fishers@bnpmedia.com Twitter: @aplncdsgn
Bob Brown, Branson Ultrasonics Derek Silva, Intertek John Davis, Traulsen Tom Lipinksi, Henkel
| HVAC | Majors | Water Processing | Housewares | Commercial Appliances | Vending | Medical | Lab | | Test & Measurement | Lawn & Garden | Electronics | Computers | Communications | Business Equipment |
APPLIANCE DESIGN (ISSN 1552-5938) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $220.00 USD (includes GST & postage); all other countries: $233.00 (intl mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2012, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: APPLIANCE DESIGN, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to APPLIANCE DESIGN, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or KalbR@bnpmedia.com.
volume 60, no. 7

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MicroGroove technology is changing the game of air conditioning and refrigeration (ACR) OEM product design. OEMs are going back to their drawing boards. They are designing ACR products with high energyefciency, while minimizing materials usage and reducing refrigerant volume. The resulting ACR products are smaller and lighter yet can be produced using familiar manufacturing methods. Its a whole new game!
Gustav Lorentzen Conference June 2527, Delft, Netherlands Purdue Conferences July 1619, West Lafayette, Indiana For more information, visit www.microgroove.net/events
SHIPMENTS
Product
Total COOKING-TOTAL ELECTRIC COOKING - TOTAL Electric Ranges Electric Ovens Surface Cooking Units GAS COOKING - TOTAL Gas Ranges Gas Ovens Surface Cooking Units MICROWAVE OVENS HOME LAUNDRY - TOTAL AUTOMATIC WASHERS DRYERS - TOTAL Electric Gas KITCHEN CLEAN UP - TOTAL DISPOSERS DISHWASHERS - TOTAL Built-In Portable COMPACTORS FOOD PRESERVATION - TOTAL REFRIGERATORS 6.5 & OVER FREEZERS - TOTAL Chest Upright HOME COMFORT - TOTAL ROOM AIR CONDITIONERS DEHUMIDIFIERS
FORECASTS
May-12
5,283.30 1,327.80 352.2 278 51.3 22.9 191.5 165.1 2.1 24.4 784 1,093.90 607.8 486.1 391.8 94.3 929.7 474.6 452.4 448.8 3.5 2.7 894.7 748.4 146.3 94 52.2 1,037.30 944.9 92.4
May-11
5,222.60 1,223.50 314.7 250.7 38.5 25.5 191.3 167.6 2 21.7 717.5 1,107.10 611.4 495.7 400.4 95.3 833.7 412.7 418 412.7 5.3 2.9 928.5 781.9 146.6 82.7 63.9 1,129.90 978.7 151.1
%Chg
1.20% 8.50% 11.90% 10.90% 33.50% -10.40% 0.10% -1.50% 1.60% 12.80% 9.30% -1.20% -0.60% -1.90% -2.20% -1.00% 11.50% 15.00% 8.20% 8.70% -33.20% -8.00% -3.60% -4.30% -0.20% 13.70% -18.30% -8.20% -3.50% -38.90%
YTD 2012
25,732.30 6,111.20 1,677.90 1,333.60 225 119.2 1,011.40 882.7 12.8 115.9 3,422.00 5,131.80 2,859.10 2,272.70 1,855.00 417.8 4,639.00 2,396.80 2,227.50 2,205.90 21.7 14.6 3,918.00 3,215.70 702.3 470.5 231.8 5,932.30 5,453.10 479.2
YTD 2011
26,533.80 6,503.70 1,734.60 1,360.50 231.3 142.8 1,031.80 893.3 16.4 122.2 3,737.20 5,742.90 3,173.40 2,569.50 2,077.00 492.5 4,465.10 2,172.20 2,276.50 2,245.50 31 16.4 4,129.70 3,398.70 731 441.5 289.5 5,692.40 5,037.30 655.1
%Chg
-3.00% -6.00% -3.30% -2.00% -2.70% -16.60% -2.00% -1.20% -21.90% -5.20% -8.40% -10.60% -9.90% -11.60% -10.70% -15.20% 3.90% 10.30% -2.20% -1.80% -30.20% -11.10% -5.10% -5.40% -3.90% 6.60% -19.90% 4.20% 8.30% -26.80%
MAJOR APPLIANCES (Thousands of Units)
AUTOMATIC WASHERS Shipments (Thousands of Units) Qtr: 2010 2011 2012 1 2040.7 2024.0 2042.2 2 2023.4 1861.7 1923.1 3 1902.5 1896.8 1955.6 4 2038.6 2046.8 2147.0
For 2010, a 1.8% increase to 8.005 million units For 2011, a 2.2% decline to 7.829 million units For 2012, a 3.0% increase to 8.068 million units
Qtr: 1 2 3 4
DRYERS Shipments (Thousands of Units) 2010 2011 1702.0 1609.7 1659.5 1519.9 1468.5 1403.9 1720.8 1695.0
2012 1614.5 1564.0 1453.0 1759.4
Note: Figures (in units) include shipments for the U.S. market whether imported or domestically produced. Export shipments are not included. Source: Association of Home Appliance Manufacturers (AHAM).
Qtr: 1 2 3 4
FREEZERS Shipments (Thousands of Units) 2010 2011 434.2 437.5 516.0 509.3 526.9 528.5 480.4 491.0
2012 448.0 524.6 547.5 514.0
HVAC - Shipment figures for unitary air conditioners, heat pumps, furnaces, and water heaters can be found at www.ahrinet.org.
For 2010, a 4.2% decline to 1.958 million units For 2011, a 0.4% increase to 1.966 million units For 2012, a 3.5% increase to 2.034 million units
GAS RANGES and OVENS Shipments (Thousands of Units) Qtr: 2010 2011 2012 1 656.2 659.1 669.0 2 694.4 602.9 631.2 3 673.1 633.4 658.7 4 766.1 746.9 773.8
Qtr: 1 2 3 4
GAS FURNACES Shipments (Thousands of Units) 2010 2011 506.9 506.0 552.6 475.7 646.6 615.6 747.2 733.7
2012 516.6 488.5 642.7 761.6
Qtr: 1 2 3 4
DEHUMIDIFIERS Shipments (Thousands of Units) 2010 2011 551.2 349.8 668.4 553.3 250.6 279.9 82.0 97.4
2012 371.1 593.1 289.2 102.0
For 2010, an 8.7% decline to 1.552 million units For 2011, a 17.5% decline to 1.280 million units For 2012, a 5.9% increase to 1.355 million units Data Source: AHRI/AHAM Forecast Source: Delano Data Insights
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NEwS watch
ahaM Releases First Sustainability Standard for household Refrigeration appliances
he Association of Home Appliance Manufacturers (AHAM) released the Sustainability Standard for Household Refrigeration Appliances. The voluntary AHAM 7001-2012/CSA SPE7001-12/UL 7001 is the first in a family of product sustainability standards under development by AHAM, CSA Group, and UL Environment intended for use by manufacturers and others to identify environmentally preferable products. According to AHAM, the standard will serve as an objective and practical measurement tool to assist refrigeration manufacturers in evaluating the environmental sustainability of home appliances. The notion of product safety as we know it is evolving and expanding. In-
creasingly, consumers are concerned about the lifecycle-based environmental impacts of the products they buy and use in their homes. Appliances are no exception, said Sara Greenstein, president of UL Environment, a business unit of UL, in a statement. AHAM 7001-2012 is based on a lifecycle approach for identifying the environmental impacts of refrigeration products in five key areas: manufacturing, energy, materials, end-of-life and performance. AHAM, CSA Group and UL Environment will form consensus committees to move the standard through the U.S. and Canadian accredited standards process, following the requirements of the American National Standards Institute (ANSI) and the Standards Council of Canada (SCC). For more information, visit www.aham.org. < hicle technology (LVT) developed to eliminate problems that have prevented wider use of liquid color and additive concentrates in extrusion blow molding of polyolefins.
USPS BaN oN LIthIUM IoN
As of Wednesday, May 16, the United States Postal Service (USPS) is banning all international shipments containing lithium ion batteries. Businesses have faced restrictions for shipping lithium ion batteries and equipment or devices containing them for several years, as enforced by the U.S. Department of Transportation (DOT). Lithium batteries are considered Class 9 Hazardous Materials as defined by the government, because they can overheat and ignite under certain conditions. Fast Company magazine reported that lithium ion batteries are thought to have been the cause of at least two fatal cargo plane crashes since 2006, including a UPS jet in Dubai. U.S. DOT rules for shipping hazardous materials involve specific packaging requirements such as anti-static bubble wrap, hazard class labeling and specific documentation such as a Shippers Declaration for Dangerous Goods as required by International Air Transport Association and International Maritime Organization.
8 applianceDESIGN June 2012
With the USPS ban, shippers will not be allowed to send any internationalbound packages containing a lithium ion battery, including personal devices such as laptops, iPads, smartphones, and small appliances such as power drills and electronic shavers. The USPS says it may change the ban on January 1, 2013 and allow customers to mail certain quantities of lithium ion batteries internationally, including to APO and FPO locations.
NEw LIqUID coLoR tEchNoLoGy FoR PoLyoLEFIN BLow MoLDING
Swiss Chemical company Clariant Masterbatches announced a liquid ve-
Extrusion blow molders and brand owners in the personal care and household products markets often find liquid masterbatches to be an attractive alternative to solid concentrates. However, until now, use of liquid color has been limited in blow molding of polyolefin resins because many liquid based carrier systems, including mineral oil, would not incorporate well with the resins. It was pigment friendly, but not resin friendly, stated Raymond Sloan, head of liquid color, Clariant Masterbatches North America.
EDITORS NOTE:
RETRACTIONS AND ADDENDA:
We have made a few errors in recent issues that I would like to address here. First and most egregiously, in our April issue feature, Low-GWP Blowing Agents, we wrongly referred to Solstice Liquid Blowing Agent as HFC-1234yf. The molecule should have been identified as HFO-1233zd. The original version of this article has been retracted. A corrected version of the article is available in our digital edition at http://digital.bnpmedia.com/ publication/?i=105031, and will be reprinted in its entirety in our upcoming September issue.
2012 EID
I would also like to add a few addenda to our June issues announcement of our annual Excellence in Design Awards. When publishing the issue, we inadvertently left one of the Gold winnersThe Jura Impressa Coffeemakerout of the final layout, and the wording for another winner was accidentally included with the final Bronze recipient, the Draftmark Tap System by Anheuser Busch. These two items are correct as follows:
GOLD 2012
I Twenty Fifth Annual EID GOLD Awards
The IMPRESSA is the first model in the companys J-line to feature TFT color display. A 3.5-inch screen combines graphics and text to showcase the type of beverage, number of ounces, coffee strength and amount of milk . Users operate it by turning the rotary dial, then pressing a button. A built-in conical burr Category: Small Appliances grinder grinds beans before. It features the companys fine foam system. The machine also stands out for Price Range: Top of the Line its six-inch, height-adjustable cappuccino spout and adjustable coffee spout to accommodate one or two Market: United States glasses of varying sizes. Attention to detail won it high praise from judge Caruso, who noted The expression of a subtle sculptural form with state-of-the-art features, e.g. display, make this a fine entry. The flagship machine for the series, its sophisticated lines and glossy silver lacquer finish on an aluminum front panel and ABS/ Stainless Steel sides give it a modern edge, while subtle lighting showcases the units professional coffee preparation. The TFT screen really makes this special; colorful images of coffee-house quality beverages glide across the screen with each turn of the rotary dial. The energy-conscious designers also included a Zero-Energy Switch; no ongoing processes are interrupted if the machine is switched off. The switch then disconnects the machine entirely from the electrical mains.
BRONZE 2012
I Twenty Fifth Annual EID BRONZE Awards

