888.496.5143
schmersalusa.com
Visit website
Call or click for
Guide To Navigating
Man-Machine Safety Regulations
RS# 101
COPYRIGHT 2012 NEWPORTELECTRONICS, INC. ALLRIGHTSRESERVED.
e-mail:info@newportUS.com
1-800-NEWPORT
Universal Inputs
'
Thermocouple
'
RTD
'
Process Voltage
'
Process Current
'
Strain
Choice of Outputs
'
Ethernet TCP/IP
'
Serial RS232/485
'
PID Control
'
Relays
'
Analog Control
Sizes and Styles
'
1/32, 1/16 and 1/8 DIN
'
Big Display
'
Compact Case
'
DIN Rail
'
Panel/Bail
Visit us at
Monitor and control your Wafer FAB, MEMS, Micro Electronics, Semiconductor
process and manufacturing, and much more.
The and INF-B temperature controllers, panel meters, and signal
conditioners connect to an Ethernet network and can email or send text
messages to your cell phone. You can monitor and control temperature or
any process through a web browser over the Internet!
RS# 102
FEATURES
REPORTERS NOTEBOOK
pressure data to the researchers
through the entire crash event.
The original ESA engineer
worked to convert the foil into a
strip of about 50 individual sen-
sors, each about a square centi-
meter. At the end of each strip is
a flexible printed-circuit board
with a 50-channel amplifier.
When it is attached to a fender
or bumper, it lets test engineers
know how fast that metal is
bending, as well as whether it is
bending 20 in one direction or
60 in the other.
VW has now used the sen-
sor in several crash tests and it
has contributed to changes that
make the cars safer, according to
VWmanagers.
ASwarmheads for space
Three identical Swarmsatellites will launch fromRus-
sias Plesetsk Cosmodrome next month on a four-year mis-
sion to explore the Earths magnetic field. This is the first
person responsible for
ground software devel-
opment at ESAs Ger-
man operations center.
Techtransfer for
piezofoil
Back in the early
1990s, a German en-
gineer was developing
a new type of pressure
sensor that would coat
the wings of Hermes,
a reusable manned-
shuttle that would be
launched into space
atop an Ariane 5 rocket
and then return to
Earth on it own, much
like the Space Shuttle. The sensor had to be light and thin
so it would not add bulk or drag to the airfoil. The engi-
neer turned to piezoelectric foil to do the job. Like other
piezo materials, the thin foil (30-microns thick) converts
vibrations and pressures into electrical pulses that can be
measured and interpreted.
The foil senors were successfully tested in a hyper-
sonic wind tunnel, but the Hermes project was cancelled.
So over the years, ESA has been looking for civilian uses
for the piezo sensors. One of the earlier applications was
converting the foil to paint and putting it on a human mo-
lar. Scientists used this instrumented tooth to measure
forces a toothbrush puts on teeth.
But just recently, Volkswagen saw the sensor demon-
strated at the Hannover Fair at a booth set up by ESAs
Technology Transfer Programme Office. They quickly de-
cided to use the piezo sensors on crash-test vehicles. Tradi-
tional sensors do well at recording pressure up to the point
of impact, then they are too often destroyed in the crash.
The foil versions, however, survive the crash, sending
Eventually ordinary
Earthlings may be able to
access spacecraft froma
browser screen.
U.S. citizens tend to think of NASA when
the topic turns to space exploration. But the
European Space Agency (ESA), established
in 1975 to combine the efforts of 19 European
nations, has its own ideas for advancing space
technology. Among the most interesting efforts
with which ESA is involved is one aimed at
extending Internet connections to spacecraft.
Though its annual budget is about $5.2 billion
compared to NASAs $18 billion, ESA is making
important strides in fundamental space research.
Nanosats totest software
Engineers and technicians at ESA today control satel-
lites and space experiments using Packet Utilisation Stan-
dards, a software suite that dates to 1994. There have been
upgrades since then, but the stumbling block to moving
to newer software is that space scientists and the organi-
zations that fund themmust ensure the software, includ-
ing operating systems, languages, and interfaces, is fit for
space.
No one wants to use new and possibly problematic
software on a multimillion-euro mission in space, says
Mario Merri, head of the Mission Data Systems Div. at
ESAoperations center.
Unfortunately, the only real way to prove software is fit
is to take it into space and run it through its paces.
To lower the cost of validating software, and to en-
sure no missions are endangered, ESA researchers devel-
oped Operations Satellites, dubbed Op-Sats. The 30 10
10-cm satellites mission is to test and validate critical
onboard and ground software. The spacecraft is outfitted
with off-the-shelf processors that have more computing
power than a satellite usually carries. It is also designed
to recover easily and quickly frombuggy software. Re-
searchers on Earth can replace the entire onboard software
suite with new and fresh code daily, letting developers
troubleshoot their work in a real but safe environment.
The first Op-Sats could launch next year.
SpinninganinterplanetaryWeb
People increasingly take reliable and fast Internet ac-
cess for granted. Now space scientists want to extend the
same simplicity and reliability of the Web to astronauts on
the Moon or Mars. The first goal will be to let astronauts
communicate among themsleves, with control centers on
Earth, and with space ships and bases. But who knows;
someday top level Internet domains may include such
names as .moon, .mars, or .sstation.
To this end, ESA, NASA, and other major space or-
ganizations and industrial partners have been working
together as part of the Consultative Committee for Space
Data Systems. They have developed standards for hard-
ware and data exchange that should pay off even in the
short termfor commercial space-flight businesses, satellite
manufacturers, and space agencies.
Satellites have already been used for links between
Earth and mission spacecraft. In 2008, for example, ESAs
Mars Express acted as a data-relay node between NASA
technicians on Earth and their Phoenix Lander during de-
cent and landing on Mars, It will repeat that task in August
this year with NASAs Mars Science Laboratory.
And last December, ESAs worldwide tracking station
network handled contact between Russian controllers
and that countrys Phobos-Grunt mission to Mars. Then,
in October of this year, an astronaut on the International
Space Station will practice at remotely controlling a plan-
etary rover at ESAs operations center, simulating orbiter-
rover communication links on a planet like Mars.
Establishing technical standards and communica-
tion architectures isnt the most high-profile part of space
exploration, but its absolutely vital for ensuring that the
more-exciting efforts, like sending an astronaut to Mars,
will work when that time comes, says Nestor Peccia, the
Authoredby:
Stephen J. Mraz
SeniorLditor
stephen.mrazQpenton.
com
Resources:
European Space Agency,
www.esa.int
Internet
in
Space?
continued on page 22
EAAS used its
35-m-diameter deep-space
dish antenna in Spain to
relay transmission froma
Russian Mars mission to
controller in Russia.
The pressure senor used in VWcrash tests is based on pressure-
sensitive piezo filmand consists of 50 individual sensors, each 1
sq cm, and a 50-channel amplifier, all flexibly printed on a thin
and bendable circuit board.
Piezo material
suspended in a
paint was applied
to a human molar
to let scientists
measure the
force of a
toothbrush on a
tooth.
Op-Sats, here shown in
an artists conception,
are simple spacecraft
designed solely to test
software. They will have
a volume of about three
liters but will carry off-
the-shelf components
such as three-axis
attitude control systems,
deployable fixed solar
arrays, GPS receivers,
and UHF communication
systems. It will also
have state-of-the-art
components such as
S-band communications with an uplink rate four times greater
than any other ESAspacecraft and a miniaturized X-band
transcmitter providing up to 50 Mbps downlink. These rates are
up to several hundreds times better than any other satellite flown
before.
1UNL l4, 20l2 MACH|NL DESIGN.com 20 1UNL l4, 20l2 MACH|NL DESIGN.com 21
SEMICONDUCTORS
Most light-emitting
diodes are made in Asia,
but future generations
of LEDmanufacturing
equipment could
still be marked
Made in the U. S. A.
The bad news for makers of semicon-
ductor-manufacturing equipment is that
sales of most kinds of fab gear are flat to
down. The good news is that the U. S.
could end up playing a bigger role sup-
plying manufacturing equipment for the
emerging area of solid-state lighting.
The U. S. Dept. of Energy used stimulus
funds to amplify the supply-chain strengths
of the U.S. The DOE recognized that the
U.S. would be an unlikely place for LED
fabs, so it tried to seed the development of
LED-manufacturing equipment here, ex-
plains Tom Morrow, executive vice presi-
dent, emerging markets group and chief
marketing officer for SEMI, the association
Authored by:
LelandTeschler
Editor
Resources:
Intel, www.intel.com
Semicon West and Intersolar 2012, http://
semiconwest.org/
Will the U. S. be an
LED
ASSEMBLY
MECCA?
Thoughthe 300-mmwafer has become the industry standard,
chipmakers are transitioningto450-mmversions, like this example
at Innolas Semiconductor GmbH, a maker of wafer-sortingand
laser-markingsystems.
JUNE 14, 2012 MACHINE DESIGN.com 62
Access our Reader Service
Web site to quickly find and
request information on the
products and services found
in the pages of MACHINE DESIGN.
www.machinedesign.com/rsc
vOLUML84
|SSUL9
1UNLl4,20l2
Internet in space?
Lventuallyordlnaryearthllngsmay
beabletoaccessspacecraftfroma
browserscreen.
20
Will the U. S. be
an LED assembly
mecca?
Mostllght-emlttlng
dlodesaremadelnAsla,
butfuturegeneratlons
ofLLDmanufacturlng
equlpmentcouldstlll
bemarkedMadelnthe
U. S. A.
62
54
82
76
68
From Engineer to Rocketman
Atralnedmechanlcalenglneerwho
serlouslydabbledlnrocketryasa
hobbylstbulldsarocketthatcllmbs
to overl00,000ft.
Made in America?
whatlttakestocompetltlvely
manufacture ln theU. S.
Hydraulic controls
transform press technology
Hydraullcmotloncontrollers
brlng hydroformlngpresseslnto
the 2lst century.
Energy-efficient
hydraulics slash machine
operating costs
Unllketradltlonalconstant-speedhydraullcs,
varlable-speedpumpdrlvessupplyonlythe
poweraprocess requlres.
1UNLl4,20l2 MACH|NLDESIGN.com 2
A
B
P3-HSI P3-HSO
Machine Process Start
1
Enable
VELOCITY MOVE
Module Name: Feed Conveyor
Channel: 2 Channel Name: CHAN-2-0.1.1
Move Setup
Direction Positive
Velocity Fill Index Speed
500
Ramp Rate Conveyor Ramp Rate
1000
Stop Setup
Immediate Stop
In Progress ConveyorMove In Progress
1
Complete Conveyor Move Complete
0
Move Status Conveyor Move Status
2
P3-HSO
2-channel
High-speed Output
$
349
Pulse/Direction,
Quadrature X1
and Quadrature X4
P3-HSI
2-channel
High-speed Input
$
329
Pulse/Direction,
Step Up/Step Down
and Quadrature
With the Productivity3000
controller, you get the power you
need for advanced applications.
Download the free
programming software
and check it out!
Start with the $599 CPU - 50Mb of memory supports
large programs, with tagname database and program
documentation stored onboard. The huge (100,000+)
I/O capacity gives you plenty of room to plan and
expand. And the CPUs seven built-in communication
ports make integrating a large system easier than
you can imagine.
Now with High-speed Motion Control
These new 2-channel modules add high-speed and motion
control applications capability to the Productivity3000 controller,
and theyre easy to use! Add up to 22 P3-HSO or P3-HSI modules
in any combination to any P3-550 CPU and P3-RS base group.
That gives you up to 44 axes of motion or high-speed counting
capability in a single base group. These modules are supported
and fully functional in the CPU base, local and remote
expansion bases.
Simple Instructions
Our standard instructions were designed to make your
everyday motion applications simpler. The Find Home, Set
Position, Simple Move and the Velocity Move instructions
(to name a few) were created to get you up and running
sooner. Capabilities such as Registration, Jerk Control and
Channel Scaling were included to give you the flexibility
to accomplish those jobs.
Drop-in Hardware Confguration
Install a high-speed module into the system hardware
configuration and define each channels behavior, status bits,
limits and scaling without the need for an external
configuration utility or software.
Application Example
High-speed outputs synchronize
the speed of the servo drive
controlling the fill conveyor. The
conveyor is synchronized with the
rotational speed of the
turntable based on the
signal(s) from the table
encoder feedback via the
high-speed input module.
http://bit.ly/p3000
RS# 103
DEPARTMENTS
Porcustomlzedartlclereprlntsandpermlsslons
pleasecontact:PentonReprlnts,l-888-858-885l,
e-mallatreprlnts@pentonreprlnts.comorvlslt
pentonreprints.com.
LdltorlalcontentlslndexedlntheApplledSclence
Technology|ndex,theLnglneerlng|ndex,SclSearch
andResearchAlert.Mlcrofllmcoplesavallablefrom
NatlonalArchlvePubllshlngCompany(NAPC),300
N.ZeebRd.,P.O.8ox998,AnnArbor,M|48l06-0998,
Ph:734-302-6500or800-420-NAPC(6272),extenslon
6578.
Permlsslontophotocopylsgrantedforusers
reglsteredwlththeCopyrlghtClearanceCenter(CCC)
|nc.tophotocopyanyartlcle,wlththeexceptlonof
thoseforwhlchseparateownershlplslndlcatedon
theflrstpageoftheartlcle,provldedthatthebasefee
of$l.25percopyoftheartlcle,plus$.60perpagels
paldtoCCC,222RosewoodDr.,Danvers,MA0l923
(CodeNo.0024-9ll4/l2$l.25+.60).
SubscrlptlonPollcy:MACHINEDESIGNlsclrculated
toresearch,development,anddeslgnenglneers
prlmarllyengagedlnthedeslgnandmanufacture
ofmachlnery,electrlcal/electronlcequlpment,and
mechanlcalequlpment.Toobtalnacompllmentary
subscrlptlonseeourwebpageat submag.com/sub/
mn.Porchangeofaddressfllloutanewquallflcatlon
formatsubmag.com/sub/mn.
PrlntedlnU.S.A.,Copyrlght20l2.PentonMedla,|nc.
Allrlghtsreserved.MACHINEDESIGN(|SSN0024-9ll4)
lspubllshedsemlmonthlyexceptforaslnglelssue
ln1anuary,Pebruary,1une,1uly,andDecemberby
PentonMedla,|nc.,9800MetcalfAve.,OverlandPark,
KS662l2.
Paldsubscrlptlonslncludelssuesl-l8.|ssueNo.l9
(OLMHandbookandSuppllerDlrectory)lsavallableat
addltlonalcost.Rates:U.S.:oneyear,$l39,twoyears,
$l99,.Canada/Mexlco:oneyear,$l59,twoyears,$239,
Allothercountrles:oneyear,$l99,twoyears,$299.Cost
forbacklssuesareU.S.$l0.00percopyplustax,Canada
$l5.00perlssueplustax,and|ntl$20.00perlssue.
ProductLocator,$50.00plustax.Prepaldsubscrlptlon:
PentonMedla(MACHINEDESIGN),P.O.8ox2l00,Skokle
|L60076-7800.PerlodlcalsPostagePaldatShawnee
Mlsslon,Kans.,andataddltlonalmalllngofflces.
CanGST#Rl2643l964.CanadlanPostPubllcatlons
MallAgreementNo.406l2608.Canadareturnaddress:
Pltney8owes,P.O.8ox25542,London,Ont.,N6C682.
Dlgltalsubscrlptlonrates:U.S.:oneyear,$69,two
years,$99,.Canada/Mexlco:oneyear,$79,twoyears,
$ll9,Allothercountrles:oneyear,$99,twoyears,
$l49.
POSTMASTLR:Sendchangeofaddressnotlceto
CustomerServlce,MACHINEDESIGN,P.O.8ox2l00,Skokle,
|L60076-7800.
ON THE COVER
DerekDevlllelaunches
one of hlsearlyrockets.
EDITORIAL
PowerPolntcanklll
EDITORIAL STAFF
LETTERS
SCANNING FOR IDEAS
Alr-poweredgrlnderboastshlghpower-to-welghtratlo
|oncannoncleansasltshoots
REPORTERS NOTEBOOK
LOOKING BACK
SENSOR SENSE
worldsblggestsensor:anlcecubeI
COMMENTARY
Doesmodel-basedenglneerlngmakesenseI
VANTAGE POINT
8enefltsofafocuseddlstrlbutorsprogram
INVENTORS CORNER
Apphelpskldsflghtleukemla
SOFTWARE REVIEW
Professlonaldesktop3Dprlnterlseasytouse
SOFTWARE PRODUCTS
PRODUCT SPOTLIGHT
Plastlcs&elastomers
PRODUCTS
DATA FILES
AD INDEX
BUSINESS INDEX
BUSINESS STAFF
BACKTALK
48
20
40
47
8
l0
l2
l6
50
52
92
94
96
98
l22
l24
l25
l26
l27
1UNLl4,20l2 MACH|NLDESIGN.com 4
$$$$$$$$$$$ $$ $$ $$ $$$$$$$$$$$$$ $$$$$$$$$ $$$$$$$$$
$$$$$$$$$$$$ $$ $$$$$$$$$$$$$ $$$$$$$$$$$$$$$$$ $$$$$$$$$$$$$$$$$
$$$$$$$$$$$$ $ $$$$$$$$$$ $$$$$$$$$$$$$$ $$$$$$$$$$$$$$
$$ $$ $$ $$ $$ $$ $$ $$ $$ $$ $$ $$ $$ $$ $$ $$ $$
$$$
$$$$$$$$$$$$$ $$$$$$$$$ $$$$$$$$$$$$$$$$$$$$$$ $$$$$$$$$$$$$$$$$$ $$$$$$$$$$$$$$$$$$
cccccc
Manufacturing Intelligent Compressed Air Products Since 1983
ll5l0GoldcoastDrlve-Clnclnnatl,Ohlo-45249-l62l-(800) 903-9247
fax:(5l3)67l-3363-L-mall:techelp@exalr.com-www.exalr.com
LXA|R
Tese have serious limitations.
On hot summer days when
the temperatures of the room
and inside of the enclosure
are about equal, theres
not enough dierence for
eective heat exchange.
They fa|| when dust and
d|rt c|ogs the h|ter
The coo||ng capac|ty |s
||m|ted due to amb|ent
cond|t|ons
EXAIR Cabinet Cooler
Systems
EXAIR has a complete line of Cabinet Cooler Systems
to dependably cool and purge your electrical enclosures.