Draftmark Tap System (Model: NBABPD1000-1AB), by Anheuser-Busch Companies Inc. and design firm Metaphase Design Group Inc., St. Louis
This affordable tap system offers beer drinkers a true draught beer experience in the comfort of their own home. This draught system allows the host to provide an assortment of draught choices while guests can create their own perfect pour by choosing their own glass, mastering the proper draught pour, and controlling their beer portion and consumption. Visit www.draftmark.com
GOLD 2012
IMPRESSA J9 One Touch TFT, by Jura Capresso Inc. Alameda, Calif.
Category: Small appliances Price Range: Mid-range Market: Select Dierbergs, Schnucks, Shop & Save and Randalls in the St. Louis area
applianceDESIGN June 2012 9
BRONZE 2012
NEwS watch
h caNaDa! ahaM LauNchES NEIGhborLy aSSocIatIoN
The Association of Home Appliance Manufacturers (AHAM) announced it will open its long-rumored AHAM Canada association in July 2012. This step follows interest shown over the past several years by appliance manufacturers who wish to benefit from fuller integration of home appliance industry representation in Canada and the United States.
GE to opEN chIcaGo DESIGN cENtEr
GE Monogram plans to open its firstever Midwest design center next year in Chicago. The center is slated to open in March 2013 at LuxeHome in The Mer-
chandise Mart, a prominent shopping area of downtown Chicago. The location will target the professional trades as well as consumers, and display the companys appliances in different settings. Since GE opened its first Monogram Design Center in New York Citys Architects & Designers Building in 2008, market share in the northern region of the U.S. has increased by 50%, according to the company. The Chicago location will feature working kitchens for cooking demonstrations and a showroom with more than 50 GE Monogram appliances that will be outfitted with cabinetry, millwork and finishes. Design of the 3,500-square-foot center will begin this summer with construction starting in January 2013. Once open, the GE Monogram Design Center will be staffed by three product specialists and a professional chef.
Ipv6 LauNchES, worLD MaDE SafE for wEbtocracy
On June 5-6, IPv6 was launched. The new Internet protocol is based on a 128-bit signature, as opposed to the 32bit IPv4 signature that would have run out of IP addresses after about 4 billion devices. Countries and large organizationsGE was noted as onewill receive unique signatures as IP addresses, like telephone numbers, will be assignable using logic. Major Internet service providers (ISPs), home networking equipment manufacturers, and Web companies around the world came together to permanently enable IPv6 for their products and services by the 68th anniversary of DDay. IPv6 Launch Day was organized by the Internet Society, and built on the World IPv6 Day event held on June 8, 2011.
rEport: MEtaLforMErS bEarISh ovEr NExt thrEE MoNthS

According to the May 2012 Precision Metalforming Association (PMA) Business Conditions Report, metalforming companies expect a softening in business conditions during the next three months. Conducted monthly, the report is an economic indicator for manufacturing, sampling 126 metalforming companies in the United States and Canada. Lately the reports had been trending fairly rosy, so this represents a shift. The May report shows that only 24 percent of participants anticipate economic activity to improve during the next three months (down from 37 percent in April), 60 percent predict that activity will remain unchanged (compared to 51 percent last month) and 16 percent report that activity will decline (up from 12 percent in April). Metalforming companies also forecast a downward trend in incoming orders during the next three months, with 34 percent anticipating an increase in orders (compared to 43 percent in April), 46 percent expecting no change (up from 41 percent in April) and 20 percent predicting a decrease in orders (up from 16 percent last month). Average daily shipping levels declined in May. Only 37 percent of participants report that shipping levels are above levels of three months ago (down from 46 percent in April), 44 percent report that shipping levels are the same as three months ago (compared to 41 percent last month), and 19 percent report a decrease in shipping levels (up from 13 percent in April). The percentage of metalforming companies with a portion of their workforce on short time or layoff increased to 10 percent in May, from 9 percent in April. However, this number is lower than May 2011, when metalformers reported 14 percent of their workforce on short time or layoff. PMAs manufacturing member companies report softer, but still quite positive, business conditions in PMAs May Business Conditions Report, said William E. Gaskin, PMA president. For the first three months of 2012, metalforming companies reported strong orders and shipments, up 10 percent vs. Q-1 in 2011, so the general uptick in manufacturing that has led the economic recovery continues to be reflected in our numbers. Compared with PMAs May 2011 Business Conditions Report, the 2012 outlook is similar in that softening is expected over the next few months, but with 10 percent growth in the first quarter, business levels continue to be more positive. The monthly Business Conditions Report has been conducted by PMA since 1979. Full report results are available at http:// www.pma.org/public/business_reports/pdf/BCREP.pdf.
10 applianceDESIGN June 2012
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time and every time anywhere in the world. Consistency is also criticalTransducer #1 out of the box must be interchangeable with Transducer #2 out of the boxthe parts must always act predictably. A third consideration is the ever-present challenge of cost. As electronics become smarter and more accurate, they replace a number of components previously used in the solution. Cost, therefore, is not dependent solely on the cost of the individual sensor, but on total cost. What does the sensor replace? What resource-laden activities, such as pre-calibration or fully compensated parts, no longer necessary? When selecting transducers for your industrial/transportation application, consider: 1) configurability With each transducer, what does the device feature as to standard or custom connectors, ports, pressure reference types, ranges, and output options? Can exact design requirements be met easily and rapidly either off-theshelf or with configurability assistance? Can you design the device you need and receive samples rapidly so that timeto-market is not slowed or affected? 2) Total Error Band Total Error Band (TEB) (see Figure 2) is a comprehensive, clear and meaningful measurement. It provides the true accuracy of the device over a compensated temperature range of 40 C to 125 C (-40 F to 257 F). TEB is critical to address the consistency of parts and to ensure they are interchangeable. When the TEB is established at 2 percent, for example, no matter where the temperature is within the established range, or whether pressure increases or decreases, the error will be within 2 percent of the established value. Often, manufacturers do not list TEB in their product data sheets. Instead, errors are listed individually. When added up, the total error (or what would be TEB) can be significant. TEB can be one of the most compelling aspects of selecting a transducer. 3) Quality and performance What are the performance standards to be met? In many cases, transducers are produced to one- or two-sigma tolerances. When a transducer is produced to meet six-sigma standards, however, the device combines high quality and high performance and consistency and the resulting confidence that the transducer will perform to spec. 4) other considerations Additional checklist items for heavy duty transducer selection include: 4Transducers should be compensated, calibrated, amplified, and finished additional resources should not be required to make it fit. 4Custom calibration, or custom calibration with custom outputs, should be available with a variety of regulated output voltages to meet the specifications of the design without design modification. 4CE compliance, IP rating, long mean time to failure, and an EMC (electromagnetic compatibility) rating provide for durability in harsh environments. 4A broad compensated temperature range allows the same device to be used throughout the system design, as well as designed into a broad range of applications. 4A variety of connectors and ports allows the transducer to meet a variety of application needs. 4Consider flexibility in device placement based on the transducers small footprint. 4The transducer should meet applicable industry standards, such as ISO 9001. 4The total cost of the transducer should be considered, which includes integration, configurability and implementation. Another major consideration is design and application support. What is available for the designer to answer important questions during the design, development, launch and production phases? Are there sufficient global presence, products, and support to assist from design to global manufacturing? Many modern pressure transducers are highly configurable, designed for potential use in HVAC, refrigeration, industrial and transportation applications. Based on piezoresistive-sensing technology with Application Specific Integrated Circuit (ASIC) signal conditioning, they meet the criteria for use in harsh environments. Fully calibrated and compensated for transducer offset, sensitivity, temperature effects and non-linearity, they feature a TEB of 2 percent over the operation temperature range of -40 C to 125 C (-40 F to 257 F). By using an in-depth checklist to select heavy duty pressure transducers, designers can make rapid and sound decisions based on true and verifiable data. While the level of accuracy available in todays transducers is light years ahead of products on the market just a few years ago, it is important that designers select a product that fits without modification and that is ready to go as rapidly as possible. <
Gas Ignition Controls

Features
Combustion blower control Rollout switch input Flame stabilization Thousands of timing options 120V or 24 VAC operation Fastest delivery in the industry Made in USA
Series 8X: Smart Hot Surface Ignition Control Series 2X: Direct Spark or Intermittent Pilot
5vdc, 24vac, 24vdc or 120vac Alarm

CSA ANSI Z21.20 CSA C22.2 No. 199-M89
Applications Applications
Commercial Cooking Equipment Gas Furnaces Residential and Commercial Boilers Water / Space Heaters Spa and Pool Heaters New and Replacement Applications
Series 9X: Direct Spark or Intermittent Pilot
CE EN 298:2003
CUSTOM OEM VERSIONS AVAILABLE

Capable Controls Inc.
790 Maple Lane Bensenville, Illinois 60106
Certified to Standards AG206 and AG210
630-860-6514 www.capablecontrols.com info@capablecontrols.com
GAS TECHNOLOGY
A Look at Possibilities
Before outlining an effective shopping list for a transducer, its important to see the potential range of solutions. What are some of the alternatives, and how can you meet the specification of your own design? As previously stated, the realities of control and monitoring systems have changed greatly in the last few decades, mostly as a result of design complexity. A move from manual to electronics-based systems, a high component count evolving to a highly integrated one, and a greater focus on the bottom line have been part of the change. There is a range of possible solutions for heavy duty applications. But first its important to define exactly what constitutes heavy duty? Environments representing a wide temperature range, for example between -40 C to 125 C (-40 F to 257 F), and environments where a variety of harsh media such as refrigerants, engine oil, brake fluids, hydraulic fluids, and compressed air are used are some good examples. While these temperatures and harsh environments are not necessarily the most extreme, they represent the bulk of conditions in both transportation and industrial environments. Heavy duty pressure transducers may potentially be used in: HVAC/R applications to monitor system performance for environmental control of compressor inlet and outlet pressure, rooftop chillers, compressor rack rooms, refrigerant recovery systems, and compressor oil pressure. Air compressors to monitor compressor performance and efficiency such as compressor inlet and outlet pressure, filter pressure drop, cooling water inlet and outlet pressure, and compressor oil pressure. Transportation applications to maintain heavy equipment performance by monitoring system pressure, fluid power, fluid flow, and fluid levels in such key systems as pneumatics, light hydraulics, brake pressure, engine oil pressure, transmission, and truck/trailer air braking. The number of transducers available is nearly endless, making it critical to put potential selections under a powerful microscope. The transducer should be analyzed for reliability, calibration, offset compensation, sensitivity, and total error band.
Figure 2. Error components of TEB. Source: Honeywell Sensing and Control.
The Selection Criteria

As with the majority of electronic products, the selection criteria mirror important design challenges. Systems design requires reliability so that the system works the first
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GaS TEchNoloGy
time and every time anywhere in the world. Consistency is also criticalTransducer #1 out of the box must be interchangeable with Transducer #2 out of the boxthe parts must always act predictably. A third consideration is the ever-present challenge of cost. As electronics become smarter and more accurate, they replace a number of components previously used in the solution. Cost, therefore, is not dependent solely on the cost of the individual sensor, but on total cost. What does the sensor replace? What resource-laden activities, such as pre-calibration or fully compensated parts, no longer necessary? When selecting transducers for your industrial/transportation application, consider: 1) configurability With each transducer, what does the device feature as to standard or custom connectors, ports, pressure reference types, ranges, and output options? Can exact design requirements be met easily and rapidly either off-theshelf or with configurability assistance? Can you design the device you need and receive samples rapidly so that timeto-market is not slowed or affected? 2) Total Error Band Total Error Band (TEB) (see Figure 2) is a comprehensive, clear and meaningful measurement. It provides the true accuracy of the device over a compensated temperature range of 40 C to 125 C (-40 F to 257 F). TEB is critical to address the consistency of parts and to ensure they are interchangeable. When the TEB is established at 2 percent, for example, no matter where the temperature is within the established range, or whether pressure increases or decreases, the error will be within 2 percent of the established value. Often, manufacturers do not list TEB in their product data sheets. Instead, errors are listed individually. When added up, the total error (or what would be TEB) can be significant. TEB can be one of the most compelling aspects of selecting a transducer. 3) Quality and performance What are the performance standards to be met? In many cases, transducers are produced to one- or two-sigma tolerances. When a transducer is produced to meet six-sigma standards, however, the device combines high quality and high performance and consistency and the resulting confidence that the transducer will perform to spec. 4) other considerations Additional checklist items for heavy duty transducer selection include: 4Transducers should be compensated, calibrated, amplified, and finished additional resources should not be required to make it fit. 4Custom calibration, or custom calibration with custom outputs, should be available with a variety of regulated output voltages to meet the specifications of the design without design modification. 4CE compliance, IP rating, long mean time to failure, and an EMC (electromagnetic compatibility) rating provide for durability in harsh environments. 4A broad compensated temperature range allows the same device to be used throughout the system design, as well as designed into a broad range of applications. 4A variety of connectors and ports allows the transducer to meet a variety of application needs. 4Consider flexibility in device placement based on the transducers small footprint. 4The transducer should meet applicable industry standards, such as ISO 9001. 4The total cost of the transducer should be considered, which includes integration, configurability and implementation. Another major consideration is design and application support. What is available for the designer to answer important questions during the design, development, launch and production phases? Are there sufficient global presence, products, and support to assist from design to global manufacturing? Many modern pressure transducers are highly configurable, designed for potential use in HVAC, refrigeration, industrial and transportation applications. Based on piezoresistive-sensing technology with Application Specific Integrated Circuit (ASIC) signal conditioning, they meet the criteria for use in harsh environments. Fully calibrated and compensated for transducer offset, sensitivity, temperature effects and non-linearity, they feature a TEB of 2 percent over the operation temperature range of -40 C to 125 C (-40 F to 257 F). By using an in-depth checklist to select heavy duty pressure transducers, designers can make rapid and sound decisions based on true and verifiable data. While the level of accuracy available in todays transducers is light years ahead of products on the market just a few years ago, it is important that designers select a product that fits without modification and that is ready to go as rapidly as possible. <
Gas Ignition Controls

Features
Combustion blower control Rollout switch input Flame stabilization Thousands of timing options 120V or 24 VAC operation Fastest delivery in the industry Made in USA
Series 8X: Smart Hot Surface Ignition Control Series 2X: Direct Spark or Intermittent Pilot
5vdc, 24vac, 24vdc or 120vac Alarm

Applications Applications
Commercial Cooking Equipment Gas Furnaces Residential and Commercial Boilers Water / Space Heaters Spa and Pool Heaters New and Replacement Applications
Series 9X: Direct Spark or Intermittent Pilot
CE EN 298:2003
CUSTOM OEM VERSIONS AVAILABLE