Tey convert an ordinary supply of compressed air into
clean, cold 20
System w|th the same S0FN
rat|og aod 8t0lhr. o0tp0t.
F|ectron|cs can overheat
before |t turns on
|t runs far |onger than
necessary before shutt|ng off
|ncreased cyc|e t|me wastes
compressed a|r
Opening the panel door
and aiming a fan at the
circuit boards is a bad idea.
|t |s an 0SHA v|o|at|on
that presents a shock
hazard to personne|
The fan b|ows hot, hum|d,
d|rty a|r at the e|ectron|cs
The coo||ng effect |s
m|n|ma|
|t |s ||ke|y to fa|| aga|n
s|nce the env|ronment
|s st||| hot
How To Keep Your Electronics Cool
When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery
up and running again. Tere are several cooling options out there and its important to know the facts.
line up of coolers that are prone to bad behavior
If you would like to discuss
an application, contact an
Application Engineer at:
EEEEEXXXXX
EX EX EX EX
to to dd
TTT
cl cllll cle
kn kn
th h th
www.exair.com/45/44045a.htm
WATCH
THE VIDEO!
..
in in iinto to too
Reliable and maintenance free!
Scao Ior V|deo
RS# 104
E
D
I
T
O
R
S
W
E
B
P
I
C
K
S
Whats new online machinedesign.com
FREE WEBCAST:
HOW PROPER HOSE MAINTENANCE CAN REDUCE EXPENSIVE FAILURES
Tuesday, June 26, 2012, 2:00 p.m. ET
Hlghpressuresandtemperaturesassoclatedwlthhydraullcsmake
componentselectlon,lnstallatlon,andmalntenancecrltlcalto
efflclency.Hose-systemfallurecangrlndproductlvltytoahalt,butsome
stralghtforwardstepscanhelppreventdowntlmeorlnjury.Thlsweblnar,
presentedbyGates Corp.,wlllcoverkeycomponentstoahydraullc-hose
preventlve-malntenanceprogram,explalnhowtoselectproperhoseand
coupllngs,dlscusscuttlng-edgetechnologlesavallabletosolvecommon
problems,andofferlmportanttlpsforasafe,productlveworklng
envlronment.AQ&Asesslonwlllfollowthepresentatlon.Learnmoreand
reglsterathttp://hydraulicspneumatics.com/events.
CASINO GAMING EMBEDDED APPLICATIONS
LnglneerlngTvtalkswlthexpertsatAMDaboutthe
companysnewR-SerlesAPU(accelerated-processlng
unlt)formoderncaslnogames.|tfeatureshlgh-end
graphlcsandanlmatlons,andsupportsuptol0
dlsplaysforsldebetsandorderlngrefreshmentsrlght
fromaslotmachlne.|tmeetsregulatoryrequlrements
forsecurebutaccesslbleembeddedcomponents,
andthedevlcesarealsosultedfordlgltalslgns,sales
klosks,andmedlcal-lmaglng
dlsplays.Learnmoreathttp://www.
engineeringtv.com/video/Casino-
Gaming-and-Other-Embedde;Only-
Engineering-TV-Videos.
Free data translation
Delcamsonllnedata-exchange
servlce,DelcamLxchange,whlchnor-
mallycostsabout$50permodel,wlll
befreeforanyonewhollkesthecom-
panyonltsPacebookpageatwww.
Facebook.com/DelcamAMS.Users
downloadandstorethesoftwareon
acomputer.Thlsmakestranslatlons
qulckandsecurebecauseCADmod-
elsarenotsenttoanoutsldeservlce
provlder.Thesoftwarereadsand
wrltesallcommonCADformatflles.
New motors Web site
Pittman Motors,amanufacturerofdc-
brushandbrushlessmotorsandgear-
motors,haslaunchedanewwebslteat
www.Pittman-Motors.com.Resources
lncludetechartlcles,whltepapers,and
catalogs,aswellasdownloadableCAD
modelsforvlrtualprototyplng.Abuy
onllnefeatureletsusersorderstandard
partsforsame-dayshlpplngorcustom-
lzemotorswlthspeclalshafts,lead-wlre
assemblles,motorwlndlngs,andother
optlonstomeetmostanyenglneerlng
requlrement.
Webcast on simulation-
data management
Ansys wlllofferafree,l-hrweblnaron
1une2ltodlscussstorlngandmanag-
lngenglneerlng-slmulatlondata.|twlll
examlneslmplestrateglesforgettlng
startedwlthdatabasemanagement
andhowtosecurelyuseandsharedata
lnamoblle-computlngenvlronment.
Learnmoreathttps://marketing.ansys.
com/rc/ansysinc/tp/scalable_4.
Video demonstrates
tubular linear motors
Anew3-mlnvldeofrom
Dunkermotor letsdeslgnenglneers
seethecapabllltlesoftubular
llnearservomotors.Constructed
ofastalnless-steelrodfllledwlth
rare-earthmagnetsandaforcer
contalnlngaserlesofcollsconnected
asthree-phasewlndlngs,themotor
generatesllnearforcewhenexclted.
Thlsdeslgnprovldessmooth,
cogglng-freemotlonandhlghheat
dlsslpatlonatspeedsto250lpsand
l2-mrepeatablllty.watchthevldeo
atwww.dunkermotor.com/videos.
FREE WEBINARS
ON INDUSTRIAL
CONTROLS
Take30to45mlnandwatchfree
weblnarsonlndustrlalcontrols
toplcs.Seeequlpmentlnactlon,
andtakeadvantageofthe
questlonandanswerperlodatthe
endofeachsesslon.
s
Y
o
u
r
A
n
g
l
e
?
W
h
a
t
s
Y
o
u
r
A
n
g
l
e
?
EDITORIAL STAFF
EDITOR
Leland E. Teschler
leland.teschler@penton.com
MANAGING EDITOR
Kenneth J. Korane
ken.korane@penton.com
SENIOR EDITORS
Leslie Gordon
leslie.gordon@penton.com
Stephen J. Mraz
stephen.mraz@penton.com
ASSOCIATE EDITOR
Robert J. Repas, Jr.
robert.repas@penton.com
INDUSTRY COVERAGE
AUTOMOTIVE, PACKAGING,
MEDICAL
Stephen J. Mraz
CAD/CAM, MANUFACTURING
Leslie Gordon
ELECTRICAL, ELECTRONICS
Robert J. Repas, Jr.
FLUID POWER, MECHANICAL
Kenneth J. Korane
EDITORIAL PRODUCTION
Denise Greco
Editorial Production Manager
Randall L. Rubenking
Art Director
l300L.9thSt.Cleveland,OH44ll4-l503
RS#ll0
RS#l09
1UNLl4,20l2 MACH|NLDESIGN.com 10
Ever wonder how producers of extremely advanced
consumer electronics, like smart phones, manage to
keep launching new generations of these products at
such a ferocious tempo with consistently high quality?
SKF product manager Satyen Bohidar and SKFs
sales team have part of the answer SKF-SNFA high-
speed super precision bearings. They allow the machine
tools used for manufacturing key components of these
products to run awlessly and precisely at up to
60.000 rpm 365 days a year.
The result? Smart products are brought to the
market even faster. Its another great example of
knowledge engineering at work. Find out more at
www.skf.com/poke
The Power of Knowledge Engineering
Milling spindle running
at 40.000 rpm
Satyen Bohidar,
SKF Product Manager
SKF-SNFA high-speed
bearings
Producesmartphonesfaster
withhiqhspeedbearinqs
RS# 111
LETTERS
asustalnabllltystandard(Dowe
NeedaSustalnabllltyStandardI
March22).oucanbetthatthls
lsanotherwayofmaklngmoney
by thestandards freaks and a
way for the government to put
morecostburdensonmanufac-
turlng. |ts also just more buzz-
wordstoflllthelawbooksbythe
envlronmentcrowd.
Thegovernmentwlllseethls
as a way to force employers to
hlre more people to shuffle the
sustalnabllltypaperwork.Larger
companl es wl l l feel forced to
spend mllllons on thls stuff be-
cause they seek government
contracts, and the costs of the
standardwlllbepassedontothe
customer,theAmerlcantaxpay-
ers.Andsmallercompanleswlll
beforcedtodlvertresourcesfrom
lnnovatlonandbreakthroughsto
morenonproductlvepaperwork.
Asusual,Amerlcancltlzenswlll
betheonespaylngforthlsuseless
stuff.
Thanksforyourcomments.|t
wlllbelnterestlngtoseelfother
buslnesspeoplehavethecourage
tospeakagalnstthlshare-bralned
ldeaofanotherstandard.
Gerald W. Yankie
Thlslsnomorethanajob-secu-
rltyprogramforthlrd-partyqual-
lty-controlconsultantsandeco
freaks.ouwouldhavetobecrazy
toevenconslderestabllshlngthls
programlnyourcompany.Lndless,
mlndless,andnever-endlngmake
workforwant-to-bebureaucrats.
Leo V. Cranch
We can fix for the
patent office
TheU. S.patentsystemlssufferlng
fromtwobaslcproblems.|tlsbe-
slegedbysubmlttalsthatarefunda-
mentallyflawed,butlnventorsare
encouragedtopatentthembased
onexaggeratedpromlsesfromthelr
patentlawyers.Andsecond,the
PatentOfflceemploystechnlcally
weakstaffthatlsoverwhelmedby
thesheernumberofpatentappllca-
tlon.8utwecanflxthls.
Prom l977 to 2000, | was ln-
volved ln an effort to evaluate
concepts submltted to the Na-
tlonal|nstltuteofTechnology.|t
wasfundedbytheLnergyDept.
andwaseventuallycalledtheOf-
flce ofTechnology |nnovatlons.
|deas were analyzed and evalu-
atedbyexpertslnthelnventlons
subjectmatter,andnotallldeas
revolvedaroundenergygenera-
tlonorconverslons.Therewasno
chargetolnventorsforthlsservlce,
andpromlslngentrleswentonto
furtherlnvestlgatlonlnasecond
phase.|ftheysurvlvedthesecond
round,lnventorscouldrecelveup
to$200,000todevelopworklng
proof-of-conceptmodels.
|workedatN|STlnthlsOfflce
andanalyzedabout750concepts
overal2-yearperlod.About5%
ofthemlnvolvedpatents.Thevast
majorltyoftheconceptsweredls-
mlssedatflrstglancebecausethey
wereobvlouslylmpractlcalorfun-
damentallylncorrect.Therestgot
closerscrutlny,butfewwentonto
thesecondstageofevaluatlons.
|bellevethatreestabllshlngthls
OfflceofTechnology|nnovatlons
andbroadenlngltsscopetocover
allnewlyrecelvedpatentappllca-
tlonswouldsavelnventorsconsld-
erableeffortandmoney,aswell
astaklngpressureoffthepatent
offlce. Of course, the patent of-
flcewouldalsohavetohlremore
knowledgeablestaffersaswell.
Andrew Wortmang
Not another standard
ouarecorrect,wedonotneed
Crank up the
apprenticeships
|readtherecentcolumn(Dont
waltforGovernmenttoAddress
SklllsGap,March8)wlthgreatln-
terest.8ut|contendthattheSocl-
etyofMechanlcalLnglneers(SML),
togetherwlththeNatlonalToollng
&MachlnlngAssoclatlon,hasfalled
mlserablyatendlngtheshortage
ofskllledmachlnlstsandatcreat-
lngquallty,long-termmachlnlng
tralnlng.whatsneededlsamod-
ernlzedmachlnlngapprentlceshlp
runonanatlonallevel.
|nstead,herelsatyplcalexample
oftheklndofshort-termprogram
thattheNTMAputson(www.train-
ingcenters.org/ ).|tremlndsmeofa
late-nlghtlnfomerclal,areallybad
one.Afteryearsandyearsoffallure,
SMLandtheNTMAshouldnolonger
haveanythlngtodowlthmachlnlng-
apprentlceshlpprograms.
Jon Banquer
Lasers make bad
table lamps
Regardlessofhowpleasantanar-
row-bandlaserllghtmlghtbeforll-
lumlnatlon(ourNextTableLamp
Could8eaLaser,Peb.9),ltstlllls
composedofseveralnarrowbands.
Thlsmeansobjectsthatarereflec-
tlveovernarrowbandsoffrequen-
clesthatdonotmatchupwlththe
laserslllumlnatlonspectrummayof-
tenlookunnaturalundersuchllght-
lngwhencomparedtollghtlnghav-
lngablackbodyspectrumslmllar
todayllghtorlncandescentllghtlng.
Christopher James
Yes and no
Readerssaynotounlonsandanewsustalnabllltystan-
dard,aswellastouslnglaserslnlampsandllghtlngfor
houses.8uttheysayyestoapprentlceshlpsasawayto
relnvlgoratetheU. S.manufacturlngbaseandto
effortsatstreamllnlngandupgradlngtheU. S.
PatentOfflce.Andoneofmanyreaderspolnted
outthatl80-hpoutboardmotorsforboatswererareas
hensteethlnl962.
1UNLl4,20l2 MACH|NLDESIGN.com 12
Q
Graphical Software
Q
Sensor Connectivity
Q
Signal Analysis
Q
Control Algorithms
Q
Custom Timing
Q
Custom Triggering
Q
Actuator Connectivity
Q
Embedded Storage
Q
Industrial Networks
Q
Expansion Systems
All the Tools you Need for Embedded
Measurements and Control,
in one rugged box.
The NI CompactRIO hardware platform can handle your embedded measurement
and control applications, and do it in a way that outperforms other off-the-shelf
systems so you dont have to spend time developing a custom solution. The range
of high-quality measurements, coupled with an extremely rugged design and the
ability to modify the hardware using NI LabVIEW system design software, gives you
all the benets of customization with the convenience of an off-the-shelf platform.
>>
To learn more about CompactRIO, visit ni.com/compactRIO 800 891 2755
2012 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.
Other product and company names listed are trademarks or trade names of their respective companies. 05312
RS# 112
Solutions for
Semiconductors
Aerotech has extensive
experience in semiconductor
device manufacturing and
inspection. Our unmatched
product line incorporates
the most sophisticated
motion control technology
available today.
Powerful motion controllers
with advanced control features
like Harmonic Cancellation,
Iterative Learning Control and
Directional Gain Scheduling
Top of the line planar air-
bearings that provide up to 5 g
acceleration and 2 m/s velocity
A full line of nanotechnology
stages that provide 1 nm
resolution and <1 nm in-position
stability
450 mm wafer scalability
Dedicated to the Science of Motion
Aerotech, Inc., 101 Zeta Drive, Pittsburgh, PA 15238
Ph: 412-963-7470 Fax: 412-963-7459 Email: sales@aerotech.com
www. aerot ech. com
AH0510G_TM
A e r o t e c h Wo r l d w i d e
United States France Germany United Kingdom China Japan Taiwan
LETTERS
penswhenthependulumswlngs
toofar,unlonsbecometoopow-
erful, and unlon executlves be-
cometoogreedyI
Amerlcabecamegreatbecause
ofltsmanufacturlngpower,but
overlypowerfulunlonsnowseem
to be more of a hlndrance than
a help to economlc prosperlty.
Hugesalarlestounlonexecswho
getfullpayevenwhenworklng
unlonmembersareonstrlkewlth
measlystrlkebenefltslsnomore
falrthanwallStreetexecspulllng
downhugebonuseswhenthey
runthelrcompanleslntothered.
Do unlon leaders really rep-
resentthebestlnterestsofthelr
memberslftheykeepthemout
onlongstrlkestonegotlaterldlc-
ulousovertlmeratesthatbank-
rupt the company and throw
membersontounemploymentI
|m not so much antl-unlon as |
ampro-Amerlcanworker.
Name withheld by request
Corrections
|stherethe sllghtest posslblllty
that there l s a ml sprl nt l n the
Looklng 8ack sectlon (March
22)I|tlshardformetobelleve
that arubber boat, wlth slzes
froml0tol5ft,couldsupport
a l80-hp outboard. |n fact, go-
lngbacktol962,lfmymemory
servesme,thelargestoutboard
engl ne you coul d buy was a
l00-hp Mercury, whlch was an
ln-llneslxcyllnder.
Robert Herol
It should have read 18 hp. Leland
Teschler
|n the artlcle,How Servos and
SteppersStackUp(Peb.9),the
stepperandservoproflleswere
ml s t akenl y s wapped l n t he
graphl c tl tl edStepper versus
servoproflles.
No to the unions
Theresareasontheycall8oelng
theLazy8(TlmeforLnglneers
toThlnkAboutUnlonlzlngI1an.
l9). Theres a reason 8oelng ls
expandlng productlon lnto the
South.TheresareasonGMwent
lntobankruptcy.Theresareason
Amerlcancompanlesareshlftlng
productlon to forelgn soll. And
theresareasonunemployment
lshlgh,especlallylntradltlonally
strongunlonreglons.Andltsbe-
cause overly strong unlons are
strangllng the ablllty of Amerl-
can companles to remaln com-
petltlve, resultlng ln domestlc
l ayoffs, bankruptcl es, and l n-
creaseslntheoffshorecontentof
Amerlcanproducts.
Unlonslndlsputablyralsedour
standardofllvlngandestabllshed
falrwageslnthesweat-shopera
ofearlyAmerlca,andtheywere
responslbleforgreatlncreasesln
safetystandards.8utwhathap-
RS#ll3
1UNLl4,20l2 MACH|NLDESIGN.com 14
www.zero-max.com 800.533.1731
2010 ZERO-MAX
Together a winning combination for todays
servomotor applications.
Our ServoClass
HPSFDPNFNJ
&.*("4,&54"/%
(306/%*/(1"%4
REPORTERS NOTEBOOK
NVDIA VGX block diagram
Hypervisor
Virtual
GPU manager
Virtual machine
Guest O
Laptop
Laptop
Laptop
Laptop
Application
Citrix XenDesktop
NVDIA driver
& software
GPU
MMU
Kepler
GPU
Per-VM
channel
Remote
display
How to solve latency issues: Currently, the display of graphics from the cloud involves
passing data between the GPU, GPU RAM, through the graphics driver and graphics
API into system memory, and the CPU where its converted into a color image and
then converted into an H.264 video stream before being sent off to the end user. With
NVIDIA VGX, the data passes between the GPU, GPU RAM and immediately converts
into the H.264 video stream, bypassing the GPU driver, graphics API, system memory,
and the CPU. What makes this process possible is NVIDIAs Kepler GPU, the first such
device that can be virtualized in hardware, or shared, by many users in the cloud.
Service providers can install a few high-end NVIDIA Kepler-based VGX cards into
servers and serve multiple users and application instances.