Capable Controls Inc.
790 Maple Lane Bensenville, Illinois 60106
Certified to Standards AG206 and AG210
630-860-6514 www.capablecontrols.com info@capablecontrols.com
MotorS & BlowErS
inear motors have made irreversible inroads into highly dynamic applications such as manufacturing and measuring equipment in the semiconductor industry, in PCB assembly machines, textile machines and in automation. Direct drives for open and closed-loop control require continuous real-time and exact information on the position of the slide. The accuracy, performance and reliability of the individual axes depend on the linear measuring devices used. In connection with linear motors, this task is now performed primarily by compact, contact-free measuring devices called exposed linear encoders. The decisive advantage of direct drive technology is the very stiff coupling of the drive to the feed component without any other mechanical transfer elements. This allows significantly higher gain in the control loop than with a conventional drive. Here, the efficiency of a linear motor is greatly influenced by the selection of the position encoder. High-control loop gain can only be reached if the encoder provides high-quality position signals. With the high gain required in the control loops, even minor disturbances in the encoder output signal can cause serious trouble in drive performance. The higher quality of the position information noticeably improves velocity control and positioning. The motor operates quietly and develops only a small
Linear Encoders for Linear Motors

amount of heat.
Velocity measurement on direct drives

On direct drives, there is no additional encoder for measuring the speed. Both position and speed are measured by the position encoder: linear encoders for linear motors, angle encoders for rotating motors. Since there is no mechanical transmission between the speed encoder and the feed unit, the position encoder must have a correspondingly high resolution in order to enable exact velocity control, particularly at slow traversing speeds. The velocity is calculated here from the distance traversed per unit of time. This method, which is also applied to conventional axes, represents a numerical differentiation that amplifies periodic disturbances or noise in the signal. The significantly higher control loop gain on direct drives dramatically increases the influence of the signal quality on drive performance. Linear encoders that generate a highquality position signal with only small interpolation error are therefore essential for the meaningful operation of direct drives. Encoders that use photoelectric scanning are particularly suited here for this task, since very fine graduations can be used as measuring standards by this method. These encoders provide benefits in the position-
Knowing the exact
position of the slide is the key to applying linear motors. New measuring devices aim to improve that accuracy.
Provided by Dr. Johannes Heidenhain GmbH, Traunreut, Germany

applianceDESIGN July 2012 15
MOTORS & BLOWERS

Figure 1: Scale tape of the LIC.
immediately upon machine switch-on. There is no need to move the axes over the reference marks to find the reference position. The absolute position information is scanned from the scale graduation, which is configured as a pseudo-random-coded track (PRC) and a separate incremental track. The position information is ascertained with a newly developed scanning method through the evaluation of the PRC track and the incremental track. Adding a highly integrated opto-ASIC makes it possible to achieve new dimensions in terms of accuracy and reliability of position information.
Measuring accuracy and high reliability contribute to machine safety

This scanning method is based on the high quality of the graduation and provides absolute position values with a specified interpolation error of less than 40 nm. Exposed linear encoders are therefore optimized for use on fast, precise machines. In spite of their exposed design, everyday con-
ing, speed stability, and thermal behavior of a direct drive. Up to now, an absolute position value calculation and the associated availability of the position value immediately after encoder switch-on without any axis movement were not yet available with exposed linear encoders. Sealed absolute linear encoders are not always used on direct drives because they often required compact dimensions. Exposed encoders, which thanks to their lack of an enclosure have very small dimensions and therefore low weight, were previously available only in incremental versions.
tamination and thereby greatly enhances encoder reliability. With absolute graduation, the position value can be available from the encoder
The graduation carriera scale tape

Encoders with optical scanning incorporate measuring standards of periodic structures are known as graduations. They are characterized by their high edge definition and excellent homogeneitya fundamental prerequisite for low interpolation error, and therefore for smooth operating performance and high control loop gain. The quasi-planar graduation structure applied in the process is extremely tolerant to conFigure 2: Design and functional principle of the optical scanning method of the LIC 4000.
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MotorS & BlowErS

tamination resulting from small quantities of oil, dust, fingerprints, hair or small metal objects applied were tested intensively in a laboratory and show few effects on operational reliability. The measuring accuracy of such devices is also hardly influenced by the tested types of contamination (see Figure 3).
Summary
Applications with direct drives often place special requirements on control and measuring technology. Encoders for acquisition of position and drive velocity need to provide high-quality signals. Short-range errors in the position measuring signal are particularly critical for direct-driven feed axes because they can result in positioning error, speed ripple, loud noise and additional heat generation. Encoders that use optical scanning and provide small signal periods have proven to be particularly effective by enabling machines to operate with high accuracy and resolution values. Absolute encoders with resolutions of 1 nm are now available. Meanwhile the EnDat protocol makes it possible to transfer various data that can be used, for example, for system diagnostics. For demanding positioning and control tasks in various applications such as in the semiconductor industry, metrology, medical technology, automation and textile machines, machine tool builders and plant manufacturers are now flanked by an exposed absolute encoder. <
Benefits of serial position transmission with EnDat 2.2

The scanning signals of such encoders are digitized directly in the scanning head and are converted into a high-resolution position value. This eliminates the previously prevailing transmission of analog signals from the scanning head for drive control. With digital position transmission via EnDat 2.2, the accuracy and resolution can be exploited without loss in the transmission. Both the speed stability and positioning behavior of linear direct drives can be increased significantly. Highly dynamic drives running on position signals, also with very high proportional gain in the velocity controller, feature quietness in operation. The high control loop gain would not have been possible without the high clock frequency of the EnDat interface and the
Figure 3: Contamination on the graduation: measuring accuracy of the LIC without the application of electronic corrective measures.
resulting short read-out times. EnDat 2.2 is now the fastest purely serial interface for position encoders based on RS 485 transmission characteristics (www.endat.de). Valuation numbers provided over EnDat 2.2 for the absolute track, incremental track and position value calculation provide a real-time status report on the condition of the encoder. Strong mounting tolerances are important in conjunction with valuation number. The valuation numbers can be called through EnDat 2.2 during motor operation without sacrifices in the performance of the servo control.
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2011 CoorsTek, Inc. J0111 8510-1678 Rev. A
JOINING
NEW MATERIALS,
LOWER COSTS
The things that bind us all together have had a profound impact on the things that bind our things together.
he era of the basic plastic fastener, foot, strap, wire harness or circuit board hardware as the standard connective tissue of almost every appliance in recent years has now given way to a new generation of fastening component materials, including thermoset rubber, metal and high-temperature plastics. These new material choicesboth individually and in combinationnow offer appliance manufacturers not only higher operational performance, but also in many cases can help lower production cost by combining materials in a way that eliminates a number of traditional separate parts. These new materials not only meet the traditional UL flammability requirements, but also the newer demands of the EU RoHS and REACH environmental regulations, as well as toxicity certification, conflict materials laws, etc.
by bob reisel Manufacturer need has been the primary driver

The development of many of these new Bob Reisel is Vice President of Engineering at Richco Inc. He can be contacted fasteners and hardware assemblies has been at: BReisel@richco-inc.com driven by the need for manufacturers to
simultaneously solve performance problems, reduce production costs and meet the increasing controls imposed on them by global regulatory agencies. External controls related to recyclability and re-use, and internal engineering needs related to higher operating temperatures have been important drivers of new material adoptions, as have the higher costs to which manufacturers are extremely sensitive. Changes in appliance design that offer new convenience features have also been drivers of new material adoption. For example, a major manufacturer of electric cooking stoves, when moving from knob controls to touch controls, experienced a problem with touch pressure consistency. Touch control pressure problems are sometimes related to the touch control spacer (TCS), which absorbs the varying pressures from the impact caused by using the controls. A new touch control spacer, made of plastic with an integrated metal spring that consistently absorbs touch pressure, solved the problem while simultaneously reducing the
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In specific applications
In addition to those critical components like touch control spacers, even basic appliance fastening and hardware needs common to all appliances, such as hole grommets, snap rivets, circuit board supports, wire routing and releasable product designs can benefit in terms of longevity, reliability and cost reduction by adopting these new materials. Something as basic as a leg leveling foot that uses an overmolded rubber/plastic part with a fastener and screw to produce a more resilient foot while eliminating parts, and stainless steel wire ties to replace the traditional plastic, can result in lower cost over the life of the product. Appliances in commercial settings like restaurants and fast food retail operations differ from those in homes because of size and capacity, of course, but also by being computer controlled and monitored, so that management can control volume production and monitor appliance performance. Similarly, in upscale homes, kitchens are sometimes designed so that ovens, microwaves, dishwashers and refrigerators can be controlled from the homeowners computer system or even from a smart phone or tablet. Will this technology, if it becomes more common in consumer appliances, with its remote controllers and new wire routings, require new appliance designs, and perhaps new heat-stabilized grommets, stainless steel wire ties, etc.? Associations and providers have had numerous inquiries from appliance manufacturers about such new requirements, but whether they will become standard features, only the future can tell. However, some manufacturers are already thinking about it.
cost required in a traditional TCS. As a result of the opportunities offered by these new materials, joining companies have been dramatically adding new plastic components, overmolded combinations, and metal and thermoset rubber products to their offerings.
Benefits should be much more widespread

While many manufacturers have taken advantage of the benefits offered by the new materials, their use could be more widespread if more manufacturers design engineers took greater advantage of newer options. Thermoset rubber, for example, performs well in higher temperatures and resists drying, and also can be lower in overall cost than the comparable plastic and metal parts it replaces. A circuit board support spacer molded as a thermoset rubber unit will outperform the plastic by being more durable, will provide more shock and vibration isolation and support, and can lower overall production cost. Thermoset rubber should be considered as an option along with plastic or metal in the design of any fastening, foot strap, support or other hardware function. However designers dont yet know it as well, and therefore dont exploit the market inefficiency it provides. Temperature and humidity are critical considerations when making the decision about what materials to choose for an appliance. Appliances are situated in a wide variety of locales, from warm kitchens to cool basements to unheated garages. It is incumbent on designers to specify materials that offer the highest performance across the widest potential range of temperature and humidity.
Nylon is not always the optimal choice due to its sensitivity to humidity; thermoset rubber could provide a much more satisfactory performance across a wide range of temperatures and humidity levels. For these reasons, it is incumbent on appliance designers and engineers to either become more familiar with the performance characteristics of the materials they specify including new materials that are available or to rely on the recommendations of suppliers who do devote the time and research required to stay aware of those new materials.
The next generation of appliances?

We live in a country that reveres the new, sometimes without looking beyond the word. But manufacturers will be wise to have their designers and engineers explore these and other future materials that can help create better-performing, longer-performing appliances while helping to contain costs. Will these materials create a new generation of appliances? That is going a little far. As appliance manufacturers continue to innovate through the latest technologies, such as LED lighting and touch controls, advances in material technologies can aid in their development. But that is not to say that they cannot be made to perform more reliably, more efficiently, and help to lower production costs as well. <
2012
[FREE]
SMART GRID
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This useful webinar is aimed at the appliance DESIGN Magazine audience to educate, encourage and energize you in your current on-the-job needs as well as better position you to cope and succeed with future anticipated and unanticipated challenges. Spotlighted are logical pathways that will lead now and into the future to intelligent appliances in a connected home delivering sustainability, enhanced controls and energy savings to the homeowner as well as sales and after-sales service/maintenance advantages for appliance manufacturers. Insightful information provided by key knowledge leaders will also complement the evolution of utilities and their influence in a smart grid world.
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HEATING TECHNOLOGY
DE FO S H R IG EA E N T F IN TR F I G CI AN E S F NT ER
T
he steps involved in the design of heat exchangers for air conditioning and refrigeration applications using smaller diameter copper tubes are summarized here. These steps are intended as a general guideline. Specific choices and recommendations are not given here, since such choices may depend upon other components in the system design. Simply put, an air conditioning or refrigeration system consists of a compressor for work input; and condenser and evaporator coils for heat output and input, respectively. Energy efficiency is dependent upon keeping the refrigerant passing through the condenser and evaporator coils as close as possible to the surrounding outdoor and indoor temperatures, respectively. Much attention has been focused in recent decades on refrigerants and valves for controlling and regulating refrigerant flow. Yet in the past half a decade, significant advances have also been made in the design of evaporator and condenser coils. These advances have been motivated by the conflicting needs to increase energy efficiency while also reducing materials usage. It has long been understood that a smaller diameter tube would increase the local heat
Fin efficiency is determined by the pitch ratio, the longitudinal tube pitch, the transverse tube pitch, fin spacing and fin patterns as seen here. Computational fluid dynamics (CFD) allows for the optimization of these features to the tube size and air flow rates. The use of a smaller tube size typically requires a complete redesign of the coil to maximize fin efficiency, since the smaller diameter tubes are less restrictive to the airflow.
A step-by-step procedure for optimizing the use of smaller diameter tubes in eco-friendly AC designs.
transfer coefficient (HTC or ) that governs the heat transfer between the refrigerant and the inside of the tube wall. The challenge has been to fabricate smaller diameter tubes and assemble them into heat exchanger coils. The proving ground has been the highly competitive, high volume manufacture of residential air conditioning (RAC) systems, including window-type air conditioners as well as split units. The same design principles apply as well to larger commercial units.
Establishing a Consortium
The ICA sponsors a research and development consortium dedicated to the development of more efficient heat exchanger coils. The consortium includes not only copper tube suppliers but also several major research universities as well as many OEMs who are responsible for a major share of the global production in this product category. Initially, prototypes were made simply by replacing the larger-diameter copper tubes with smaller diameter copper tubes. The footprint of the heat exchanger in the product was unchanged and the fins in the coil designs were not optimized to the smaller diameter tubes. This could be
by wenson zheng and nigel cotton

Wenson Zheng is the Deputy Director of Technology for the International Copper Association (ICA). He can be reached at wensonzheng@copper.org.cn Nigel Cotton is the MicroGroove OEM Team Leader for ICA, and can be reached at ndc@eurocopper.org For more information visit www.microgroove.net/contact-us
HEATING TECHNOLOGY
Tube Spacing
How far apart should the tubes be spaced? The outside air pressure drop must be equal to or less than the design criterion; if the tubes are spaced too closely, this air pressure drop may be too high. The objective is to maximize performance while minimizing the cost. An overly large fin size would cost more to manufacture because it uses more fin material. It would also result in a heat exchanger that is larger-than-necessary. For evaporator coils, the condensate film that forms on the fin influences the choice of fin size. Tube spacing dictates the fin size that will be used in fin-design simulations.
This single-row coil for an outdoor condenser unit of a split system from Midea features highly efficient, smaller diameter, inner-grooved copper tubes. The tubes are only 4-mm in diameter.
Fin Design
The next step is to optimize the fin pattern. The two most common types of fin patterns are the louver fin and the slit fin (or slotted fin). The CFD method is used to simulate both fin patterns. For the louver pattern, the independent variables are the louver angle and the louver number; the louver height and pitch are determined by these independent variables. For the slit pattern, the slit height is determined as one-half the fin pitch, so the only independent variable is the slit number. It should again be stressed that the fin patterns that worked best for larger diameter tubes are not optimized to smaller diameter tubes and related fin sizes. Thus it is necessary to re-examine the design space for all types of fin patterns using CFD simulations. Only in this manner can the fin pattern be optimized for smaller diameter tubes. Ease of manufacture and assembly can also be a factor in the selection of the fin pattern. The final fin pattern design that is selected may be specific to the final application. The objective in all pattern designs is to maximize
referred to as the cut-and-try method. Nonetheless, the results were immediate and dramatic and this intensified interest in further development. Consider that if tube diameter is halved then the cross sectional area is cut by 75 percent. Besides reducing the amount of tube material, refrigerant volume could also be reduced. Furthermore, it is well known from tube stress analysis that the burst pressure increases as the tube diameter decreases, hence wall thickness could be decreased, resulting in a further savings of material. Once it was fully understood how smaller-diameter copper tubes provide major competitive advantages, more systematic approaches were taken by the various OEMs in the design and optimization of coils for specific products using various refrigerants.
compared to conventional tubes because the airflow around the tubes is not obstructed as much for smaller tubes. If there are two rows of tubes then the ratio (Pt /Pl) between transverse and longitudinal tube spacing must be approximated before any further steps can be taken. Initially, values commonly used in heat exchanger designs are selected for fins with high efficiency with operating conditions such as airflow and tube-wall temperature as defined by the applications. The tube pitch ratio is then optimized for the particular application using CFD calculations.
Tube Pitch Ratio

An evaporator coil or condenser coil is, of course, a component in a system and the tubes and fins are sub-components. The first step toward an optimal heat-exchanger design is to select the tube pitch ratio, which may be quite different for smaller-diameter tubes
Smaller diameter copper tubes with inner grooves transfer heat more efficiently than conventional tubes, prompting the redesign of evaporator and condenser coils for many types of air conditioning and refrigeration products.
This 2600 W split-unit, room air-conditioner from the Kelon Corporation uses coils made with MicroGroove technology. The use of smaller-diameter copper tubes in the evaporators of the split units resulted in a higher coefficient of performance while reducing the total weight of tube material.
HEATING TECHNOLOGY
Typically, in round tube plate fin (RTPF) heat exchanger coils, the fins are laced into the tubes, which are then mechanically expanded to make contact with the fins. The tubes are flared at the ends to allow for the insertion of U-bends to complete the tube circuitry.
Typically, the fins are laced into the tubes and then the tubes are expanded using a tube expander, such as this horizontal tube expander. Vertical tube expanders are also available to mechanically expand the tubes until they make contact with the fins.
the heat transfer capacity while meeting the requirement for a low air pressure drop. Of course, efficient heat transfer through the coils results in higher energy efficiency for the system because the refrigerant cools down faster in the condenser and heats up faster in the evaporator.
Build and Test