RS#l25
framebuffer.
Nv|D|Aalsosaysdellverlng
vlrtuallzeddesktopsthlswaycan
mlnlmlzethesecurltyrlskslnher-
entlnsharlngcrltlcaldataand
lntellectualproperty.Porexample,
sourcedataforCADmodelsneed
neverleaveasecureserver,but
canbemanlpulatedbyusers
acrosstheglobelnrealtlmeuslng
thevGXscheme.
Plnally,Nv|D|Asayslntegratlng
thevGXplatformlntothecorpo-
ratenetworkalsoletsenterprlse|T
departmentshandle8ODcom-
putlng,thatls,employeesbrlnglng
thelrowncomputlngdevlceto
work.|tdellversaremotedesktop
tothesedevlces,glvlngusersthe
sameaccesstheyhaveonthelr
desktoptermlnal.
Therearethreepartstothe
Nv|D|AvGXtechnology:
vGXboardsThesecarry
Nv|D|AKeplerGPUs.Theflrst
Nv|D|AvGXboardlsconflgured
wlthfourGPUsandl6Gbytesof
memoryandfltslntothelndustry-
standardPC|Lxpresslnterfaceln
servers.LachKeplerGPUhasl92
Nv|D|ACUDAarchltecturecores
and4Gbytesofframebuffer.
vGXGPUHypervlsorThls
softwarelayerlntegrateslntocom-
merclalhypervlsors,suchasthe
CltrlxXenServer,lettlngmultlple
userssharecommonhardware
andensuresvlrtualmachlnesrun-
nlngonaslngleserverhavepro-
tectedaccesstocrltlcalresources.
Nv|D|AUserSelectableMa-
chlnesThlsoptlonletscompa-
nlesconflgurethegraphlcsthey
dellvertolndlvldualuserslnthe
network,basedonthelrdemands.
CapabllltlesrangefromPCexperl-
encestoprofesslonal3Ddeslgn
andenglneerlngexperlences. MD
1UNLl4,20l2
(03&8JSFBOE$BCMF
when reIiabiIity, durabiIity, and
perIermance can be cempremised
by harsh envirenments,
C0k
Corp
Motion Controlled. Problem Solved.
I
n matters of motion, when your inventive vision requires unparalleled
degrees of accuracy and the kind of pigheaded force consistency that
can be almost impossible to nd, look no further than AirpotCorp. Our
problem- solving line up of instrument -quality products will keep
your project moving.
And our Accurate Force Pneumatics is the key.
With a precision glass cylinder/seal-free piston technology, coupled
with ultra-high quality pneumatics, youll nd products that give you
levels of force and motion control nearly unobtainable by any other
pneumatic means.
Whats more, many of our products can outlast any machine you
put them in. And thats something we can guarantee!
So, when your specications call for a damping, actuation, pressure
sensing, or displacement device that is optimized for exceedingly accurate
and repeatable force control and at a cost lower than other methods
providing comparable function and performance give one of our
application engineers a call.
Lets get started. Whether youre designing or improving a product
line to better serve your customers, or building specialized equipment for
research, high-level testing, or precision assembly, get AirpotCorp
involved early in your process. Call 800-848-7681.
We will move you in ways you might never have imagined.
Airpot Corp, Norwalk CT USA Learn more at Airpot.com
Airpot
& Airpel-AB
MEGAFLEX
1FSGPSNJO
UFNQFSBUVSFTGSPN
-65$UP+260$
&OBCMFTDPNQBDU,
MJHIUXFJHIU
BTTFNCMJFT
PMFYJCMFTJMJDPOFnBU
DBCMFTUJOUJHIU
TQBDFT
$PNQMFUF
BTTFNCMJFT,
JODMVEJOHBOZ
DPOOFDUPST,NBEF
JO-IPVTF
A49l00DFSUJFE
RVBMJUZ
Visit Cicoil at Booth 6646,
San Francisco, July 10-12
RS# 136
REPORTERS NOTEBOOK
COMPANNEWS
RS#l37
PERSONNEL
RobertL.Pletrafesahasjolned
Tegra Medical,Pranklln,Mass.,as
presldentandCLO.Mr.Pletrafesa
hasmorethanl6yearsofexperl-
enceasapresldentandCLOlnthe
medlcal-devlcemanufacturlng
lndustry.TegraMedlcalproduces
complexcomponentsandfln-
lsheddevlcesforleadlngsurglcal,
lnterventlonal,andorthopaedlc
companles.
DISTRIBUTOR
AGREEMENTS
Dunkermotor,Llgln,|ll.,has
enteredlntoanagreementwlth
Cymatix Inc.,Petaluma,Callf.,and
Texas-basedShepherd Controls &
Associates,todlstrlbutebothlts
llnearmotorllneandsubfractlonal
horsepowerbrushedandbrush-
lessdcmotorsandlntelllgentser-
vomotors.
NAME CHANGE
Rexnord Corp.,Mllwaukee,has
changedthenameofltslndepen-
dentlaboratoryfromRexnord
Technical Services(RTS)tothe
Rexnord Innovation Center.The
Centerhandlesconfldentlaltest-
lngandanalysesofproductslnthe
areasoffatlgueandwear,shock
andvlbratlon,falluremodeandef-
fects,andfleld-loadmeasurement.
AWARDS
Agilent Technologies Inc.,Santa
Clara,Callf.,recelvedthe20ll
GlobalProst&SulllvanAwardfor
Companyoftheearforltsperfor-
mancelntheoscllloscopemarket.
Frost & SullivannotedAgllents
concertedeffortstobecomea
marketleaderbylntroduclng
productslnallsegmentsofthe
oscllloscopemarket,aswellas
Agllentslnvolvementlnvarlous
technologystandardsgroups.
Danfoss Power Electronics,Loves
Park,|ll.,aprovlderofvLTdrlves
andpanels,hasbeennamedthe
Sllverwlnnerforthe20llGlobal
AwardsforLxcellenceln8uslness
ProcessManagement(8PM)and
workflow.Thlsawardrecognlzes
productsleadlngtoslgnlflcant
buslnessbeneflts.TheAwardsPro-
gramlsmanagedbyFuture Strat-
egies Inc.andsponsoredbyBPM.
com,Object Management Group
(OMG),andWorkflow Manage-
ment Coalition.
OMGlsanlnternatlonalnot-for-
profltcomputer-lndustryconsor-
tlumandworkflowManagement
Coalltlonlsanonproflt,lnterna-
tlonalorganlzatlonofworkflow
vendors,users,analysts,andunl-
verslty/researchgroups.
1UNLl4,20l2 MACH|NLDESIGN.com 42
/PNO(JJ\YHJ`ALYV)HJRSHZO.LHYOLHK
The OSF-./ 8u|ck Oonnect .earhead eas-
||y mounts to any servo motor yet ma|nta|ns
a|| of the benefts of /armon|c Dr|ve gear-
|ng |nc|ud|ng 1arc-m|n accuracy and aero-
back|ash. A h|gh capac|ty cross ro||er bear-
|ng |s used at the output and |s ava||ab|e w|th
e|ther a Shaft or F|ange output |nterface. The
gearhead have rated torques of 76 |n-|bs to
9,320 |n-|bs and peak torques of 343 |n-|bs
to 46,550 |n-|bs depend|ng on s|ae and rat|o.
.ear rat|os of 50, 80, 100, 120 and 160:1
are ava||ab|e.
:/-:/./VSSV^:OHM[:WLLK9LK\JLYZ
Ava||ab|e |n a w|de range of s|aes, these aero
back|ash, 1 arc-m|n accuracy /armon|c
Dr|ve gearheads enab|e des|gn eng|-
neers to pass shafts, w|res, tub|ng, or other
components d|rect|y through the center of
the gear. They |ncorporate an output fange
supported by a |arge cross ro||er bear|ng,
prov|d|ng except|ona| moment st|ffness and
|oad capac|ty. The sma||est un|t has a ho||ow
shaft 0.D. of 14 mm and an outer d|ameter
of just 64 mm. The |argest un|t of the fam||y
has a ho||ow shaft 0.D. of 80 mm and has
a rated output torque of 1236 |n-|bs, and a
peak torque of 6175 |n-|bs. .ear rat|os from
30:1 through 160:1 are ava||ab|e.
/HYTVUPJ+YP]L33*
^^^/HYTVUPJ+YP]LUL[
*:-*:.7YLJPZPVU.LHYOLHKZ
The OSF and OS. h|gh torque 7rec|s|on
.earhead Ser|es are |dea||y su|ted for robot|c
and mach|ne too| app||cat|ons. The OS. de-
||vers 30% more torque and 40% |onger ||fe
wh||e ma|nta|n|ng aero-back|ash, 1 arc-m|n
accuracy, and +/- 5 arc-sec repeatab|||ty. An
accurate, h|gh|y r|g|d cross ro||er bear|ng |s
bu||t |n to d|rect|y support the externa| |oad. A
w|de var|ety of s|aes and reduct|on rat|os are
ava||ab|e w|th max|mum peak torques rang|ng
from 450 |n-|bs. to 60,500 |n-|bs.
/PNO7YLJPZPVU4V[PVU*VU[YVS
*HSS
^^^/HYTVUPJ+YP]LUL[
7V^LY7YLJPZPVU
:/(/VSSV^:OHM[(J[\H[VY
)Y\ZOSLZZ:LY]V4V[VY
/HYTVUPJ+YP]L
.LHYPUN
0U[LNYH[LK)YHRL
)P[(IZVS\[L,UJVKLY
/PNO;VYX\L+LUZP[`
HYJTPU(JJ\YHJ`
HYJZLJ9LWLH[HIPSP[`
/PNO*HWHJP[`6\[W\[
)LHYPUN
;OL UL^ :/( ZLYPLZ VM /VSSV^ :OHM[ (J[\H[VYZ OHZ [OL OPNOLZ[ [VYX\L
KLUZP[` VM HU` HJ[\H[VY PU P[Z JSHZZ `L[ WYV]PKLZ L_JLSSLU[ WVZP[PVUPUN
HJJ\YHJ` :L]LYHS ZPaLZ HYL H]HPSHISL ^P[O V\[W\[ [VYX\LZ \W [V
PUSI ;OLZL HJ[\H[VYZ HYL PKLHSS` Z\P[LK MVY YVIV[PJZ H\[VTH[PVU
THJOPUL [VVS HUK HU[LUUH WVZP[PVUPUN HWWSPJH[PVUZ ^OLYL WLYMVYTHUJL
HUKYLSPHIPSP[`HYLLZZLU[PHS
RS# 138
ITS ALWAYS GOOD TO HAVE THE CHOICE.
IMS.techline offers the customization of
the modular standard gear drives to exactly
match your needs. Ultimate flexibility for
high volume production.
FOR EVERY PROBLEM THERE IS ONE SOLUTION.
With our standard modular system for
Pla netary Gears you have over 10,000 con -
guration possibilities to choose from.
Small and medium volume production or
prototypes? Then IMS.baseline is the fast
and reliable solution with a selection of
Standard Planetary Gears.
Germany | USA | Mexico | China
Gear Technology. Worldwide.
Unlimited
possibilities. Unique solutions.
Planetary Gears.
High quality for all volumes.
IMS Gear ofers the optimum solution and the process that you need.
From prototypes to high-volume series.
IMS Gear Planetary Gears Inc.
440 Viking Drive Suite 110
Virginia Beach, VA 23452
phone 757-227-5553 x401 www.imsgear.com
REPORTERS NOTEBOOK
COMPANNEWS
RS#l39
EXPANSION
TV SD America, Peabody,
Mass.,hasexpandedltsbattery-
testlngcapabllltlesatltsAuburn
Hllls.,Mlch.,andNewmarket,
Ontarlo,Canadalabfacllltles.TUv
SUDAmerlcalspartoftheTUv
SUDtestlng,lnspectlon,andcertl-
flcatlonorganlzatlon.
SUSTAINABILITY ROADMAP
Freudenberg-NOK Sealing Tech-
nologies(PNST),Plymouth,Mlch.,
hasdevelopedastrateglcsustaln-
abllltyroadmaptoguldeltslong-
termeffortslnreduclngenergy
usage,lowerltscarbonfootprlnt,
andproducegreener,cleaner
productsandprocesses.
PNSTspeclallzesln
sealsandvlbratlon-control
technology,nonwovens,flltratlon,
lubrlcants,andreleaseagents.
NETWORK LAUNCH
Xenon Corp.,wllmlngton,Mass.,
amakerofpulsedUv-llghttech-
nology,haslaunchedthePrinted
Electronics Test Center Network.
TheNetworkconslstsofmanufac-
turers,lntegrators,andunlversltles
thatwlllmakethelrlabsavallable
toresearchersandproductdevel-
opersfortestlngldeasandpro-
cesseslnprlntedelectronlcs.
CERTIFICATION
TheC-Lltefam-
llyofllghtwelght
marlnecablesfrom
TE Connectivity,
Harrlsburg,Pa.,has
beenawardedthe
Germanischer
Lloyd(GL)Approval
Certlflcatlon.
TLConnectlv-
lty,Harrlsburg,Pa.,
deslgnsandmanu-
facturesproducts
thatconnectandprotectpower
flowanddata.GLlsatechnlcal
supervlsoryorganlzatlonthatof-
ferscertlflcatlon,lnspectlon,and
consultlngservlces.
TECHNICAL SEMINARS
Avnet Electronics Marketing,
Phoenlx,anoperatlnggroupof
Avnet Inc.,beganltsNorthAmerl-
canlts20l2X-festtechnlcalseml-
narserles.TheX-fest20l2pro-
gramfeaturesl2technlcalcourses
basedonXlllnxsnewArtlx-7,Kln-
tex-7,andvlrtex-7PPGAs,aswell
asthenewZynq-7000Lxtenslble
ProcesslngPlatform(LPP)famlly.
Upcomlnglocatlonslnclude8al-
tlmore,Dallas,andMlnneapolls.
Pormorelnformatlon,gotowww.
em.avnet.com/xfest.Avnethascre-
atedashortvldeooftheevent.
Thevldeocanbevlewedathttp://
avnet.me/01625.MD
1UNLl4,20l2 MACH|NLDESIGN.com 44
[ MOTOR TRUTH #7 ]
sewmotortruth.com
Can I save
energy by using
a VFD (inverter)?
The truth is that it depends on your
application. If you have a high-cycling
application, a VFD can save money by
reducing the starting current.
Or, if you have a hoisting application
(such as a storage retrieval system), a
VFD can provide energy regeneration.
Also, if your VFD has ux control, it can
maximize the motor efciency when the
motor is oversized on a small load.
Otherwise, a VFD acts as a load and
actually consumes energy, especially if
you are using a high carrier frequency.
Visit sewmotortruth.com to get the
whole story on VFDs and energy-
efcient drivetrains.
YES
NO
MAYBE
RS# 140
UPTIME, ALL THE TIME
EPIC
connectors can stop electrical failures
before they stop your packaging lines.
KEEP RUNNING WITH LAPP
EPIC
Air Cylinders
Short stroke air cylinders outperform rivals in tough applications.
Rugged construction provides unequalled strength, rigidity, and piston rod support maintaining
perpendicularity and concentricity for locating, mounting and making attachments to the rod.
Heavy wall prevents damage to the bore from external impacts. Magnetic position sensors fea-
ture surge suppression, polarity protection, LED indicators and extremely fast switching speeds.
Bores: 1/2" 4"; Strokes: 1/16" 4".
Custom cylinders to your specifications.
Piston rod is 303 hard chrome plated
stainless steel shafting.
Non-metallic rod bearing is captured
internally and can NOT "blow out".
Self lubricated, the rod bearing has
a loading capacity of 60,000 psi
vs. 4,500 psi for porous bronze.
Low operating pressure allows
for use in vacuum applications.
Dial-A-Stroke
Bundled
Automation
Solutions
communications, control and power. All bundled
WRJHWKHUWRPHHW\RXUVSHFLFQHHGVHYHQLQWKH
harshest environments. With our worldwide reputa-
tion for innovation, we will keep your automated
lines running smoothly. Lets grow together.
www.molex.com/brad/md RS# 154
OEM SERVICES/ MADE IN AMERICA
The Fabricating.com dashboard shows a buyers current
activity, a list of to-dos and a quick lookup of favorite
suppliers. This version shows the way it presents the actual
part drawing while the buyer is reviewing the RFQ.
Salem Design and Manufacturings
newest machine uses an eddy-current
probe to inspect automotive spindles for
cracks or flaws that cannot be seen by
the naked eye under a microscope.
school bus full of kids. Huge liabil-
ity. So we sell equipment whenever
a company has had a problem re-
gardless of how their business is doing.
This means that our sales dont fluctuate as
much as the others as the economy goes up
and down.
The company also serves the nuclear-en-
ergy market. It builds equipment used in the
manufacturing and inspecting of nuclear
fuel-rod tubing.
According to Warga, the company has
stayed competitive while manufacturing in
the U.S. primarily because it does not build a
product such as a small widget. We dont have
to worry much about overseas competition, he says. I
would equate us to a home contractor. For example, the
Chinese would have a hard time competing on building a
house for you. Because China is so far away, trying to meet
with companies there periodically to see how your house
is coming along would be impractical. That is probably the
biggest reason we dont have any offshore competition.
Almost paradoxically, another advantage to compa-
nies that build machine tools in the U.S. is that the dollar
is weak right now, says Warga. So Europeans are looking
here because we are a bargain compared to the Euro. If a
business such as ours were operating in Germany, lets say,
machines are going to be more expensive. Labor costs in
Germany for machinists or engineers are similar to those
in the U.S., so the big difference is which country has the
weaker currency. Plus, the world still needs power, even
specific kinds of expertise and ma-
chine capacity needed, says Russo.
This is where we fit in.
Examples of capabilities manu-
facturers might look for include
machines with a specific capacity
for making parts with unusual
diameters, says Russo. Com-
panies might also be looking
for suppliers, say, that can handle
large or unusually heavy parts.
Many machine shops typically have
weight-limited capabilities in terms
of overhead conveyors and cranes.
Fabricating.com decided to re-
strict suppliers to those from the
U.S. because it saw a good mar-
ket potential in doing so. Also,
we feel strongly about bringing
manufacturing back to the U.S. because the
strength of our country depends on it. We dont see the
market space as billions of dollars. Instead, we see it as pro-
viding great quality leads for suppliers, connecting them to
good-quality buyers.