At this stage, a reality check is necessary. An actual heat exchanger needs to be built and thoroughly tested in a laboratory wind tunnel. The heat transfer capacity can be experimentally measured as the refrigerant flow rates and wind velocities are varied. The former controls the internal rate of heat transfer and the latter determines the external rate of heat transfer. Heat transfer through the tube wall is also a factor. The various components of the heat transfer can be represented as a circuit diagram. Todays CFD simulations are very good. For examples, case studies specifically on designing with small tubes of copper were presented at the 23rd IIR International Congress of Refrigeration last year in Prague and another paper will be presented this month at the 14th International Refrigeration and Air Conditioning Conference on the campus of Purdue University in West Lafayette, Indiana.[1, 2]
The results of a well-designed simulation can be expected to agree very well with experiment. Nonetheless, there is no substitute for the real thing. The experimental measurements can be used to develop prediction correlations, which can be used in further refining the heat exchanger design and the results can also be used in the design of the next step.
ticated software programs to do the hard calculations. The software is based on the differential equations governing heat transfer and mass flow through the tube branches. The design space of possible tube configurations can be quite large so a knowledgebased search method is commonly used to reduce the search space without losing optimal solutions.
Tube Circuitry
An entirely new series of simulations is required to optimize the tube circuitry. Tube circuitry simulations answer the questions about how many separate tube paths (branches) should be included in the circuit and what should be the length of each branch. If the paths are too short then the refrigerant might not reach the target temperature; if too long then the inside pressure drop may be too great, which is an important consideration as tube diameter decreases. Temperatures vary throughout the heat exchanger as the refrigerant passes through the various circuit branches. Branches can be placed in the first or second row. Tubes at similar temperatures can be placed farther apart or closer together. The problem of optimization can become a complicated puzzle indeed. Fortunately, there are sophis-
Design for Manufacture

Once the fin pattern and tube circuitry has been optimized then the heat exchanger is ready for use in the product design. The time to market for new products can greatly shortened by using the design principles outlined above. Already several case studies are available on the design of optimized heat exchangers using smaller diameter, inner grooved copper tubes[1, 2]. Technologies for manufacturing smaller diameter copper tubes are now available as
These are 5 m
m tubes for wi
ndow units.
Evaporator Coil (indoor coil) from a Split System. The coil employs 5-mm diameter MicroGroove copper tubes, which resulted in a 30 percent reduction in tube weight for the same performance (2500W cooling capacity) as previous models.
HEATING TECHNOLOGY
well as the equipment for making coils from the smaller diameter copper tubes. These technologies have been developed and proven in the highly competitive manufacture of residential air conditioners. The same manufacturing technologies can be applied to a wide range of air conditioning and refrigeration products. The only limitation is the imagination of the designer.
DESIGN MART
This appliance DESIGN Design Mart section brings you information on new products and services available through print and online. To receive more information about the the products and services in this section, visit appliance DESIGN online at www.applianceDESIGN.com.
Supply Chain
The International Copper Association uses the brand MicroGroove to promote the adoption of smaller diameter copper tubes with enhanced surfaces. Both of these features contribute to improved rates of heat transfer between the refrigerant and the tube walls, making it possible to use less material in smaller, lighter evaporators and condenser coils. ICA members supply many variants of microgroove technology, depending on application-specific needs and market focus. For example, the enhancements of the inside surface of the tubes vary widely from one tube manufacturer to another. Various patterns of inner grooves are used to further increase the local heat transfer coefficient for the transfer of heat between the refrigerant and the tube walls. Round copper tubes offer several important advantages over brazed aluminum multichannel tubes. Using round copper tubes, heat transfer can be increased without the added costs and risks associated with aluminum brazing. In evaporator applications, moisture is more readily removed from the evaporator coils because there are no flat tubes between the fins but rather the fins surround round copper tubes, allowing for easy drainage. Durability is an issue. For most environments, copper tubes are preferred over aluminum tubes on the basis of durability and corrosion resistance. Copper is proven as a tube material in ACR applications. Costly coating processes, as often required for all aluminum heat exchangers, are not necessary. Finally, microgroove coils can offer smaller refrigerant volumes because the tube ends are connected by small U-joints rather than bulky headers associated with aluminum coils. For more information, the interested reader is invited to contact ICA member companies directly. A list of MicroGroove contacts at member companies can be found on the supplier directory webpage at microgroove.net. In addition, technical papers and recorded webinars are available. References 1. G.L. Ding, T Ren, Y.X. Zheng and Y.F. Gao, Simulation-Based Design Method for Room Air Conditioner with Smaller Diameter Copper Tubes, 23rd IIR International Congress of Refrigeration, Prague, Czech Republic, July 2011. 2. W. Wu, G.L. Ding, Y.X. Zheng, Y.F. Gao and J. Song, Principle of Designing Fin-And-Tube Heat Exchanger with Smaller Diameter Tubes for Air Conditioner, 14th International Refrigeration and Air Conditioning Conference, Purdue Conferences, West Lafayette, Indiana, July 2012.
UL is seeking Sr Design Engineers specializing in Dishwasher or Cooking Appliance Design!
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Exciting opportunities available with our UL Verication Services team at the UL Springboard ofce in Newton, Iowa! Manage a variety of dishwasher and/ or cooking appliance design projects. If you have: A University Degree in Mechanical Engineering or applicable discipline Eight (8) years of experience Experience with Design for Six Sigma, Lean Manufacturing principals, and ProEngineer we would like to hear from you! For more info & to apply, visit www.ULCareers.com and enter IRC76359 (Dishwashers) or IRC78535 (Cooking Appliances) in the keyword search. Relocation assistance will be considered.
appliance DESIGN CASE STUDY
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CASE STUDY
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Applications: Boilers Water heaters Packaged burner systems Commercial cooking equipment Commercial humidification equipment Features and Benefits: 12 models available sized for input rates up to 4 MM Btuh Rated voltage: 24VDC, 115VAC, 230VAC and 460VAC Resilient motor mounts for vibration dampening Long life, maintenance-free ball bearing system PWM signal input for full speed modulation Anti-spark backward curved impellers Die-cast aluminum sealed housings The world leader in manufacturing fans, blowers and motors will find an air moving solution thats right for you.
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HIGH ENERGY EFFICIENCY WITH LESS MATERIALS

Attend a MicroGroove webinar on the design of air conditioning and refrigeration products using smaller diameter copper tubes with inner grooves. The following three recorded webinars in the MicroGroove webinar series are available for viewing anytime for free. The Manufacture of ACR Coils with Smaller Diameter Copper Tubes Presented in partnership with Burr Oak Tool Inc. and moderated by Kyle Gargaro, this webinar focuses on the manufacture of heat exchanger coils. Familiar processes for making copper tube / aluminum plate-fin coils are reviewed; and the evolution of coil manufacturing equipment as the market moves to smaller diameter copper tubes is fully explained. View anytime; this webinar requires registration. Achieving Higher EnergyEfficiency with SmallerDiameter Copper Tubes The advantage of MicroGroove technology is clearly demonstrated through data comparisons of products in this webinar, which is moderated by Barbara Checket-Hanks of the ACHR News. This webinar concludes by showing how improved heat transfer results in a systemwide savings of energy and materials. View anytime. No registration is required. Small Tubes of Copper in ACR Applications This webinar was a smashing success. Listen especially for the lively Q&A session moderated by Mike Murphy. With hundreds of live participants there were plenty of questions from the audience. View anytime. No registration is required.
To view a past webinar or register for an upcoming webinar visit www.microgroove.net/webinars
DIE CUT ELECTRICAL INSULATIONS

Custom die cut electrically insulated parts that provide high dielectric strength, are flame retardant per UL94V-0, and are RoHS compliant are being introduced by Interstate Specialty Products, Inc. of Sutton, Massachusetts. Interstate Specialty Electrical Insulations are digitally die cut from ITW Formex GK which is a flame retardant polypropylene material that provides a high dielectric strength and is offered in 0.005 to 0.062 thicknesses. Suitable for a variety of applications, the parts produced can be folded repeatedly without cracking or splitting, are non-hygroscopic, provide superior chemical resistance, and operate at up to 115C continuous. Supplied embossed, printed, and with EMI/RFI shielding where required, Interstate Specialty Electrical Insulations are available with dielectric strengths from 1080 to 2625 V/mil per ASTM D-149 and volume resistivity of 3.97 x 1015 ohm-cm per ASTM D-257. Applications include appliances, auto-motive, battery packs, circuit boards, instruments, and wire harnesses. Interstate Specialty Electrical Insulations are priced according to material grade, configuration, and quantity. Price quotations and material samples are provided upon request. Interstate Specialty Products is a world class leader in custom converting and die-cutting of nonmetallic and specialty materials. A veteran team has specialized expertise in serving the electronics, industrial, medical, scientific, transportation, and water filtration markets.
Interstate Specialty Products, Inc. Phone: (800) 984-1811 Fax: (508) 234-5558 Email: sales@interstatesp.com Website: www.interstatesp.com
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LET US CLEAR YOUR PATH TO THE HOME APPLIANCE MARKETPLACE