Russo also says that people have done a great job in the
past few years of educating buyers and suppliers on the to-
tal cost of ownership. Even some of the larger companies
are beginning to see that offshored products do not neces-
sarily translate to larger profits.
Additionally, recent news has described the rising mid-
dle class in China. Labor costs there are, thus, going up,
contributing to the total cost of ownership. And it seems
there are always quality issues, says Russo. Therefore,
just the largest corporations that are currently basing their
procurement decisions only on price will continue to do
so, he says. But we think there is a large custom manufac-
turing market here in the U.S. that is vastly underserved.
Even smaller job shops have now invested in high-quality
machines and CAM equipment. So they can compete if
given the chance to find the right buyers.
Target a critical market
In another example, Salem Design and Manufactur-
ing LLC (SDM) in Salem, Ohio, designs and builds cus-
tom manufacturing equipment along with gaging, eddy-
current and ultrasonic testing machines to inspect safety-
critical parts. Says President Phillip R. Warga III, such
parts might be something like a ball joint, which if not heat
treated properly could cause a catastrophic accident. The
company remained successful even during the downturn
because manufacturers that make safety-critical parts
must invest in equipment to inspect them, to ensure they
dont have a lawsuit down the line.
Says Warga, our machines dont build parts cheaper or
make parts faster. The machines are an insurance policy.
Lets say you are making automotive spindles and one of
them is fractured, he says. It could go into a car and cause
the wheel to fall off, which could result in the car hitting a
1UNLl4,20l2 MACH|NLDESIGN.com 70
tailored
to suit
Get the right unit for the right job.
Tough. Tested. Trusted.
From catalog-issue units to custom, one-of-a-kind solutions,
Continental Hydraulics is your go-to resource for hydraulic power
units that get the job done right.
Whether manufacturing to exacting specs or bringing a napkin
sketch to life, we analyze your concepts feasibility from every angle,
while 3D solid modeling and complete BOMs provide pre-fab
peace-of-mind. Our standard power units offer assurance, too, thanks
to ISO 9001 and our uid power trained assemblers. To support
immediate installation, each unit is 100% inspected. Our 18-month
warranty and nationwide local distributor support covers you
coast-to-coast.
PUMPS VALVES POWER UNITS
952. 895. 6400 | www.continentalhydraulics.com
RS# 155
OEM SERVICES/ MADE IN AMERICA
The A-Jet cutting
head accessory on
an Omax waterjet
makes angled
cuts and bevels
and automatically
corrects for the
taper normally
found in abrasive
waterjet cutting.
called UniWest, Pasco, Wash., also developed a cost-com-
petitive inspection machine designed primarily to inspect
automotive spindles for the proper heat treatment or flaws.
The machine includes two robots, one manipulates an
eddy-current probe along the surface of the spindle while
it rotates. The other robot is used to load and unload the
spindles. The probe creates eddy currents in a localized
spot, which generates a signal that can be detected should
it sense a crack or a flaw. The technology finds flaws that
are difficult to see, even under a microscope, says Warga.
The machines go in-line for the 100% inspection of auto-
motive spindles.
SDM has been in business for seven years. Of course,
there have been ups and downs like always, says Warga.
But Ive reached a point where money isnt really the main
objective I just really enjoy doing the work. And that is
true for most of our employees. I think good employees
are a huge factor in a company being successful. We are
not slave drivers, the profit just kind of came. Businesses
have to make money to survive, but we have never priced
things to make a lot of money right now. You can run your
profitability high in the short term, but that just opens the
door for competitors. So we came into the market at times,
about half of our competitors price for the same test. I
dont think our competitors will be able to make a similar
machine for the price.
A main reason for the poor economy is greed, contin-
ues Warga. As a business owner, I do not strive to make
a maximum profit every year. I would rather make less
money and be patriotic and help this country than I would
to make an extra 5 or 10% and end up hurting the country.
I think that bigger businesses should consider that going
to foreign countries in the long-term is damaging.
True, some of the components SDM uses in its ma-
though there is talks of windmills and a lot
of other methods, nuclear is not about to
go away for a long time. So that market is
increasing in size.
Another reason SDM was able to hold
its own during the downturn was because
it is fairly lean, says Warga. We reach
around 3 million a year in sales with just six
people, he says. Over the years, we have
found extremely good people some-
thing I put a lot of effort into. We shopped
around and went through a lot of individu-
als and the result is we have ended up with
an exceptional crew. We dont even have a
foreman. Everyone just knows what needs
to get done.
The machinery the company manufac-
tures is quite complex. One of our lines
uses a lot of robotics, says Warga. In gen-
eral, companies that build machines and
become profitable usually dont like to cus-
tomize its products. They will say, Here
is the machine, take it or leave it. In con-
trast, SDM always starts with a clean sheet
of paper.
Our strength is we are mostly an engineering service
and tackle difficult applications, says Warga. This ap-
proach is always risky because if we promise a company
that we can design a machine to do what the firm wants,
should we fail, we are probably bankrupt.
According to Warga, in the past few months, European
nations have been looking internally to find their weak-
nesses whether from a natural disaster or a terrorist at-
tack. One area they discovered is in nuclear-fuel-rod pro-
duction, he says. Fuel rods supply the energy for power
plants to make the steam that runs the generator. Fuel rods
last a couple of years and then need replacing. Analysts
found problems with a certain rod and came to us to see
if we could make a machine to produce them. The tubes
required an exceptionally tight, specialized chamfer on the
OD and ID. The tubes are about 15-ft long, 3/8 in. diam-
eter, with 0.020-in.-thick walls.
Cutting the chamfer is difficult because tube diameters
can vary slightly, continues Warga. So we developed a sys-
tem that uses a laser to find the centerline of the tube down
to 5 millionths of an inch. We also developed a mecha-
nism that positioned the cutter to within 10 millionths of
an inch. Integral to that, we developed the gaging system
that would do a 100% inspection after every tube was
chamfered.
Up until that time, only one European company could
make that specific kind of fuel rod. SDMs goal was to pro-
duce machined tubes that would equate to the European
tubes, however, the end result was that SDMs machine
produced tubes with accuracy exceeding those from Eu-
rope. This type of machinery costs approach 1 million dol-
lars and is quite large.
SDM, in conjunction with an eddy-current company
1UNLl4,20l2 MACH|NLDESIGN.com 72
Generic
Motion Control
Technology by THE INNOVATORS
Perfection in Automation
www.br-automation.com
` Maximum system productivity through exceptional
performance and system synchronization
` Supports advanced manufacturing technologies by
integrating CNC, robotics and motion control with
integrated safety technology
` Easy implementation of machine options because of
software compatibility across all drive technologies
` Supports all machine topologies through the use of
centralized and decentralized drive technology
` 5educed hardware costs and simplied service
RS# 156
OEM SERVICES/ MADE IN AMERICA
Machinetec
Corp. of Fairfield,
Ohio, says its
Omax waterjets
have saved costs,
increased output,
and brought
previously
outsourced work
back in-house.
our programming system automatically
takes into account.
So producing a part just involves
entering the CAD file and inputting
the part thickness, material, and qual-
ity a rough cut or a fine cut. The
machine basically then programs it-
self, says Parry. The result is great
for short runs. The sweet spot for
abrasive waterjets is one part to a cou-
ple of hundred parts, 0.040 to 4-in.
thick. Setup time is almost nothing.
We have also been successful in
manufacturing in the U.S. by always
making continuous improvements to
the technology, says Parry. Improve-
ments are more easily done because
we make parts as we need them, he says. We have ev-
erything right here instead of in a long supply chain.
Another reason Omax is continuing to be successful
is its machines also give the companys customers more
flexibility. Abrasive waterjets are kind of a new tech-
nology and take a little bit of getting used to, says Parry.
So we stand behind the product with training and sup-
port. Waterjets are not like cars where you can just hand
someone the keys and say, Here it is, go and run it.
The machines are useful in that they can cut every-
thing from superalloys to composites, coated materials,
hardened tool steel, and really soft materials that are
difficult to machine. This capability lets U.S. manufac-
turers make better-quality products, says Parry. One
example is a shop that makes elevator-control panels.
Not a really big thing, but our technology can cut the
panels after the shop has them all nice and polished.
There is no heat situation to cause problems.
According to Parry, there are abrasive waterjets that
are made in China. But they lack high quality, he says.
And, above all, the control system that lets us make
quick-turnaround parts is just not there. We have seen
people bringing over lower-cost Chinese cutting ta-
bles XY tables and adding their own controllers.
But we look at how it is being done and realize that we
can actually build high-quality waterjets competitively
priced in the U.S. simply by building them as we need
them. We keep coming back to the idea that we can do a
better job right here with our own people.
Continues Parry, The state of manufacturing in the
U.S. is encouraging. One thing I am a little distressed
about, though, is that youngsters today do not want to
get into a trade or be a manufacturing engineer because
it seems like manufacturing is all going away. But those
of us in our 50s and 60s are not seeing it going away. We
are getting smarter about how to stay competitive while
manufacturing in the U.S. We must get more young
people enthused about making stuff, so we can continue
to compete in the future. We can be smart in the way we
build and design things and use the latest technology,
which offshore manufactures cant necessarily do. MD
chines are made offshore. But that is because there is no
company in the U.S. it knows of that makes them. But
the machine base, guarding, and other components are all
made in America.
Make parts only as needed
In another case, H. Laird Parry, senior applications
engineer of Omax Corp. in Kent, Wash., says, We are a
small manufacturer that uses its own abrasive waterjets
to make parts for abrasive waterjets that we sell to other
companies. The nifty thing is we can make parts as we
need them. When companies send things offshore, they
have to order a big-enough quantity to make economic
sense. And then they dont have the flexibility needed to
make a relatively small number of machines. They must
purchase large containers of parts and often there is a
design change before the parts even arrive.
Omax is relatively small, with only about 275 em-
ployees up from 150 about two years ago and it
produces different variations on a theme, says Parry.
So as orders come in, we want to be able to make parts
for those orders rather than have a whole bunch of in-
ventory tied up on the shelves which may or may not be
used that year.
We held our own during the downturn because our
machines complement rather than compete with other
technologies such as machining, laser cutting, EDM, or
plasma, says Parry. For example, lasers cannot cut com-
posites, he says. Smaller EDM shops can use blanks cut
from waterjets then finish them off to close tolerances.
And laser shops cant cut copper or aluminum, but wa-
terjets can. In addition, waterjets are set up for a quick
turnaround. Just clamp the material down on the table
and away you go.
Omax also tries to always stay one step ahead of the
competition. One of the big technological advantages we
have although other companies are moving this way
is our control system. The challenge of a waterjet is that
the cutting jet itself is flexible. So programming the ma-
chine used to involve a lot of trial and error. Now we have
a software model that models the behavior of the jet that
1UNLl4,20l2 MACH|NLDESIGN.com 74
Every 3.5 seconds, a Banner sensing solution is installed somewhere.
Being engineers, were trying to improve on that.
Solving automation challenges, one application at a time, for over 45 years.
For nearly half a century, when industry has an automation challenge, they turn to Banner for solutions.
And among the thousands of global sensing innovations engineered by Banner, many started as a
tailored response to a single customers needs. Challenges solved quickly. Efciently. And affordably.
Responses that have helped to create over 30,000 products and applications, with more on the way.
Because at Banner, engineering is not just part of our name, its what we do. Every second.
bannerengineering.com
safety vision sensing wireless I/O lighting & indication
2012 Banner Engineering Corp.
Minneapolis, MN
more sensors, more solutions
RS# 157
FLUIDPOWER TECHNOLOGY GUIDE
The 24-in.
model of the
Triform sheet-
hydroforming
press has a
clamp housing
enclosing the
bladder, visible
at the center of
the image. The
operator interface
supporting recipe
controls is on the
right.
Hydroforming is a process that uses fluid pressure to shape metal parts. Sheet
hydroforming, one variation, can produce formed parts that are impossible to
make using a stamping process. Also, sheet hydroforming shapes deep objects
in a single operation, whereas stamping might require multiple operations.
Another advantage of hydroforming is that the tooling typically costs much
less, as little as one-tenth the cost of that used in metal stamping. This can make
hydroforming more attractive for low-volume applications.
Hydroforming basics
The process has been used by metal fabricators for more than half a
century. Following initial interest during the aerospace boom of the 50s
and 60s, however, development of new machines and technical innova-
tion languished through the latter part of the 20th century. More recently,
hydroforming has experienced a measurable resurgence, thanks to the
Hydraulic motion controllers
enhance the precision
and repeatability of
hydroforming presses.
Authoredby:
Richard Meyerhoefer
ReglonalAppllcatlonsSpeclallst
Delta Computer Systems
8attleGround,wash.
LdltedbyKenneth J. Korane
ken.korane@penton.com
Key points:
Hydroformlngcanmakepartsnotposslble
wlthstamplng,andthetoollngtyplcallycosts
muchless.
Hydraullcmotloncontrollersthatcontrol
toollngposltlonandfluldpressurevastly
lmprovethepreclslonandrepeatabllltyofthe
hydroformlngprocess
Resources:
Delta Computer Systems, http://deltamotion.
com
RS# 621
Pryer Technology Group,www.
pryertechgroup.com
RS# 622
Hydraulic controls
TRANSFORM
press
technology
1UNLl4,20l2 MACH|NLDESIGN.com 76
Groschopp uses the Fast Track department to quickly build motors/gearmotors to meet customers demands. Because
Groschopp stocks components rather than nished motors/gearmotors, we can easily make modications to the motor/
gearmotor to meet your requirements. Modications include:
t Various bolt hole patterns
t Face/foot mountings with special ange
t Shaft size/diameter/shape
t Special bearings and seals
t Terminal box
t Insulation
t Keyway
t Threading
Because our Fast Track designs are based on standard product lines our experienced, on site machinists can quickly
alter bolt hole patters, create custom shafts, threadings and more.
After the entire build process is complete the Fast Track department has two rooms designated for testing the motors/
gearmotors. Computers and high tech testing equipment allow them to perform accurate tests on the hand-built motors.
From there the motors are packed with the help of a sophisticated Styrofoam packaging system.
Need a few motors quickly? Submit your application specs at www.groschopp.com/specs or call (800) 829-4135 and
ask to speeak with a regional account manager.
48 HOUR
Fast Track Gearmotors
|ntegroteoMot|on3o|ut|ons
Groschopp Inc.
420 15th St. NE
Sioux Center, IA 51250-2100 USA
(712) 722-4135 Phone
800.829.4135 Toll Free
(712) 722.1445 Fax
sales@groschopp.com Email
www.grosohopp.oom
REGISTERED
ISO 9001:2008
C
E
R
T
I F
I
E
D
Q
U
A
L
I
T
Y
M
A
N
A
GEMEN
T
S
Y
S
T
E
M
Lonneotw|thus.
(Purchase Order to Shipment)
RS# 158
FLUIDPOWER TECHNOLOGY GUIDE
The RMC151E electrohydraulic motion controller can
synchronize up to eight axes and control pressure and position
simultaneously.
model, eight axes are under closed-loop control.
Programs developed for the motion controller let oper-
ators select production recipes that contain up to 30dif-
ferent steps in a press cycle. Each step corresponds to a
target bladder pressure and punch position. Besides the
target values, motion instructions specify how the ma-
chine will reach the next target.
For example, at the beginning of a machine cycle, a
quick move instruction brings the punch cylinder to its
start position. At the same time, the bladder is precharged
to a designated pressure. Then, during the forming cycle,
the punch axis receives a position command with an accel-
eration and deceleration value for each step in the process.
Meanwhile, to control bladder pressure and coordinate its
operation with punch-axis movements, the RMC is given
a gearing command. This sets up the punch axis as master
and forces bladder pressure to follow the punch as a slave.
To smooth motions between steps, acceleration of the axes
ramps up and down gradually using an S-curve motion
command.
An intensifier cylinder pressurizes the bladder. It works
like a syringe to inject or remove oil under both position
and pressure control. A pressure transducer monitors
bladder pressure and sends the data to the motion con-
troller. The transducer can typically read between 1 and
10,000psi. The RMC also commands a directional valve
to control the position of the intensifier cylinder. A lin-
ear magnetostrictive-displacement transducer (LMDT)
mounted inside the cylinder provides position feedback.
A second LMDT monitors punch position. To ensure pre-
introduction of precision motion controls.
Case in point is a new line of sheet-hy-
droforming machines called Triform presses,
made by the Pryer Technology Group of
Tulsa, Okla. In these presses, a bladder filled
with hydraulic fluid surrounds the tool-
ing form. A hydraulic-cylinder-driven
punch presses the tooling and metal
sheet into the bladder, causing it to con-
form to the required shape.
As fluid pressure in the bladder
builds, it clamps the material and forces it
against and around the form. Simultaneously,
a hydraulic cylinder presses the form against
the bladder, bending the metal sheet to con-
form to the tooling. Its important to control
how quickly the material bends. Otherwise, it
will tear or wrinkle, according to Darrell Har-
relson, technical director with the Beckwood
Press Co. of Fenton, Mo., a design partner
with Pryer on the new Triform hydroforming
machine project.
Sheet hydroforming requires the manage-
ment of several variables to ensure quality
parts: position and speed of the punch; bladder fluid pres-
sure; lubrication of the part, which is relatively easy to con-
trol; and material variances, which can be controlled by
working with metal suppliers.
When making complex parts on traditional hydro-
forming presses, operators face differences in pressure
from cycle to cycle, causing the position of the punch
to vary, says Scott Pryer, president of Pryer Technology
Group. Historically, highly skilled and experienced ma-
chine operators were needed to deal with this variability.
And often, even that wasnt enough. Some older ma-
chines used two joysticks for control and dials to monitor
pressure in the chamber. Operators couldnt see the actual
process, resulting in poor consistency among parts made
by a single operator; and even less uniformity in parts pro-
duced by different operators.
Metal fabricators demand machines that perform
consistently, every time, so that operators can focus on
improving other process factors such as the materials and
lubrication, says Pryer.
Position and pressure control
To solve the control problem, engineers designing the
Triform presses turned to RMC electrohydraulic motion
controllers from Delta Computer Systems Inc. of Battle
Ground, Wash. They precisely control position and pres-
sure throughout the process and reduce the number of
forming steps in the manufacturing cycle.
On smaller Triform machines, the Delta RMC controls
two motion axes: the punch cylinder that pushes tool-
ing into the bladder, and the cylinder that varies bladder
pressure. On larger presses, it also controls containment
clamps and the upper chamber that closes around the
bladder and workpiece. On the largest machine, a 32-in.
1UNLl4,20l2 MACH|NLDESIGN.com 78
RS# 159
FLUIDPOWER TECHNOLOGY GUIDE
Hydroforming operation
Intensier
cylinder
Directionalvalve
LMDT
Pressure
transducer
Proportional
valve
LMDT
Motioncontroller
Clamp
Bladder
Metal
sheet
being
formed
Tooling
Punch
cylinder
The Delta
multiaxis
motion
controller
synchronizes
operation of
the intensifier
cylinder and
punch cylinder,
providing
closed-loop
control of
the sheet-
hydroforming
process.
to close the outer shells before the pressurization cycle
begins. Closed-loop position control for this operation en-
sures smooth motion, avoiding any shocks that would cre-
ate maintenance problems over time. The controller also
monitors shell-position feedback to detect any faults or er-
rors. For example, if a wrench left in the machine prevents
the shell clamps from closing properly, a following error
(a mismatch between target motion and actual motion)
would signal a problem that needs to be fixed.
Similar controls activate the lid on a 32-in. deep-draw
press. Four cylinders, one at each corner, each with its
own proportional valve, raise the lid. The motion of these
cylinders is linked using the multiaxis synchronization ca-
pability of the Delta controller to
avoid wracking or jamming the
lid frame.
The biggest design challenge
in developing the Triform was
gearing the bladder pressure to
the punch position, says Har-
relson. Getting them to synch
requires calculating appropri-
ate ramp times in the open-loop
section. To test the design and
tune it for optimal performance,
Beckwoods engineers used Delta
Computer Systems RMCTools
software. It includes a Plot Man-
ager and pressure and position
Tuning Wizards that analyze
the system response to control
outputs and produce the proper
gains for the control-loop equa-
tion. It simplifies tuning the sys-
tem for best performance, says
Harrelson.
Results
The design goal of the Tri-
form machines was to permit
experienced operators to spend
less time controlling the machine
and more time improving the
process, while also letting inex-
perienced operators use the reci-
pes to make complex parts con-
sistently, with little training.
Precise control improves
quality and performance. On
moderately difficult forming
projects in the past, 10% of the
material would often be wasted
due to lack of precision, says
Scott Pryer. And on complex
forming operations, it could be
as high as 25%. Now, with the re-
peatable process, the scrap rate is
almost zero. MD
cise punch operation, outputs from the motion controller
drive a servo-quality proportional valve that controls the
punch hydraulics.
The trick in the hydroforming process is to avoid
wrinkling the sheet as it first bends around the corners
of the tool, notes Harrelson. To accomplish this, most of
the programmable motion steps in each press cycle oc-
cur within the first inch of punch travel. Cycle time varies,
depending on the profile of the part and the needed pres-
sure. The machines operator interface locks in all of this
information for each part by calling up a preprogrammed
recipe from the RMC. Theres no guesswork.
In some larger machines, the motion controller is used
1UNLl4,20l2 MACH|NLDESIGN.com 80
INDUSTRIAL
AUTOMATION
There are no short-cuts to innovation. Inspired ideas come from hard
work, clever engineering, and those special partners who always
seem to have just the right solution to bring your ideas to life. Thats
what fuels our sense of urgency at B&B making the connection
between our wide range of USB, Serial, Ethernet and Wireless
connectivity platforms to drive your current burst of creativity.
With over 7,000 connectivity products, and deployments in more
than 75% of Fortune 100 companies, B&B is the right connection
for your next project. Learn how at www.bb-elec.com.
UNITING IDEAS.
www.bb-elec.com
1-800-346-3119
RS# 160
CONNECTING DEVICES.
FLUIDPOWER TECHNOLOGY GUIDE
Energy consumption is often the major contributor to overall costs of owning
and operating industrial plants and machinery. On average, energy consump-
tion accounts for between 20 and 30% of total equipment operating costs. And
in energy-intensive hydraulic applications, the share of energy costs are often far
greater. In such cases, variable-speed pump technology quickly pays for itself.
Fixed versus variable
Traditional hydraulics run continuously at a constant speed to generate the
power required to operate a machine. In these circuits, an electric motor typically
runs at its rated speed, say 1,800 rpm, and drives a fixed-speed pump. The pump,
in turn, rotates continuously and generates flow without regard to the actual power
needed by the machine at any given moment. The varying hydraulic flow a machine
demands is regulated via internal adjustment mechanisms in the pump, or by divert-
ing excess flow back to the tank.
Innovations over the years have improved the efficiency of fixed-speed pump
circuits, but applying variable-speed techniques raises potential energy savings to
a new level. Such systems use variable-speed electric drives to rotate pumps at their
most-efficient speed often less than 200 rpm while supplying only the hydrau-
lic power a process requires at any given moment. Depending on the application,
this can produce energy savings between 30 and 80%, compared to fixed-speed op-
eration, without sacrificing performance or limiting operating pressure.
In addition, lower energy consumption indirectly reduces the emission of CO
2
,
helping companies significantly reduce their carbon footprint.
Operating the pump and motor at less than full speed also means they generate
less noise. In some cases, noise emissions have been reduced by as much as 20 dB(A).
Variable-speed
pump drives
supply only the
power a process
requires, cutting
energy costs
in hydraulic
systems by up
to 80%.
Authoredby:
Neal Gigliotti
Manager,PlastlcsGroup
Jan Komsta
Manager,NewTechnologles&
Slmulatlon
Bosch Rexroth Corp.
8ethlehem,Pa.
LdltedbyKenneth J. Korane
ken.korane@penton.com
Key points:
Tradltlonalhydraullcsrunata
constantspeedandgenerateflow
wlthoutregardtotheactualpower
neededbyamachlne.
varlable-speedelectrlcdrlves
rotatepumpsatthelrmost-efflclent
speedtosupplyonlythehydraullc
poweraprocessrequlres.
Lnglneersshouldconslderuslng
varlable-speedpumpdrlves
wheneveramachlnecyclehas
fluctuatlngflows.
Resources:
Bosch Rexroth, www.
boschrexroth-us.com
RS# 623
Energy-efficient
HYDRAULICS
slash operating costs
Variable-speed pump drives not only reduce energy
consumption, they run quieter than fixed-speed units,
generate less heat, and require less cooling.
1UNLl4,20l2 MACH|NLDESIGN.com 82
Optical Isolators are the only isolation devices that
meet or exceed the IEC 60747-5-5 International
Safety Standard for insulation and Isolation. Stringent
evaluation tests show Avagos optical isolators deliver outstanding
performance on essential safety and deliver exceptional High Voltage
protection for your equipment. Alternative isolation technologies such
as magnetic or capacitive isolators do not deliver anywhere near the
high voltage insulation protection or noise isolation capabilities that
optical isolators deliver.
For more details on this subject read our white paper at:
www.avagoresponsecenter.com/672
|.+eIec|ae|e|e.0jteceaj|er.
Safety Certied Protection...
Everywhere Under the Sun.
IEC 60747-5-5 Certied
Technology You Can Trust
SMA Solar Technology
trust Avagos IEC certied
optocouplers to protect
thier Sunny Boy
3000TL/4000TL/5000TL
series of inverter products.
Another example of
Technology You Can Trust.
RS# 161
FLUIDPOWER TECHNOLOGY GUIDE
tion, providing high efficiency over a wide speed range.
It is can run at more than 3,000 rpm, but in partial-load
operation it reduces speed to less than 200 rpm without af-
fecting operating pressure. This also substantially reduces
noise from the hydraulic power unit.
The FcP 5000 is well suited for clamping and tensioning
operations, such as required in machine tools. Depending
on cycle characteristics, energy consumption falls by 30
to 80%, average flow is reduced over the entire machine
cycle, and the oil stays cooler.
The second line, the DFEn 5000, consists of an axial-
piston, variable-displacement pump driven by an asyn-
chronous standard motor and a frequency inverter. Its for
high-performance, high-power applications.
Digital onboard electronics calculate the best operating
speeds for the pump and motor. Destroking the variable-
displacement pump lowers the flow rate and motor load,
with optimum speed for maintaining pressure generally
between 300 and 400 rpm. During production breaks, the
software can stop the pump without affecting the operat-
ing pressure. With machines that operate on a cyclical ba-
sis, a teach-in process can be used to bring the system back
up to speed just before a needed increase in flow rate.
With noncyclical machines, sensing demand lets the
controller increase speed to the required minimum shortly
before additional flow is required, for instance in case of a
batch change. That way, the full output of the pump is
available if and when it is needed.
Finally, for high-end applications, the Sytronix SvP
7000 servopump drives offer the greatest responsiveness
and precision. They take advantage of the high dynamic
capabilities of permanently excited synchronous servomo-
tors to boost efficiency and substantially reduce energy
consumption, for example in presses and plastics-process-
ing machines.
The drives use an internal gear or axial-piston pump.
A pressure transducer senses hydraulic pressure, which is
This eliminates potential hazards to workers and the need
for personnel-protection measures. And the cost and has-
sle of secondary noise containment or damping measures
is cut accordingly. This adds to the potential savings of
variable-speed drives, helping pay off the investment in
relatively short order.
Due to lower energy consumption, another benefit
is that the hydraulic fluid does not heat up excessively.
In many cases, it is possible to eliminate heat exchang-
ers or fans to cool the power unit. This, in turn, permits
a more-compact design, which can reduce a systems
complexity and up-front costs. Commissioning becomes
easier and quicker, and it simplifies troubleshooting and
maintenance.
Finally, variable-speed pump drives can be integrated
into existing equipment without major redesigns, thus
letting them increase the energy efficiency in machines
already installed on the plant floor.
High-performance drives
A number of fluid-power and motor manufacturers
offer variable-speed pump drives, and the available com-
binations of pumps and motors seems to be growing by
the day. For example, Rexroths Sytronix product line has
more than 140 modular, variable-speed pump/drive com-
binations, covering a broad spectrum of applications for
demand-based control of hydraulic systems. The variable-
speed pump drives currently fall into three general groups:
The frequency-controlled Sytronix FcP 5000 pump
drive is the basic version. It consists of an asynchronous
standard motor and a frequency inverter driving an inter-
nal or external gear pump. This combination offers a good
price/performance ratio, especially for high-power appli-
cations. Its primarily used in constant-pressure systems.
It maintains system pressure by matching flow with de-
mand. For example, the units PGH-3x internal gear pump
has been designed specifically for variable-speed opera-
Rexroths Sytronix
SvP 7000 servo-
pump drives offer
high responsiveness
and precision. They
combine permanently
excited synchronous
servomotors with an
internal gear or axial-
piston pump. They
can be used in open
hydraulic circuits to
control pressure and
flow, and for simple
positioning. And highly
dynamic position control
is possible in closed-
loop circuits, often
eliminating the need for
control valves.
1UNLl4,20l2 MACH|NLDESIGN.com 84
RS# 162
FLUIDPOWER TECHNOLOGY GUIDE
ciently generate the required flow. In addition, the drives
improve efficiency by eliminating throttling losses across
control lands. Required oil flow is precisely metered, and
the electric motor switched off when the press does not
need flow or pressure. When retrofitting existing presses,
they clearly improve a machines capacity while signifi-
cantly reducing energy costs and noise.
In continuous papermaking, variable-speed pump
drives can significantly improve energy efficiency. For
example, during pressure-holding functions for rolling
up paper, intelligently reducing speed directly saves up to
60% on electricity compared with power units with non-
regulated fixed displacement motors. At the same time,
variable-speed pump drives can run faster, permitting
smaller-size units with lower cooling demands. Thus,
they cut operating costs and space requirements.
In all these applications, variable-speed pump drives
maintain the reliability and power density of hydraulics,
and combine it with the flexibility of electric drives. The
extended diagnostics options of these closed-loop drives
also opens up additional options for preventing expen-
sive machine failures, thanks to condition monitoring.
And keep in mind the possibility for upgrading ex-
isting plant machinery by replacing fixed-displacement
units with variable-speed pump drives. This lets users
quickly reduce energy consumption without having to
invest in new equipment. Simulation programs are avail-
able that evaluate a machines hydraulic circuits and de-
termine possible savings for an application, before in-
vesting in hardware. And because existing hydraulic
circuits often remain unchanged, the switch can be made
with surprisingly little effort. It also opens up possibili-
ties for replacing classic, constant-speed hydraulic power
units with variable-speed pump drives. MD
controlled by software in the frequency converter. Here,
pressure control has a limiting effect on pump speed.
Closed-loop comparison of required and actual values for
pressure and flow can be sent to the higher-level machine
controller via analog signals (0 to 10 V) or fieldbus. As in
the other versions, the pumps are designed for variable
speed operations, combining low leakage and noise with
high overall efficiency.
The SvP 7000 with an internal gear pump can be used
in open hydraulic circuits to control pressure and flow, and
for simple positioning. And highly dynamic position con-
trol is possible with an axial-piston pump in a closed-loop
circuit. Precisely metered flow allows for direct control of
cylinder movements, letting the unit position an axis with-
out the need for control valves. Thus, it can considerably
simplify hydraulic systems.
And several servo-variable pump drives can be com-
bined into one cascading system. Ethernet-based, real-
time communication between several controls using Ser-
cos III lets users synchronize an almost unlimited number
of SvP 7000s to satisfy most any application demand.
Typical applications
Variable-speed pump drives arent warranted for ev-
ery hydraulic system. But engineers should consider
them whenever a machine cycle has fluctuating flows.
Intelligent servodrives sense demand and regulate
speed and, thus, power consumption of the electric mo-
tors. The more time a machine spends running under
partial-load conditions, the greater the potential energy
savings. Applications where variable-speed pump drive
offer substantial energy savings include:
Machine tools
Plastics-processing machines
Die casting
Presses
Woodworking and papermaking.
For instance, variable-speed pump drives in plastics-
processing machines reduce pressure-holding losses
during pauses and partial-load operation. High-per-
formance units, like the SvP 7000, accelerate twice as
fast as conventional variable-speed pumps, shortening
cycle times for higher productivity. Digital speed control
ensures high repeatability, and the setup compensates
for pressure-related leakage losses. With sophisticated
closed-loop pressure control, quick pressure changes are
possible while minimizing under or overshoots. Software
can even prevent cavitation when changing from high to
low pressures.
In, hot-chamber die-casting machines, closed-loop
control corrects for deviations in pressure and speed, and
compensates for leakage past the pump. It can also sim-
plify the hydraulic circuit. In one redesign, an SvP 7000
eliminated the need for separate pumps for high and low
pressure circuits, replaced some high-response control
valves, and supplied an accumulator-charging circuit for
the shot cylinder.
For press automation, variable-speed controls effi-
0
l,000
2,000
0
5,000
l0,000
5.6kw l.3kw
41.4% 2.2 kW 33.1% 8.4 kW
50-ton,
30-seccycletlme
l60-ton,
l5-seccycletlme
Energy savings
Variable-
speed
pump
Constant-
speed
pump
Comparing energy consumption
|njectlon-moldlngmachlnes
Comparisons on plastic injection-molding machines show
that replacing constant-speed, electrohydraulic variable-
displacement pumps with variable-speed pump drives
cuts energy consumption well in excess of 30%.
1UNLl4,20l2 MACH|NLDESIGN.com 86
FOR MAINTENANCE-FREE LINEAR WAY PERFORMANCE,
HEAD STRAIGHT FOR IKO TECHNOLOGY.
Our linear motion rolling guide
lineup scores big with maintenance-free
performance in a wide variety of applications.
Maintenance will never slide with our
self-lubricating C-Lube maintenance-
free rolling guides that run up to ve years.
Our C- Lube family of linear motion
rolling guides offers you great load capacity,
high rigidity, superior running accuracy
BALL ROLLER BALL SPLINE
Lubricant is deposited
directly to the surface of the
rolling elements.
and smooth motion for machine tools, semi
conductor and liquid crystal manufacturing
applications.
These great performers make
different from others, providing superior
cost performance for your machines
and offer an unending run of long term
maintenance-free lubrication for up to
5 years or 20,000 km.
IKO International, Inc.
www.ikont.co.jp/eg/
New York: 800-922-0337 / E-mail: eco@ikonet.co.jp UChicago: 800-323-6694 / E-mail: mwo@ikonet.co.jp
Atlanta: 800-874-6445 / E-mail: seo@ikonet.co.jp UDallas: 800-295-7886 / E-mail: swo@ikonet.co.jp
Los Angeles: 800-252-3665 / E-mail: wco@ikonet.co.jp USilicon Valley: 800-252-3665 / E-mail: wco@ikonet.co.jp
5 YEARS
12,500 MILES
MAINTENANCE
FREE
IKO C-LUBE LINEAR WAY SERIES
RS# 163
FLUIDPOWER PRODUCTS
Low-temperature hoses
New 472LT and 722LT hoses are engineered to work in temperatures as low
as 70F (57C). The hoses are suited for high-impulse, heavy-duty mining, drilling, and construction equipment found through-
out northern Canada and the Arctic Circle. They are also suited for snow groomers, side booms, snowmaking machinery, and
cold-storage applications. Available in -4 to -16 sizes, two-wire braided 472LT hose is rated to 5,800 psi (40 MPa). Four-wire spiral
722LT is available in sizes from -6 to -24 and rated to 4,000 psi (28 MPa). Upper temperature limit is 212F (100C).
Parker Hannifin, Hose Products Div., 30240 Lakeland Blvd., Wickliffe, OH 44092, (440) 943-5700, www.parkerhose.com
RS# 624
Air-pilot and
manual valves
The NITRA line of pneumatic prod-
ucts has been extended to include
air-pilot and manual-control valves.
The AVS-5 Series now includes
single and double-pilot directional
control air-pilot valves, offering
spring return or center-closed
operation. All are body ported
five-port (four-way) spool valves
available in 0.12 to 0.50-in. NPT port
sizes with flow coefficients from
0.67 to 2.79. Manual valves in tog-
gle-style hand lever, push-pull, and
rotary-style hand lever models have
aluminum-alloy bodies, 0.12 to
0.50-in. NPT ports, and flow coeffi-
cients from 0.78 to 5.29. Models are
available in two or three-position
detented styles.
AutomationDirect, 3505
Hutchinson Rd., Cumming, GA
30040, (800) 633-0405, www.
automationdirect.com RS# 628
Pilot-control
cartridge valves
New 09 Series cartridge valves are for
proportional and on/off pilot control of
clutches, brakes, and directional-control
valves. The hybrid units combine a 10
size cavity with an 08 size tube/coil,
providing high flow in a compact pack-
age with low-power consumption. They
include two on/off solenoid valves and
a proportional pressure-reducing valve. The solenoid valves are two position, three way or
four way, and operate to pilot pressures of 100 bar (1,450 psi) and flows to 20 lpm (5.3 gpm).