In choosing your testing partner, you need someone with the reliability of a strong appliance background, the resources of the latest technology, and expert foresight into the future needs and requirements of the industry. Intertek is that testing partner. The latest, high-end test equipment will test your product for energy efficient operation. A vast network of labs provides local service for quick entry into the global marketplace. Our industry-leading experts can help you to get your product ready for RoHS II. With over 50 years experience in helping to bring home appliances into the global marketplace, Intertek brings a deep knowledge of exactly what is needed to get your product out to the market quickly, safely, and with a competitive advantage in the marketplace. Contact us now for a fast, simple, clear path to market.
Web: www.intertek.com Email: icenter@intertek.com Phone: 1-800-WORLDLAB
CORD KNOTS? NOT WITH DOTZ!

Weve all been thereon hands and knees under or behind a piece of furniture, wrestling with a tangle of cords looking for the one that needs to be plugged, unplugged, or otherwise manipulated. In calmer moments, many of us have wished that someone would come up with a way of sorting out the mess. Micah Maraia, actually invented one. The patented Dotz CordIdentifier is a small, colored plastic bubble that snaps onto the end of a power or connecting cord. It displays, through a clear window, an icon showing the appliance/electronic device thats on the other end of the cord and can make your stay behind the couch or under the desk briefer and a lot less frustrating. Beginning with sketches, Maraia produced the 3D CAD models. I had developed detailed visual representations but still needed functional prototypes for testing and initial marketing. I looked at SLA and other prototyping methods, but features like the living hinge can only be produced by injection molding. Proto Labs rapid injection molding service, Protomold, provided the capabilities I neededreal molded parts, quick turnaround, and affordable prices. Their ProtoQuote online quoting and design analysis can be fairly aggressive in pointing out potential problems, but its fast, helpful and lets you ascertain that your 3D CAD model can be molded. To read this entire case study: visit bit.ly/pl-cordotz
Phone: 877-479-3680 E-mail: customerservice@protolabs.com Website: www.protolabs.com

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FULL SERVICE PRODUCT DEVELOPMENT SERVICES

What do you do if you are a manufacturer and no matter how many times you reengineer your product to meet or exceed the jointly created EPA and DOE Energy Star guidelines, you still cant seem to gain the results you desire? In the case of a particular customer, they turned to Springboard Engineering. Springboard Engineering, a UL Company, provides advisory engineering, testing and prototyping services. This particular customer came to Springboard Engineering for advisory engineering help with regards to achieving a better score on an Energy Star qualifying product. The product was not meeting the baseline energy requirement to qualify under the Energy Star program. After advising the client on some changes to their existing design, the manufacturer not only met the baseline energy star requirement for this category, but Springboard Engineering helped them exceed this requirement by 30%. By exceeding the energy star requirement by 30%, this customers product qualified for the Consortium for Energy Efficiency (CEE) Tier 3 energy distinction, which is the highest energy efficiency distinction a product can achieve. Springboard Engineering also provided a working prototype of this design to this customer, along with performing reliability life cycle testing, to ensure this new design would perform during normal usage and competitive benchmark performance testing, to gauge how well it performs against their competition. This Cradle to Grave product development solution is why manufacturers continue to turn to Springboard Engineering for their advisory engineering, testing and prototyping needs.
Springboard Engineering Phone: 641-787-8700 Email: SBE@UL.com Web: www.springboardengineering.com
WHAT HAPPENS WHEN NEW MEETS NOW AT UL?

UL is pleased to announce a new streamlined certification process, the UL Advantage Program, available for select small appliances, combining the proven benefits of UL certification with a faster, simplified, more costeffective approach. The UL Advantage program offers small appliance end product and component parts manufacturers a significantly more agile and innovative path to certification. It has been carefully developed and backed by ULs technical expertise and uncompromising standard of quality. Created to meet the needs of specific businesses in exceptionally fast-paced industries, UL Advantage enables manufacturers to achieve UL certification for their products with virtually no turnaround time, no waiting in project queues and no interruption to product development cycles. The UL Mark differentiates quality products in the global marketplace, providing a true competitive edge. Whether you make blenders to electric fans, electric shavers to hair care appliances and more or simply the critical parts that make them work UL Advantage could be for you. Surprised? You shouldnt be. UL remains the innovative leader in the small appliance end- product and component manufacturer space. We have to be, because the customers and industries we serve are. Thats what being a trusted certification provider for over 100 years is all about. We invite you to visit www.ul.com/advantage for more details, or call UL at 1-877-UL Helps (877-854-3577). For outside the US and Canada please visit http://www.ul.com/ global/eng/pages/corporate/contactus/ for global contact numbers. Certification made simple. Brought to you by UL, the organization that the world has relied on for safety since 1894.
UL LLC Phone: 1-877-UL Helps (877-854-3577) Web: ul.com/advantage

www.applianceDESIGN.com applianceDESIGN July 2012 29
New Products
Micro Plastics
The company has added color to their polyethylene and nylon lines of wire routing split loom. They now offer all sizes of their nylon split loom in orange, to accommodate applications where identification is critical to safety. The polyethylene split loom is now available in red, yellow and green. Perfect for organizing cables and managing cords into color-coded bundles, the colored split loom comes in six standard sizes: 1/4-, 3/8-, 1/2-, 5/8-, 3/4-, and 1-inch. Theyre extruded from durable materials, and resistant to temperature and corrosion conditions. Visit www.microplastics.com between 200mV and 5V in a single measurement range, and charts system energy usage over time. Developers can optimize both hardware and software for maximum energy efficiency within any development environment and on any development platform. Visit www.pocketpico.com time on a desktop system, clear transparent material and high-temperature resistant material. The Objet30 Pro takes its place as the new top-of-the-line addition to the companys existing desktop 3D printer line. With a small footprint, professional 28 micron print quality and wide ranging material versatility, the printer produces high quality prototypes with a choice of seven different materials and functional properties.
A.W.T. World Trade

These expertly designed and engineered machines enable glass printers to deliver rapid output with high-quality printing on an array of rigid substrates including solar panels, architectural glass, automotive glass, appliance components and decorative mirrors. The printers include a remote diagnostics tool that connects to the Internet. Standard printer features include parallel peel for a more consistent flood stroke and ink deposit, automatic leveling of squeegee/ floodbar pressure across the substrate, patented upfront stroke adjustment for easier print positioning and advanced ink recovery. Visit www.awt-gpi.com
W.L. Gore & Associates

Venting solutions for portable electronics prevent contaminants from entering, while preserving sound transmission quality through the use of high-transmission materials employing Gores unique ePTFE (expanded polytetraflouroethylene) technology. These are available in a variety of product forms for protection from dust and splash as well as full immersion. Precut adhesive vents and unique custom vent designs are also available. The company has formed a new business unit for its portable electronic vent technology, offering dust, splash and immersion protection that meets a range of IP standards up to IP68 (full dust protection, complete immersion). Visit www. gore.com
Sensirion
The Swiss sensor manufacturer is launching its new digital SFM3000 mass flow meter for high-volume applications in medical devices, process automation and burner control. The flow channel is designed to achieve a very low pressure drop of less than 3mbar through the sensor element. The flow meter bi-directionally measures the flow of air and other nonaggressive gases at rates up to 200slm with high accuracy and very high speed. It outputs a 14-bit digital signal at a 2kHz update rate. The signal is internally linearized and temperature compensated. Visit www.sensirion.com
Ix Innovations
The PocketPico P200 PowerMate energy optimization instrument was designed for embedded systems engineers and other low-power electronics developers, It accurately measures current from 1nA to 30mA
Objet
The Objet30 Pro, unveiled at RAPID, is a new desktop 3D printer that offers seven different materials, including, for the first
Global Lighting Technologies