The proportional pressure-reducing /relieving valve gives pilot control of a clutch or direc-
tional valve. The valve comes with standard reduced pressure settings of 20 and 25 bar (290
and 360 psi) with flow capability exceeding 25 lpm (7 gpm).
Comatrol, 1407 Pelzer Highway, Easley, SC 29642, (864) 644-0055, www.comatrol.com
RS# 626
Diaphragm pressure regulators
Miniature diaphragm pressure regulators feature a
low-friction pressure-sensing element and a propri-
etary valve mechanism for regulation in small pack-
ages. An innovative spring system provides a range
of outlet pressures while also ensuring the lowest
installed height and lowest weight in the industry.
Single (PRD) and two-stage (PRD3/PRD2)
models are just over 1 in. in diameter. The single-
stage regulator weighs only 25 gm in stainless steel
and brass. The two-stage version weighs 66 gm in stainless steel and brass. Aluminum
versions for ultralow-weight requirements are also offered.
The regulators accurately reduce inlet pressures as high as 500 psig down to an out-
let pressure range of 0 to 30 psig. The regulators are available in 316 stainless steel, 303
stainless steel, brass, and aluminum. For applications with inlet pressures above 500 psi,
the PRD3HP three-stage regulator can reduce inlet pressures as high as 3,000 psig
down to an outlet pressure range of 0 to 30 psig.
Beswick Engineering Co. Inc., 284 Ocean Rd., Greenland, NH 03840, (800) 354-
5014, www.beswick.com RS# 625
ISO air cylinders
Extruded body, ISO 6431-compliant air cylinders have standard magnetic pistons in seven bore
sizes from 32 to 125 mm. Stroke lengths are to 1,000 mm. Adjustable air cushions at both ends
and machined male rod threads with jam nut are also standard. The hard-anodized aluminum
cylinder tube ID and OD ensures corrosion resistance and long product life, and lubrication
is not required. Optional position sensor mounting brackets fit over any of four extruded
housing rails. See Catalog #FAQR-09 for complete specs and prices.
Fabco-Air, 3716 NE 49th Ave., Gainesville, FL 32609, (352) 373-3578,
www.fabco-air.com RS# 627
1UNLl4,20l2 MACH|NLDESIGN.com 88
Get the Original from
Avago Technologies!
Technology You Can Trust
Avago has been making encoder modules
previously used in US Digital kit encoders
for over 25 years. Get your US Digital
replacement kit encoder from the original
source... Avago Technologies.
For further information, visit us at:
www.avagotech.com/encoders
If you have been using US Digital
kit encoders in the past, then youve
been using Avago encoders all along.
RS# 164
Standard and Custom Clutch, Brake
& Power Transmission Solutions
291 Boston Turnpike Bolton, CT 06043
Phone: 860-643-1531
Reliability
inaClutch
...a clutch, brake or power
transmission part for that
matter. Since 1903 Carlyle
Johnson has solved some of
historys toughest motion
control challenges its what
we love to do. Our precision
electrical, mechanical, air and
hydraulic power transmission
products consistently prove
reliable and dependable in
every application. Underwater,
on the ground and in the air,
CJM is everywhere.
www.cjmco.com
FLUIDPOWER PRODUCTS
Pressure sensors
The new Model IP pressure sensors are CE certi-
fied and come in common pressure ranges (5 to
10,000 psi and 0.5 to 700 bar). IP sensors include tem-
perature in its Total Error Band (TEB) configuration,
improving measurement confidence and eliminating
the need for supplementary calculations. Models
IPG1 and IPG2 offer accuracies of 0.15 % and 0.25%,
respectively. They are compatible with many liquids,
chemicals, and gases and are designed for demand-
ing industrial environments with temperature swings or
pressure spikes. Typical applications include heavy-equipment monitoring, process and
factory automation, and testing.
Honeywell Sensing and Control, 2080 Arlingate Lane, Columbus, OH 43228,
(800) 848-6564, http://sensing.honeywell.com RS# 629
ISO tie-rod cylinders
MH Series metric hydraulic tie-rod cylin-
ders meet ISO 6020/2 160-bar standards.
The products have pistons with cast-iron
rings and polyurethane U-cup seals; rod
and rod bearings with hard-chrome-
plated/high-strength steel and bronze
construction; and carbon steel tie-rods
with rolled threads. Ten different bore
diameters range from 25 to 200 mm, with working pressures to 210 bar. Multiple
mounting configurations, as well as double-rod versions, are available.
Milwaukee Cylinder, 5877 S. Pennsylvania Ave., Cudahy, WI 53110, (414) 769-9700,
www.milwaukeecylinder.com RS# 630
Check-valve assembly
A compact manifold assembly that includes a check valve and an inverted
shuttle valve is for full-power brake systems. The assembly is suited for hydrau-
lic-brake systems that must store energy in two separate accumulator circuits.
The inverted shuttle valve isolates the higher pressure of the
two circuits, while directing lower pressure to the switch
port. A check valve prevents pressure from leaking back
to the inlet port. Maximum flow capacity is 11 gpm
and operating pressure is 3,625 psi. Applications
include split systems with a pressure-compensated
pump and electrohydraulic accumulator charging
controlled by a pressure transducer at the switch
port.
MICO Inc., 1911 Lee Blvd., North Mankato, MN
56003, (507) 625-6426, www.mico.com RS# 632
Request free information via our
Reader Service Web site at
www.machinedesign.com/rsc
Function-block library
The updated PLUS+1-compliant J1939 software function-block library supports EPA Tier
4 emissions-compliant systems and the companys related products. The library contains
30 new function blocks, including support for messages commonly used in Tier 4-com-
pliant systems, and 12 updated function blocks with protocol upgrades and new fea-
tures. These include basic PGN Receiver, PGN Transmitter, and Diagnostic function blocks.
The software supports CAN-based communications in the truck, bus, and off-highway
markets, letting OEMs quickly develop custom control systems.
Sauer-Danfoss, 2800 E. 13th St., Ames, IA 50010, (515) 239-6000,
www.sauer-danfoss.com RS# 631
RS#l65
1UNLl4,20l2 MACH|NLDESIGN.com 90
RS# 166
SOFTWARE REVIEW
muchmaterlalremalnslnthe
machlne.|nfact,theMojowont
letyoubulldlftherelsntenough
materlaltocompletethejob.Prom
here,justhltPrlntandthemachlne
startsbulldlngtheobject.when
thejoblscomplete,anotlceap-
pearsontheControlPanel.
Theonlynlt-plckythlngthat|
cansaylsthatatadmorevlbratlon
damplngcouldbelnorder.On
veryfastmoves(e.g.,rasterflllofa
thlnwall)therelsamlnoramount
ofshaklng.|saynltplckybecause
ltdldntbothermeorlnterruptmy
work.
Somyflrstpartbullttookless
than5hr.|tcomprlsed0.007-ln.
layerswlthasolldflll.Allthede-
tallswerepresent,lncludlngthln,
0.020-ln.rlbs,walls,andhorlzon-
talsurfaces.Thepartwasgood
looklngandconslstent.Andthe
machlnelstrulyofflcefrlendly.|t
dldntthrowoffanyheat,fumes,
orodor.
Alsoexceptlonallyeasylssup-
portremoval.Aspartofthepack-
ageprlce,thecompanylncludesa
nlcesupport-removalcarafecalled
wavewash55.Agaln,ltlssmall,
compact,andslmplejusta
plug,on/offswltch,andCycleStart
button.1ustdroplntheLcoworx
tablet,thepart,andaddwater.To
acceleratesupportremoval,the
carafeheatsthewaterandagltates
ltwlthanlftymagnetlc-drlverota-
tor.Alsonlcelsthatyouneedno
plumblngconnectlons,onlyaccess
toatapanddralnnoplumblng
lsnecessary.MD
processmyflrstpart.|selecteda
Test8lockfromwlndowsLxplorer
andhadtheflrstpartreadytoprlnt
lnl5mln.
ThePrlntwlzardlnterfacefor
prlntpreparatlonlsclean,slmple,
andlntultlve,lnpartbecausethe
onlythlngauserhastodolsselect
oneofthreesupportstyles,and
orlentthepart.8othtasksarevery
easy.Therearealsotheoptlonsto
dopartscallngandmakemultlple
coples.Once|knewhowtopro-
cessapart,lttookmejust30secto
openatestSTLandmakemyselec-
tlon.|thenpressedPrlnttoprepare
andsendtheSTLtothecontrol
software.Thattookjustl9sec.
whenflnlshedlnPrlntwlzard,
usersopentheControlPanel.|t
glvesjobdetallssuchasestlmated
tlme,showsthemodel,andthe
supportmaterlal.|talsollstshow
TheMojolsanewdesktopprlnter
fromStratasys,LdenPralrle,Mlnn.,
that|reallyllke.At$9,900,lt
opensthedoortomoreusers
suchassmallshopsandsmall
teams.TheMojohasasmall
bulldvolume,butthlslsnota
problemslnceabout80%ofall
partsdeslgnerscreatefltlna5
55-ln.workenvelope.Thema-
chlneltselfls25
l82lln.
Setupwas
easy.|nfact,
wlthoutrush-
lng,95%of
userswlllbeupand
bulldlngthelrflrst
partlnlessthan45
mln.Thlslncludes
unboxlng,setup,
softwarelnstalla-
tlon,learnlngthe
software,processlng
theflrstpart,and
launchlngabulld.|n
fact,theentlrepro-
cesswasldentlcal
tothatofbrlnglng
homeanewall-ln-
oneprlnter.Clear-cutandeasy.
8aslcally,usersjustplacesMojo
wheretheywantltandremove
thepacklngmaterlal.Next,they
lnstalltheprlntenglnesbydrop-
plngthemlnandsnapplngthem
lnplace.Theprlntheadlsconsum-
able,comprlslngtheheadandthe
materlal.Assuch,ltlsaseasyas
lnstalllnganlnkjetlnkcartrldge.
Nextcomeslnstalllngthebulld
platformandplugglngMojolntoa
computervlaaUS8cordandalso
lntoawalloutletvlathepower
cord.|twaseasytoloadthePrlnt
wlzardsoftwareandControlpanel
software.|wasverypleasedthat
therelsnocallbratlonoruser-run
setuproutlnes.Allofthatlsdoneln
thebackgroundbythesystem.
Usersneednotoolsexcepta
knlfetoopenthebox.wlththe
systemreadytogo,ltwastlmeto
Professlonaldesktop
3Dprlnterlseasy to use
Authoredby:
Todd Grimm
Presldent
T. A. Grimm & Associates Inc.
Ldgewood,Ky.
LdltedbyLeslie Gordon
leslle.gordon@penton.com,Twltter@
LeslleGordon
Resources:
T. A. Grimm & Associates Inc., www.
tagrimm.com
Stratasys, www.stratasys.com
RS# 426
The Mojo is sitting on a
desktop and is hooked
to a laptop.
The printed test
part was complex
and included 0.020-in.
ribs, walls, and horizontal
surfaces.
1UNLl4,20l2 MACH|NLDESIGN.com 92
w
w
w
.m
ach
in
ed
esig
n
.com
/rsc
R
eq
uest free inform
ation via
ou
r R
ead
er Service W
eb
site at
Accelerating the Speed of Design.
Avnet is ranked
Best-in-Class* for online seminars, technology education and training, design & engineering
services, knowledgeable application engineers and our online 24-hour design support proof
that we consistently deliver:
> Proactive engineering support
> Factory certied FAEs
Accelerate Time to Market.
at: www.em.avnet.com/drc
1 800 332 8638
www.em.avnet.com
*As rated by Hearst Electronics Group: The Supplier Interface Study, 2007.
Avnet, Inc. 2011. All rights reserved. AVNET is a registered trademark of Avnet, Inc.
Follow us on Twitter!
www.twitter.com/avnetdesignwire
RS# 167
SOFTWARE PRODUCTS
PowerSubD-Nurbs
formodo
PowerSubD-Nurbsformodolsaplug-lnthatlets
deslgnersautomatlcallyconvertsubdlvlslonsurface
mesheslntoNurbs-basedCADformatsthatcanbe
exporteddlrectlytostandardCADsystems.wlththls
newplug-ln,lndustrlaldeslgnerslntheearlystages
ofthedeslgnprocesscanqulcklycreateconcept
modelsthatcanbeexportedandreflnedlntheusers
CADsystem.Theplug-lnexports|GLS,SAT,STLP,and
RhlnofllesformatsforcompatlbllltywlthCADpack-
ages.Addltlonally,modomaterlalsasslgnedbythe
deslgnercanbeusedtoderlvesurfaceboundarlesln
theresultlngflleformaxlmumcontrol.
Luxology LCC,2525L.CharlestonRd.,Sultel04,
Mountalnvlew,CA94043,(650)336-l380,www.
luxology.com RS# 429
Completedle-castlng
solutlons
Thecompanynowprovldescompletealumlnumand
zlncdle-castlngsolutlonslnasfastasthreeweeks.|t
canasslstusersfromdeslgntocastlng.Thecompany
provldesmanypostprocesses,lncludlngmachlnlng,
platlng,coatlngs,salt-fogtestlng,etchlng,stamp-
lng,andanodlzlng.Partrunscanrangefroml00to
l00,000parts.AfreeDeslgnforManufacturablllty
(DPM)revlew,(valuedat$300)lsofferedtocustomers
worklngwlththecompanyondle-castlngprojects.
Quickparts.com Inc.,30lPerlmeterCenterN,Sulte
500,Atlanta,GA30346,(770)90l-3200,www.
quickparts.com RS# 430
RS#l68
1UNLl4,20l2 MACH|NLDESIGN.com 94
www.peerlesselectric.com ) www.hbdindustries.com
800/676-3651
sales@peerlesselectric.com
) DC Servo Motors
) Explosion Proof Motors
) Hermetic AC Motors
) Military/Defense Motors
) And MORE!
) Commercial Industries/Centrifugal Pumps
) Material Handling/Motion Control
) Military/Defense Applications
) Nuclear, Specialty, Custom Design and OEM
6SURFNHWV *HDUV 6KHDYHV
%XVKLQJV &RXSOLQJV 6LQWHUHG0HWDO
6\QFKURQRXV'ULYHV 3ODVWLF
6FUHZ&RQYH\RUV 'UDJ&RQYH\RUV
%XFNHW(OHYDWRUV +'&RQYH\RU3XOOH\V
,QGXVWULDO+DQG7RROV&DVW,URQ6SURFNHWV
www.mort|nsprocket.com 817-258-3000
"The ONE You Rely On!"
Martin offers the industry's broadest
product range with fast delivery from stock,
same day / next day rebores and alterations,
fast turnaround times on Made-to-Orders.
Our broad selection continues to grow with
complete inventories in 30 North American
branch locations.
PRODUCTS
in length from 120 to 88 mm
(4.7 to 3.5 in.), while the
length of the more-powerful
BG45x30SI was reduced from
135 to 103 mm (5.3 to 4.0 in.).
The new BG45SI motors
feature digital control and
power electronics and the
45-mm brushless motors
Two new iBLDC (intelligent brushless
dc) motors with four-quadrant speed
controls in the 45-mm frame size,
have been reduced in size by 25%,
while maintaining the same power
and torque capabilities.
The new BG45x15SI was reduced
motor connector
has been updated for
space saving and con-
venience in mounting
and connection.
With a 12 or 24-V
power source,
at a nominal
speed of 3,000 rpm,
the BG45x30SI is con-
tinuous-duty rated for 80 W (/-hp)
power output. The motors can
achieve peak powers of four times the
continuous duty rating and, therefore,
a starting torque of up to 100 N-cm
(142 oz-in.) is possible.
The motor target speed can be set
using an analog 10-Vdc input signal
or be selected via digital inputs using
simple start-up software.
The drive has four digital inputs
two for selecting the four operating
conditions: rotation clockwise/coun-
terclockwise, stop with free running,
and stop with holding torque. The
other two are for selecting the motor
speed with acceleration and decelera-
tion ramps.
Dunkermotor USA Inc., A div. of
Dunkermotoren GmbH, 2511 Tech-
nology Dr., Suite 105, Elgin, IL 60124,
(224) 293-1300, www.dunkermotor.
com RS# 474
Dual-output switching
power supplies
The new VGD Series of enclosed
dual-output internal-switching power
supplies comes in 30 and 60-W
configurations.
The Series offers a universal input
(85 to 264 Vac) and dual output volt-
ages of either 5 V/12 V or 5 V/24 Vdc.
Protections include short circuit,
overload, and overvoltage. All models
include an EMI filter.
CUI Inc., 20050 S.W. 112th Ave., Tuala-
tin, OR 97062, (800) 275-4899, www.
cui.com RS# 475
RS#l86
1UNLl4,20l2 MACH|NLDESIGN.com 106
0onnactab|a(PC,8a|tsa.a||ao|e||d|are|e||a|||||cr.098|||cu|.oO2.
CUSTOM MADE IN INCH, METRIC & O-RING SIZES
e|] C|ea| || 0pe|a3|.| E||r||a3e2 Te|2|.|||( Oe5|:e2
E/:ep3|.|a| Ao|a2|.| Re2|23a|:e
L|na Shaft 0onvayor 8a|ts - 0||(||a| E0u|pre|3 & C.||e:3ao|e
www.pyram|dba|ts.com
(P, O41./92.240o E-ra||. 2a|e2@p]|ar|doe|32.:.r
o22 \.|3) \||3) A5e|ue Ea23, \e63.|, |A o0208
Ah |S0 9001
0F8T|F|F0 00NPAhY
COLORS AVAILABLE
8ound, F|at and 0onnactab|a Po|yurathana 8a|ts
A||.62 |.| a::u|a3e, |.|
de23|u:3|5e rea2u|ere|32 .|
c-|||a|doe|||||de
d|are3e| (|O, .| ||2|de
:||:ur|e|e|:e (|C,.
Ava||ab|a |n Standard and
Natr|c S|zas.
DIAMETAPE BELT
MEASURING TOOL
Samp|as ava||ab|a at ||tt|a or no cost
POWER TRANSMISSION-PART CONVEYING
PYRATHANE
BELTS
w|3) |||e3|re wa||a|3] A(a||23 |a|u|a:3u|||( Oe|e:32
RS# 188
RS# 189
Paper Tube Company
1033 S. Noel Ave., Wheeling, IL 60090
COIL WINDING BOBBINS
Fabricated or molded, hi-dielectric,
hi-temp, choice of 12 electrical insulating
materials,extra strong, w/or w/o tie-offs, low
cost, 75 years experience, Made in USA!
Full PDF info: www.pptube.com
Fhona. B476874Z60 Fax. B476876777 LMaII. saIas@ppIuba.ro
More Than 75 Years - The Original
RS# 187
Distributed by Amacoil, Inc.
PO Box 2228, Aston PA, 19014
Phone: (610) 485-8300
Zero backlash. Jam-proof design.
For positioning & reciprocating motion applications
Smooth movement; ultra-low maintenance
Uhing
Rolling Ring linear drives have zero play when the shaft
is rotated even during reversal. The threadless shaft won't
clog or jam. If the system is somehow overloaded, the shaft
simply slips instead of churning and grinding.
Example applications: material handling machines, winding
equipment, test and measurement devices, packaging &
converting equipment.
Uhing Drives are available separately or
on shaft in custom assembly.
Wide range of sizes for varying linear
speeds & axial thrust requirements.
Simple set-up & operation
Some models feature mechanical control
over speed and travel direction without
programming or electronics.
equesta8rorhureor6M
1 (800) 252-2645
LmaII. amacoil@amacoil.com
www.amacoil.com
ManuaIIysIIdedrIve
usIngreIeaseIever
Rolling Ring
linear drives
PRODUCTS
Features of the hourmeter include
low operating current, wide operat-
ing voltage and temperature range,
interlock input, and a locking 10-pin
connector harness. Users can preset
total hours and replace a failed meter
without losing total elapsed time. A
key lock prevents unauthorized access
Hourmeter
The Series PT12 hourmeter features
two 6-digit, 7-segment LCDs. A ser-
vice LED indicates when the preset
setting is reached. Accumulated hours
are stored on powerless, nonvolatile
memory (no battery) using CMOS EE-
PROM technology..
to reset and programming functions.
ENM Co., 5617 Northwest Highway,
Chicago, IL 60646, (888) 372-0465,
www.enmco.com
RS# 476
Draw-wire linear
position sensors
Positals MDW draw-wire linear posi-
tion sensors, with analog voltage or
current output, are for use in low-cost
analog-control systems. Program-
ming operating parameters, including
range and sensitivity, is through a
pushbutton and LED interface.
The sensors are an alternative to
conventional multiturn potentiom-
eters. Based on a noncontacting mag-
netic-measurement technology, they
are not susceptible to the wear or
corrosion that degrades a potentiom-
eters accuracy. The sensors provide
instantaneous measurement of linear
displacement over a 0 to 16-ft
(0 to 5-m) range.
The encoders rugged enclosures,
seals, and bearings protect internal
components for operation in harsh
conditions. The sensors heavy-duty
spools are rated for over 1 million
draw/rewind cycles.
Fraba Inc., 1800 E. State St., Suite 148,
Hamilton, NJ 08609, (609) 750-8705,
www.fraba.com
RS# 477
RS#l90
1UNLl4,20l2 MACH|NLDESIGN.com 108
PRODUCTS
Rotary stage
CCS Series rotary stages, with in-
tegrated captured collet chucks,
provide automated material han-
dling for a wide range of materials
and applications. The units collet
chucks accept C, D, or Levin-style
collets that are available from machine-tool
component suppliers in sizes that support 0.1 to 27-mm
tube diameters. The collets provide run-out characteristics for applica-
tions requiring high-precision gripping of tubular material.
The collet-chuck design allows workpiece advance without manual realign-
ment to compensate for axial tube motion during clamp/unclamp cycles. By
moving the taper around the collet instead of drawing the collet into the taper,
axial motion of the workpiece is reduced, eliminating the need for part reregistra-
tion after tube advancement, thereby increasing system throughput.
Mounting features on the units housing support customer-supplied wet-
cutting accessories. The stage also tolerates moderate fluid leakage into the ap-
erture, which is inevitable during wet-cutting operations. These features prevent
encoder contamination and collet-chuck failure, minimizing machine downtime.
The CCS Series uses direct-drive brushless motor technology to maximize po-
sitioning performance. Direct drive provides quicker acceleration and higher top
speeds than gear or belt-driven mechanisms, for higher total overall throughput.
Aerotech Inc., 101 Zeta Dr., Pittsburgh, PA 15238, (412) 963-7470, www.aerotech.
com RS# 478
RS#l92
RS#l9l
1UNLl4,20l2
WL LkCLL A1 1nCSL
Cear hobbing and gear grinding from 1 - 60 (ACVA 15)
lnternal gear grinding from 10 - 60
CNC gear inspection up to 60
Cear shaping to J6 in diameter, 9.0 face width
0esign and Analysis (excellentsoftware.com)
Peverse engineering service
Wind turbine gear box, high speed spindles, gimbal heads
and gear boxes
NEE0 CEAPS 1 - 60
WITH UALITY TD AChA 15!
(;&(L*($5IN&
WL Lk
W
A TDTAL SEPVICE CDhPANY
ISD001-2008 APPPDVE0
Phone: (815) 62J J414
quotations@ExcelCear.Com
www.ExceICear.com
PRODUCTS
Silicone solar
cables
Silicone solar cables,
rated for voltages up
to 42,000 Vdc, provide
absolute reliability in
solar-panel intercon-
nection and photovol-
taic applications. The
halogen-free cables
are flame retardant,
highly flexible, and perform well when exposed to severe heat and cold (65
to 260C).
The cables crystal-clear silicone encapsulation resists tearing, and will
not deform, break, or wear during its 10 million cycles+ lifetime, even under
tight bending radius and constant flexing conditions. The silicone self-
heals from small punctures and cable jacket damage can easily be repaired
in the field. The silicone-extruded cables do not require external armor or
conduit for protection, and are unaffected when exposed to UV-radiation,
sunlight, ozone, abrasion, salt, coarse sand, submersion, acid rain, ice, vi-
bration, shock, humidity, mechanical stress, many chemicals, and difficult
weather conditions.
The 30 to 4-awg cables are available in continuous lengths, cut to order, or
as assemblies.
Cicoil Corp., 24960 Avenue Tibbitts, Valencia, CA 91355, (661) 295-1295,
www.cicoil.com RS# 480
Safety air guns with
chip shields
Safety air guns are now available
with polycarbonate chip shields
to protect workers from chips
blown off machined parts. The
shields also keep coolant from
splashing during drying opera-
tions and help businesses com-
ply with OSHA standards. Chip
Shields can be used on safety air
guns with or without an exten-
sion pipe.
The guns use air nozzles that
maximize entrainment of room
air while minimizing compressed-
air consumption.
Exair Corp., 11510 Goldcoast Dr.,
Cincinnati, OH 45249, (800) 903-
9247, www.exair.com/cs.htm
RS# 479
Angular-style grippers
The FKHW Series of 180 angular-style pneumatic
grippers handle small parts in confined areas. The
grippers rack and pinion synchronizes finger mo-
tion. Features include heat-treated fingers,
sealed bearings, magnetic pistons, and a
hard-coated aluminum body with slots to ac-
commodate optional sensors.
Fabco-Air Inc., 3716 N.E. 49th Ave., Gaines-
ville, FL 32609, (352) 373-3578, www.fabco-air.
com
RS# 481
RS#l93
1UNLl4,20l2 MACH|NLDESIGN.com 110
When il comes lo cable and hose carriers, nobody gives you more
opIions lhan U.5. T5UAKI and KAEL5CHLEPP. Choose lrom
micro-sized lo super-duly sleel, plaslic, and hybrid carriers. Available
in a wide range ol open, lube, and special problem solving designs.
kabeIschIepp.com or call 800-443-4216
NLW! RequesI a FRLL 2012
CaIalog & 1echhical Cuide
Over 600+
!ull-color pages
126+105 51.76+105
H MORE OPTION5
RIGHT 5OLUTION !or your cabIe & hose carrier appIicaIion!
NASA Low Outgassing
Approved Epoxy
154 Hobart Street, Hackensack, NJ 07601 USA
+1.201.343.8983main@masterbond.com
www.masterbond.com
EP29LPSP Two Part
Adhesive/Sealant
Optically clear
Chemically resistant
Cryogenically serviceable
Non-stick
Chemical
resistance
Low
coefficient
of friction
We coat both small and large parts to close tolerances in
quantities from 1 to 1,000,000. Call Donwell for custom
TEFLON
COATINGS
To enhance product
performance
Donwell Company is a licensed
DuPont applicator for all TEFLON
Inflatable Seals
TYPICAL INFLATABLE
SEAL OPERATION
When inflated it expands to the striking surface creating a positive
seal. When deflated it returns to its original configuration allowing
free movement of one or both surfaces.
Inflatable seals and other custom rubber products
SEAL MASTER CORPORATION
368 MARTINEL DRIVE, KENT, OH 44240-4368 USA
800.477.8436 330.673.8410 FAX 330.673.8242
E-mail: info@sealmaster.com www.sealmaster.com
Design assistance offered
2010 Seal Master Corporation
DEFLATED INFLATED
maxon motor control
Maintaining
control has never
been easier.
maxon motor is the worlds leading supplier of high-preci-
sion drives and systems of up to 500 watts power output.
Rely on the quality of the highly specialized solutions which
we develop with and for you. www.maxonmotorusa.com
If decentralized drive intelligence is called for, maxon motor
control provides the answer: All speed and positioning con-
trollers are designed to match with DC motors up to 700 watts
power. The EPOS2 positioning controller can be used with
CANopen and Interpolated Position Mode.
RS# 202
RS# 203 RS# 204
Farmington Hills, Ml 48335
tel: 800-521-3320 / fax: 248-476-2470
e-mail: shocks@acecontrols.com
www.acecontroIs.com
3URGXFW
,QIRUPDWLRQ
$YDLODEOH
2QOLQH
Solid, Long Life Construction
Push & Pull Type Designs
Fixed Force or Adjustable Models
Stainless Steel Models Available
Expert Application Sizing
ACE Controls Gas
Springs provide
counterbalance motion
control for lifting and
lowering lids, hoods, hatches,
machine guards, panels and
more. Offered in a wide range of
body sizes, stroke lengths and forces.
Aerospace, Defense, Transportation,
RV, Medical, Furniture, Packaging,
Printing, Amusement and More
WELL DO THE
LIFTING
& LOWERING
PRODUCTS
Tilt-float switches
An expanded line of tilt-float switches
for large-volume liquid-level applica-
tions feature a watertight rubber float
with a three-conductor cable.
Available in three different
configurations, each float is made
from EPDM for long service life and
resistance to heat, oxidation, ozone,
and aging due to weather. EPDM
offers good electrical resistivity and
resistance to solvents such as water,
acids, alkalies, phosphate esters,
and many ketones and alcohols.
The switches contain an 8-A
(250-Vac) microswitch on an antivi-
bration mount. The SPDT switch el-
ement can be used for either open
or closed contact configurations
and measures both increasing and
decreasing fluid levels. The resulting
signal can be used to start or stop a
pump, open or close a valve, or actu-
ate indicator alarms.
Madison Co., 27 Business Park Dr.,
Branford, CT 06405, (800) 466-5383,
www.madisonco.com
RS# 486
Linear-shaft motor
The S605 linear-shaft motor offers up
to 3,100 N of acceleration force, and
a continuous force of 780 N, making
it suitable for applications requiring
high force, high precision,
energy efficiency, and high
precision. The motor can hit
submicron resolution.
Three types of windings
are available double, triple,
quadruple. The S605s ac-
celeration current is between
34 and 35 A and acceleration
force and current can be main-
tained for up to 40 sec. The
motor has a 60.5-mm shaft diameter,
is available with strokes between 200
and 2,000 mm, a 1.75-mm noncritical
air gap, and a rated voltage of 240 V.
The motor is available in 18 different
sizes, ranging from 4 to 60.5 mm.
Nippon Pulse America Inc., 4 Cor-
porate Dr., Radford, VA 24141, (540)
633-1677, www.nipponpulse.com
RS# 487
Miniature diaphragm pump
The 1410 Series dc diaphragm pump measures
3.3 1.2 2.1 in. and is designed to work with a
range of motor options and several design con-
figurations, depending on the life requirements
and specifications of the application. The pump
features a low sound level, weighs 0.4 lb (180 gm),
and is EMC suppression qualified to EN55011-B
on some designs. Maximum flow is 4.3 lpm, with
a maximum pressure of 27.5 psig/1.9 bar, and a
maximum vacuum of 22.0-in. Hg.
Thomas Div., a Gardner-Denver Co., 1419 Illinois Ave., Sheboy-
gan, WI 53081, (920) 457-491, www.gd-thomas.com/productlist.
aspx?id=21044&tp=v
RS# 488
RS#205
1UNLl4,20l2 MACH|NLDESIGN.com 116
RS# 206
RS# 207
RS# 208
7ULJRQRPHWU\4XL]
5)0RGXOHV
5HPRWH&RQWUROV
$QWHQQDV
5)&RQQHFWRUV
&XVWRP'HVLJQV
ZZZOLQ[WHFKQRORJLHVFRP
,IRQO\5)FRXOG
EHVRHDV\
PRODUCTS
16-mm
spindle drive
The GP16 16-mm spindle drive con-
verts rotary motion into linear mo-
tion by combining the spindle drive
with a dc motor. Gearheads, motors,
encoders, and controllers drive the
spindles. The drive, available in a self-
locking metric M6 spindle or a 5-mm
ball screw, offers high efficiency and
load capacity. The axial bearing with-
stands the high tractive and com-
pressive forces of the spindle.
For the planetary gearhead, 14 dif-
ferent reduction ratios are available,
from 4.4 to 850:1. Depending on the
reduction ratio and spindle type, feed
forces between 35 and 370 N, and
even up to 400 N for short durations,
are possible.
Nine different brushed and brush-
less motors can drive the system. For
precise positioning, the motors may
also be equipped with compatible
sensors (encoders).
maxon motor usa, 101 Waldron Rd.,
Fall River, MA 02720, (508) 677-0520,
www.maxonmotorusa.com
RS# 489
Ultrasonic sensors
The F77 Series ultrasonic sensors are
an alternative to background-sup-
pression photoelectric sensors in dirty
and dusty applications or where color
variations or
transparent
targets are
the norm.
Highly im-
mune to
acoustic
interference,
the sensors
have mini-
mal dead-
band, which
is important
when the
devices mount on machinery that
uses numerous pneumatic cylinders.
The sensors are compact and pro-
vide up to 50-Hz switching frequency
for fast response times. They come in
diffuse (up to 400-mm sensing range),
retroreflective (up to 400-mm sensing
range), and thru-beam models (up to
800-mm sensing range).
Pepperl+Fuchs, 1600 Enterprise
Pkwy., Twinsburg, OH 44087, (330)
486-0001, www.pepperl-fuchs.us
RS# 490
Intelligent power
module
Semistack_RE is an intelligent
power module (IPM) targeting
synchronous and double-fed
induction generators (DFIG) in
wind turbines, and central solar
PV inverters.
The water-cooled three-
phase converter comes in
B6CI two-quadrant or 2 B6CI
four-quadrant configurations
in a bookcase-type mechanical
design.
The previous version of Semistack-RE based on the three-bay version of SKiiP 3
has a current capability of 1,200 /module. The bigger, four-bay SKiiP 4 version has
a current rating of between 1,000 and 1,400 A.
SKiiP 4s new digital gate driver provides a safe electrical isolation between
primary and secondary side for all switching or control signals and for the tem-
perature signal. The SKiiP driver features a CANopen setup and diagnosis channel,
giving access to an error memory so errors in SKiiP 4 can be quickly identified and
saved for later diagnosis.
Semikron Inc., 11 Executive Dr., Hudson, NH 03051, (603) 883-8102,
www.semikron.com RS# 491
RS#209
1UNLl4,20l2 MACH|NLDESIGN.com 118
RCP4
ROBO Cylinder Series
PCON-CA
Power Controller
IAI America, Inc. California: 800-736-1712 Illinois: 800-944-0333 Georgia: 888-354-9470
www.IntelligentActuator.com/RCP4
7LPHVWKH6SHHG
'RXEOHWKH3D\ORDG
RS# 210 RS# 211
RS# 212
Kep-O-seal
Adjustable Relief
Valves
Available as in-line or cartridge insert
types, these valves feature the industry
proven Flexible Seal Seat design which
provides dependable control of liquid or
gas. Direct operating and spring loaded,
they are designed for applications requir-
ing fast acting relief performance and
tamper-proof pressure adjustment. Fully
adjustable 50 to 2000 psi.
For details visit: www.kepner.com
Cont rol Sol ut i ons That Act ual l y Gi ve You
. . . CONTROL!
- O
E
M
s -
Let us B
e Your P
anel B
uilder
and S
ystem
s Integrator!
Phone: (336) 589-6920 viccontroIs.com
3ys|er-W|de corrur|ca||or,
process cor|ro| ard ror||or|rg
PoWerlu| so|u||ors lor produc|
ard process |r|egra||or
\lC ollers |re |dea| so|u||or lor 0EVs
|oo||rg lor a pare| rarulac|ur|rg
resource W||r ex|ers|ve |roW|edge ol
Nor|r Arer|car s|ardard.
wre|rer || oe a s|rg|e racr|re
cor|ro| pare|, ar 0EV |oo||rg |o
add sore |oucr screer 'sa|es
dazz|e |o |re|r racr|re cor|ro|s,
or corp|e|e |rdus|r|a| cor|ro|
sys|ers, \lC goes |re ex|ra
d|s|arce |o urders|ard your
rar|e| ard racr|rery |o des|gr
ard produce cor|ro|s |ra| W|||
op||r|ze |re perlorrarce ol
your equ|prer|.
Fcrmcreinfcrmaticn,pIeaseccntact
AryanZandiebatI312!92-188crazandiebbfusa.ccm.
Partner: 0rganizedby:
www.ia-na.ccm
at
TcregisterfcrIANAandIHT5,pIeasevisit industriaIautcmaticn-na.ccm
V
InternaticnaITrade5bcwfcrFactcry,Prccessand
BuiIdingAutcmaticn5ystemsand5cIuticns
5eptember10-15, 2012 - HCc-)ik P(ae, Cbiagc, I((inci.
INDUSTRIAL AUTOMATION
NORTH AMERICA at IMTS 2012
Bekbcff A0tc)aticn provides advanced,
open automation products based upon
proven industrial technologies. Manufacturers
and machine builders can implement high
performance Beckhoff control systems
more efciently and at a lower overall cost
than traditional PLC and motion control
systems. Visit them at booth E-4271
or www.beckhoff.com.