The company has improved the performance of their standard 2x2 ft.-square edge-lit LED-based flat panel downlight
NEw ProDuctS
assembly by developing a brighter and more efficient SSL solution for ceiling lights that delivers efficiencies greater than 70 lumens per watt using standard GLT 2x2-ft. troffer packaging, with a CRI of > 80. The LEDs used in the new panel have increased in brightness from approximately 100 lumens up to 130 lumens, with no increase in price. Visit www. glthome.com numeric references, simplifies large batch marking and part serialization. The compact Class 1 laser enclosure (26 inches by 40 inches by 18 inches) sits on a bench or cart. The large, ergonomic access door makes it easy to load/unload parts. The 20W fiber laser marks a wide range of materials, including anodized aluminum, stainless steel and most plastics, and readily accommodates many shaped and sized parts. For more information visit www.technifor.us packaging, textiles and food industries. The DCX Digital Power Supply Series combine scalable technology and the industrys first closed loop amplitude control. Visit www. BransonUltrasonics.com fect for DACs (digital-to-analog converters), ADCs (analog-todigital converters), DAB (digital audio broadcasting), and professional CD audio equipment. It also features a standby functionwhen placed in disable mode, the internal oscillator is completely shut down and its output buffer is placed in TriState. This family is housed in a 9x14 mm SMT package and operates with a +3.3V power supply consuming 15mA of current. Stability is rated at 20-50ppm (0C to +70C) and 25-50ppm (-40C to +85C). E-mail sales@crystek.com
crystek
The CCHD-95 is a new ultralow phase noise HCMOS clock oscillator with standby mode, featuring an extremely low close-in phase noise of -100 dBc/ Hz at 10Hz offset and a typical noise floor of -170 dBc/Hz at 100kHz offset. This makes it per-
Systec
The company announced it will now be manufacturing and servicing the NW140 UV Digital Inkjet Printer in cooperation with Spartanics Laser Cutting Systems and JetINX UV Inkjet Printing technology in Bielefeld, Germany, beginning July 2012. The NW140 UV Digital Narrow Web Press is a fully integrated printing and laser finishing system that provides single pass printing at speeds up to 80 feet per minute. For more information, e-mail Scott Edwards at systec140@spartanics.com.
Advanced Machine & Engineering/Hennig

The company is introducing several new workholding clamping products from Jakob Antriebstechnik, the companys European partner. The series MC power clamping nut offers simple manual operation, high clamping forces through force magnification and high operating safety, as a result of a selflocking feature. The clamping force ranges from 40 to 160 kN. This product line can be used to clamp workpieces and tools, particularly in forming presses and punches, or to clamp down closing lids of tanks and enclosures on various machine types. Visit www.ame.com
Low Viscosity Silicone Potting Compound

Two Component MasterSil 151
Tough and flexible Optically clear Vibration and shock resistant
Branson ultrasonics, a subsidiary of Emerson technifor

The TFG20 gantry enclosures table (12 feet by 24 feet by 6 feet) with its X and Y axis
The company recently introduced its first global series of ultrasonic welding power supplies for automated assembly systems in the automotive,
154 Hobart Street, Hackensack, NJ 07601 USA +1.201.343.8983 main@masterbond.com
www.masterbond.com
ASSOCIATION REPORT: AHAM
Leading the Way

President Association of Home Appliance Manufacturers
Joseph M. McGuire
his year marks AHAMs 45th anniversary as the trade association of the home appliance industry. Along with this important milestone, this year AHAM also announced its new strategic plan for 2012-2015, which was presented to the membership in late April. As AHAM looks ahead, it is important to recognize the qualities, culture, and customers that empower the actions of the organization and support the values of the industry. This identity combined with a strong mission lays the foundation for how AHAM leads into the future. AHAMs mission guides our actions and moves the organization towards its vision: A single voice providing the home appliance industry and its customers leadership, advocacy, and a forum for action, and developing and implementing credible solutions for public policy, standards, and business decisions. Our vision is that AHAM leadership and member participation result in a vibrant home appliance industry enhancing consumers lives through innovative, sustainable products and services.
AHAMs expertise in developing appliance testing standards and its participation in the safety and performance standards processes of North American and global standards development bodies will always put the consumer first while maintaining product integrity.
The foundation of AHAMs strategic plan is a number of pillars that reflect the core services the association provides to its members and the opportunities before the industry in the foreseeable future. Advocacy of policies that foster innovation. Continue to work with government at all levels and increasingly with other influencers of product design such as retailers and utilities to seek public policies and market-related specifications that serve social needs and allow companies to innovate, compete, and serve consumers.
Standards that remove barriers. AHAMs expertise in developing appliance testing standards and its participation in the safety and performance standards processes of North American and global standards development bodies will always put the consumer first while maintaining product integrity. Data that drives business and consumer decisions. Services such as market statistics, third-party rating verification, and consumer safety tips drive intelligent decisions by members, trade partners and consumers. Connect with retailers through a formal channel of communication. AHAMs dialogue with the retail sector will continue to grow in substance and importance based on experience with key public policytype issues such as sustainability, safety, and product stewardship. To ensure a formal relationship to address such mutual priorities, AHAM will establish a Retail Advisory Council of senior retail executives. Strategic resource deployment in the U.S. and Canada. Appliance manufacturers wish to benefit from fuller integration of industry representation in Canada and the United States. Offering a single, dedicated appliance industry association in both countries, AHAM will open an office in Canada in July 2012 and broaden membership to include appliance manufacturers in Canada. Stay tuned to Appliance Design and the AHAM website for more information about the launch of AHAM Canada. Embrace and lead transformational industry issues. Providing leadership to the industry to prepare for and shape emerging issues is a critical valueadd for members and an essential return on member dues. AHAM will continue its work on smart appliances, sustainability, and product stewardship, and scan for other cross-cutting issues for companies and consumers. Promote value and trust in the AHAM brand AHAM is the voice of the appliance industry, its credibility honed by its proven ability to forge industry consensus on critical issues. This benefit and the breadth of member-driven services provide substantial return on member investment and value to its customers. <
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33% Electricity. 100% Cold.
The cold facts: energy savings of 67% - the result of high-efciency EC technology and sophisticated aerodynamics! In our specially developed ESM series for refrigeration technology, the motor and impeller are optimally matched. Compared to conventional shaded-pole motors with separately attached impellers, the overall efciency is substantially increased. This advantage makes a particularly great difference in refrigeration systems with a high duty cycle. By the way: our highly successful W1G200 model is now available in the 172, 230, 250, and 300 mm sizes and with an easy-to-clean surface. Learn more at: www.ebmpapst.us
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July 2012

NEW MEETS NOW

UL and the UL logo are trademarks of UL LLC 2012

bring ideas to life

For more information, were easy to reach: T: +1.641.787.8700 | E: sbe@ul.com | W: springboardengineering.com

CONTENTS JULY 2012

25 Design Marts 30 New Products 32 Association Report: AHAM 33 Advertisers Index

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blogs@appliancedesign.com (248) 244-6481 bagwellj@bnpmedia.com (480) 334-0286 britcherm@bnpmedia.com

Introducing the new 2012-2013 editorial advisory board:

Seth M. Fisher, Editor-in-Chief fishers@bnpmedia.com Twitter: @aplncdsgn

volume 60, no. 7

4 applianceDESIGN July 2012

MAJOR APPLIANCES (Thousands of Units)

2012 1614.5 1564.0 1453.0 1759.4

2012 448.0 524.6 547.5 514.0

2012 516.6 488.5 642.7 761.6

2012 371.1 593.1 289.2 102.0

6 applianceDESIGN July 2012

for your next innovation

ahaM Releases First Sustainability Standard for household Refrigeration appliances

USPS BaN oN LIthIUM IoN

NEw LIqUID coLoR tEchNoLoGy FoR PoLyoLEFIN BLow MoLDING

Swiss Chemical company Clariant Masterbatches announced a liquid ve-

RETRACTIONS AND ADDENDA:

I Twenty Fifth Annual EID GOLD Awards

I Twenty Fifth Annual EID BRONZE Awards

IMPRESSA J9 One Touch TFT, by Jura Capresso Inc. Alameda, Calif.

applianceDESIGN June 2012 9

GE to opEN chIcaGo DESIGN cENtEr

Ipv6 LauNchES, worLD MaDE SafE for wEbtocracy

rEport: MEtaLforMErS bEarISh ovEr NExt thrEE MoNthS

10 applianceDESIGN June 2012

Gas Ignition Controls

5vdc, 24vac, 24vdc or 120vac Alarm

CSA ANSI Z21.20 CSA C22.2 No. 199-M89

Series 9X: Direct Spark or Intermittent Pilot

CSA ANSI Z21.20 CSA C22.2 No. 199-M89

CUSTOM OEM VERSIONS AVAILABLE

Certified to Standards AG206 and AG210

630-860-6514 www.capablecontrols.com info@capablecontrols.com

14 applianceDESIGN July 2012

Figure 2. Error components of TEB. Source: Honeywell Sensing and Control.

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Gas Ignition Controls

5vdc, 24vac, 24vdc or 120vac Alarm

CSA ANSI Z21.20 CSA C22.2 No. 199-M89

Series 9X: Direct Spark or Intermittent Pilot

CSA ANSI Z21.20 CSA C22.2 No. 199-M89

CUSTOM OEM VERSIONS AVAILABLE

Certified to Standards AG206 and AG210