Static
Control
800.787.7325
e-mail: industrial@sealeze.com
www.sealeze.com
:0|JI|0N:
\|t|
teadact|.e
|ra.|e.
Sealezes line of brushes for
static control ofers:
t4JNQMFCPMUPOTPMVUJPOUP
TUBUJDQSPCMFNT
t/PNPOJUPSJOHPSBEKVTUNFOUT
re|a|red
t$PTUFFDUJWF
Eliminate Static
t*NQSPWFQSPEVDUJPOTQFFE
t3FEVDFDMJOHJOHQBSUJDMFTBOE
NJOJNJ[FTUBUJDJOEVDFEEFGFDUT
t*NQSPWFPQFSBUPSTBGFUZ
4&"-&;&)"4
$BMMGPSDPQJFTPGPVSUFDIOJDBMEBUB
TIFFUTPSBGSFFDPQZPGBXIJUFQBQFS
EFTDSJCJOHTFBMF[FTPGUCFSCSVTIJO
B1&5(MNOBSSPXXFCBQQMJDBUJPO
PRODUCTS
Mini actuator
A new miniature actuator de-
signed for the miniature robot-
ics and life-science markets,
consists of a small dc servomo-
tor coupled to a ball screw.
Included in the assembly is a
high-precision miniature 8-mm-
diameter ball screw, a Faulhaber
dc motor with graphite commu-
tation, rotary encoder, and gear-
less coupling for high-speed,
backlash-free positioning with
high dynamic performance. This
product is ideal for applications
in miniature robotics and preci-
sion dispensing systems. The
actuator comes in travels rang-
ing from 10 to 300 mm, with
resolution of 1 micron, speeds
up to 120 mm/sec, and capable
of peak axial loads to 800 N.
Steinmeyer Inc., 56 Middlesex
Turnpike, Suite 200, Burlington
MA 01803, (781) 273 6220 (781)
273-6220, www.steinmeyer.com
RS# 492
Rugged circular connector
The new Circular High Density (HD) connec-
tor line is a low-cost alternative to 38999 and
other circular connectors for rugged non-Mil
Spec applications. The connectors offer ease
of push-to-latch/pull-to-unlatch mating as
well as the advantage of blind
mating into small spaces that nor-
mally requires clearance for hand
tightening to mate.
Other features include scoop-
proof, blind mating; operating
range of 65 to 125C; durability of 1,000
mating cycles; five shell bodies ranging from
14 to 27-mm diameter; panel-mount recep-
tacles; IP68 rated with potted, solder cup or
PCB termination; 96-hr salt-spray exposure;
withstand 37 gs of vibration and 50 gs of
shock; cable-attached plugs and receptacles;
up to 40 signal contacts; and up to 20-A cur-
rent rating.
TE Connectivity, 1050 Westlakes Dr., Ber-
wyn, PA 19312, (800) 522-6752, www.te.com
RS# 493
Switching power supplies
A new family of 24-V power supplies converts ac to dc and provides safety ex-
tralow voltage (SELV).
With a wide input range between 90 and 260 Vac the supplies can be
used in diverse supply networks. An onboard potentiometer adjusts output voltage
from 22.5 to 28.5 Vdc, and styles are available with an output current strength of 2.5,
5, 10, or 20 A. This highly-
efficient power supply can
be run in parallel for applica-
tions requiring redundancy
and includes up to 150%
overload protection.
A power relay guaran-
tees a reliable functional
check, monitoring itself for
voltage, eliminating potential wire breakage or system malfunction. The device
can automatically bypass power failures, which lets the ac input disappear for up
to 30 msec without any effect on the output.
Turck Inc., 3000 Campus Dr., Minneapolis, MN 55441, (800) 544-7769, www.turck.us
RS# 494
RS#2l3
1UNLl4,20l2 MACH|NLDESIGN.com 121
JUNE 14, 2012 MACHINE Design.com 122
RS# 255
Digital Pressure
Gauge
AP60 digital pressure
gauge is CR2032 battery
powered, offers wide
viewing angle and provides
an accurate readout. They
are rated for pressures up
to 1.0MPa (145 psi) with
user-programmable display pressure units for MPa, kgf/cm
2
,
bar and psi. Suitable for fltered air and non-combustible and
non-corrosive gases; excellent repeatability of +0.2% F.S. +1
digit or better.
Adsens Technology Inc.
City of Industry, CA
Brushless DC and Intelligent Servo Motors
Dunkermotor releases its 2012
Low Voltage Brushless DC and
Intelligent Servo Motors catalog.
Expanded catalog includes
specifcations on custom confg-
urable BLDC motors, controls,
gearheads, brakes, encoders
and accessories. Available for
complimentary download at
Dunkermotor website or email
request for hard copy.
Dunkermotor
Email: info@dunkermotor.com
Web: www.dunkermotor.com/2012_BLDC_catalog
New tutorials and podcasts on Learn Web site
What is a PLC plus many more
topics on industrial control prod-
ucts including new videos and
podcasts on AutomationDirects
free self-service learning site.
Visit http://learn.automationdirect.com
to watch these and other tutorials
on a range of industry topics.
Rotary Dampers
Minimize noise, shock, and
safety hazards. Soft and
smooth motion enhances
functionality and provides
that touch of quality. Use on
computer hardware, fip top
phones, lids, access panels
and more.
19 new series introduced.
ACE Controls Inc.
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Fax (248) 476-2470
e-mail: shocks@acecontrols.com
www.acecontrols.com
RS# 261
Galil Motion Control
Galils Pocket PLC
Has Lots of I/O
RIO Pocket PLC is smart,
compact, low-cost, and packed
with I/O. 32 digital and 16 analog
I/O in 3.9 x 4.3 x 1.3 package.
Ethernet/RS232, RISC processor,
PID process loops, counters, timers, data logging, email
alerts. Network multiple RIOs. $295 qty 1/$195 qty 100.
Call Galil at 800-377-6329 or http://www.galilmc.com/
pocketplc for specs and free tutorials.
B&B Electronics is a global source
for rugged, reliable wired and wire-
less data connectivity systems.
Backed by strong technical
support, B&Bs Ethernet, USB,
Wireless and Serial solutions are
known for being easy to order,
install and use.
For more info, please contact:
B&B Electronics
Phone: 888-948-2248
Email: orders@bb-elec.com
URL: http://www.bb-elec.com
Download B&Bs latest white papers:
http://bb-elec.com/technical_library.asp
UL TC-ER listed TOPSERV
USA Inc.
1355 Bowes Rd, unit C, Elgin, IL 60123
(847) 930-5118, www.helukabel.com
Free design guide
to servo-hydraulic
motion control
www.da|tamot|on.com
Popular, practical 64-page guide
with 16 topics by Patar hachtway:
s#LOSEDLOOP#ONTROL
s3IZING#YLINDERSAND6ALVES
s3ELECTING!CCUMULATORS
s4RANSDUCERSAND2ESOLUTION
s4UNINGFOR/PTIMAL0ERFORMANCE
Pancake
II Cylinder
Has interchanges with
better performance. Tough
composite barrel is self-
lubricating & impact
resistant. Composite rod
bearing, captive in head,
has higher load capacity,
lower friction, zero slip-stick.
We solve problems. Let
us help!
FABCO-AIR, Inc.
Gainesville, Florida
Helical Products Co., Inc.
COUPLINGS, U-JOINTS
and MACHINED SPRINGS
Helicals 28-page catalog
features miniature fexible
couplings, u-joints, power
transmission couplings and
machine springs. Quick-
reference, product summary
chart highlights features and
technical data. Easy-to-use part
number builders make ordering
easy.
Visit: www.heli-cal.com
Avago Technologies San Jose, Ca.
The power inverter - from sunlight to power grid
This video discusses
performance
advantages of optical
isolation technology
based isolators and
optocouplers, in terms
of common mode
rejection, EMI
immunity, radiated
emissions and part
degradation over time
in renewable energy
applications.
RS# 251
RS# 260
RS# 263
RS# 254
RS# 256
RS# 259
RS# 262
DATA FILE LITERATURE ADVERTISING
www.machinedesign.com/rsc
Access our Reader Service
Website to quickly find and
request information on the
products and services found
in the pages of MACHINE DESIGN.
RS# 257
RS# 250
RS# 264
RS# 252
RS# 258
RS# 253
MACHINE Design.com 123
Smalley Steel Ring Company
New Smalley Engineering
& Parts Catalog
Smalleys new catalog combines
existing Spirolox Retaining Ring
and Smalley Wave Spring selec-
tions with series recently released
from Smalley. Now a single catalog
includes new: Hoopster Rings, Met-
ric Wave Springs, Constant Sec-
tion Rings and more. Over 10,000
standard parts in carbon and stain-
less steel; free samples available.
Specials manufactured with
No-Tooling-Costs from .200-120.
info@smalleZcomXXXsmalleZcomgetcatalog
www.masterbond.com
Resists up to 500F Thermally conductive
One Part B-Stage Epoxy EP36AO One Part B-Stage Epoxy EP36AO
Available in cookies
Over 15,000 products +
everything you need to know
about
Order your free copy today at: www.orientalmotor.com
- Stepping Motors
- Servo Motors
- AC Motors
- Brushless Motors /
AC Speed Control Motors
- Linear & Rotary Actuators
- Cooling Fans
RS# 272
RS# 274
814-894-2461 www.symmco.com
Discover Symmcos Parts
Conversion Opportunities
Your Key To Quality & Savings
Design Support (for Simple to Complex Parts)
Gears
Assembly Solutions
Materials Options
Dont Cast &
Machine Save
Time & Money
with Powder
Metallurgy (P/M)
JUNE 14, 2012
MAINTENANCE AND TROUBLESHOOTING
GUIDE NOW AVAILABLE!
A newly revised brochure by Martin
Sprocket & Gear, Inc. provides helpful
tips for routine maintenance as well
as insight for troubleshooting common
problems and corrective action on power
transmission and material handling prod-
ucts. Individual sections on chain drives,
gear drives, chain couplings, elastomeric
couplings, synchronous drives, v-belt
drives and screw & drag conveyors as
well as heavy duty conveyor pulleys
is included.
For additional information including which
of Martins 31 North American plants
are located nearest you please contact
Martin Sprocket & Gear, Inc. at 817-258-
3000. Or visit our web site at
www.martinsprocket.com.
RS# 266
RS# 270
RS# 268
High- Performance
Magnets
New catal og features hi gh
performance magnet materials
such as NdFeB and SmCo,
molded magnets, ceramic and
al ni co magnets. MCE offers
magnet ci rcui t desi gn,
custom fabrication, assembly,
and advanced coati ngs.
Complete traceability is offered.
P h o n e : ( 3 1 0 ) 7 8 4 - 3 1 0 0 ,
Fax:(310)784-3192; mcesales@mceproducts.com;
www.mceproducts.com
MagnetIr6omponentLngIneerIng
RS# 275
RS# 273
RS# 271
RS# 269
RS# 265
Trim-Lok Inc., Buena Park, CA
Vinyl & Rubber Extrusions
Trim-Lok Inc. releases a brand new
FREE Catalog 500 featuring How
to Order steps for the frst time
customer, along with an expanded
line of complete trims and seals.
FREE samples may be requested.
Latest additions include our Flap
Seal, Fire Retardanct Trim, adn
Hatch Seal. Contact us toll fee at
1-888-874-6565, e-mail us at info@
trimlok.com or visit us on-line at
www.trimlok.com
Seal Master Corp., Kent, OH
SEALS, ACTUATORS,
GRIPPERS AND BAGS
Solve difficult closure prob-
lems with custom-built, fab-
ric-reinforced, fully molded
elastomeric Seal Master
infatable seals. With close
tolerance capability and re-
sistance to compression,
theyre ideal for imaginative production and processing
applications too. Engineered specialties include fabric-
reinforced bags, bladders, plugs and other custom rubber
products. Design assistance offered.
Pelican Products
Pelican Products
Protects Sensitive
Instruments
The global leader in the design
and manufacture of both
high-performance protective
case solutions and advanced
portable lighting systems.
Sales Contact: Mark Rolfes
www.pelican.com/contact
Website: www.pelicanoem.com
23215 Early Avenue
Torrance, CA 90505
Phone: 310-326-4700
Toll Free: 800-473-5422
Fax: 310-326-3311
Brad Power Products
Brad power products replace machine hard wiring
with easy-to-install, modular, quick-connect systems
comprised of crush resistant, prewired cordsets
and factory-molded connectors. They do not require
special tools or labor.
Molex
www.molex.com
800.225.7724
Omega introduces its PSW14 series
of electronic pressure switches which
can feature either a single switch with
adjustable hysteresis or a dual switch
with xed hysteresis.This CE compli-
ant product has an easy to program
on/off set point and its compact
construction makes it ideal for OEM applications in hydraulic and pneumatic
systems, the automobile industry, lubricant monitoring and industrial control.
Price Starts at $135
Electronic Pressure Switch PSW14
Omega | Stamford, CT USA | www.omega.com/psw14
Email: info@omega.com | Twitter: @OmegaEng
Facebook: http://www.facebook.com/pages/Omega-Engineering/121219014465
Phone: 1-800-TC-OMEGA or 203-359-1660
RS# 267
RS# 276
users can
browse video
libraries using
technology-
based
navigation
to focus
on specific
technology
topics. They
can also
browse by
company
brand, trade
show, or by
publication-
specific video
playlists.
From tutorials
to trade-show
coverage,
Engineering TV
is the video
site for design-
engineering
professionals.
At
EngineeringTV.com
visit us at
EngineeringTV.com
ADVERTISER INDEX
RS# . . . . . . COMPANY. . . . . . . . . . . . . . . . . . . . . . .PAGE
205........AceControls..........................ll6
l79........AdvancedAntlvlbratlonComponentsl03
ll3........Aerotech,|nc............................l4
l3l........AlrpotCorp/Alrpel ......................36
l32........AlrpotCorp/Alrpel ......................37
2l6........AllMetrlcSmallParts.................l27
l90........Amacoll,|nc...........................l08
2l4........AnlmatlcsCorporatlon................l24
l53........AssoclatedSprlng/Raymond...........67
l03........Automatlondlrect.com.................. 3
l05........Automatlondlrect.com.................. 6
l6l........AvagoTechnologlesU.S.|nc............83
l64........AvagoTechnologlesU.S.|nc............89
l29........Avnet...................................34
l67........Avnet...................................93
l60........8&8Llectronlcs........................8l
l56........8&R|ndustrlalAutomatlon .............73
l57........8annerLnglneerlngCo.................75
l47........8elden|nc. ..............................57
l97........8ellowstech,LLC......................ll2
2l7........8eswlckLnglneerlngCompany,|nc...l27
220........8lmbaManufacturlngCompany ...... 8C
l62........8lsonGear&Lnglneerlng...............85
l65........Carlyle1ohnsonMachlneCo............90
l36........ClcollCorp..............................4l
l06........Cllppard|nstrumentLaboratory,|nc. .... 7
l55........ContlnentalHydraullcs .................7l
l42........Contrlnex|nc ...........................47
l92........Craftech|ndustrles|nc................l09
l7l........DeltaComputerSystems|nc............99
l95........DonwellCo...........................lll
2l8........Dunkermotor.........................l28
l08........L8M-Papst............................... 9
l04........LxalrCorporatlon........................ 5
l93........LxcelGear,|nc.........................ll0
l69........LxlarCorporatlon.......................95
l48........PabcoAlr,|nc............................59
l49........PestoCorporatlon ......................60
l99........Ployd8ell .............................ll3
203........PorestCltyGear.......................ll5
l66........GalllMotlonControl|nc.................9l
l33........Gates ...................................38
l77........GemsSensors.........................l0l
l58........Groschopp..............................77
l38........HarmonlcDrlveLLC.....................43
l27........HellcalProductsCompany,|nc..........32
2l2........|A|Amerlca|nc........................ll9
206........|garashlMotorSales..................ll7
l34........|gus,|nc.................................39
l63........|KO|nternatlonal|nc....................87
l39........|MSGear ................................44
l70........|ntechCorporatlon .....................98
ll8........|ntelllgentMotlonSystems,|nc..........22
ll9........|ntelllgentMotlonSystems,|nc..........23
l8l........|TT-Lnldlne|nc.......................l03
l96........KabelschleppOfAmerlca.............lll
2ll........KepnerProducts......................ll9
l4l........LappUSA...............................46
l72........LeeCompany...........................99
209........LlnxTechnologles.....................ll8
ll0........MagnetlcComponent
Lnglneerlng,|nc. ......................ll0
l86........MartlnSprocket&Gear ...............l06
While every effort has been made to ensure the
accuracy of this index, the publisher cannot be
held responsible for any errors or omissions.
l94........Master8ond,|nc. .....................lll
204........MaxonMotorUSA....................ll5
l44........MlnalexCorp ...........................50
ll7........MlnnesotaRubber......................l9
l9l........M|TRPAK..............................l09
l54........Molex...................................69
2l5........NammoComposlteSolutlonsLlc.....l25
ll2........Natlonal|nstrumentsCorporatlon......l3
ll5........Newark/Llementl4....................l7
l74........NewportCorporatlon.................l00
l73........NexenGroup|nc........................99
l80........NlpponPulseAmerlca|nc ............l03
l09........NovotechnlkU.S.,|nc. ...................l0
l5l........NumatlcsLxpress.......................63
l98........Ogura|ndustrlalCorp.................ll3
l02........OmegaLnglneerlng|nc ................. l
............Ondrlves.us .............................40
l2l........OrlentalMotorUSACorp...............26
l22........OrlentalMotorUSACorp...............27
l84........PeerlessLlectrlc.......................l05
l46........PellcanProducts ........................53
l50........Plttman.................................6l
l87........PreclslonPaperTubeCompany.......l07
2l9........ProtoLabs,|nc..........................|8C
l89........Pyramld|nc...........................l07
207........Quallty8earlngs&Components......ll7
200........QualltyTransmlsslonComponents...ll3
l82........R+wCoupllngs......................l04
l20........Rlttal ................................24-23
208........RotorCllpCompany..................ll7
l78........SA8AssoclatedwlreProducts........l02
l68........SantestCoLtd..........................94
l0l........SchmersalLLC......................... |PC
202........SealMasterCorporatlon..............ll5
2l3........SealezeCorp..........................l2l
l88........Servometer'.........................l07
l40........SLwLurodrlve..........................45
20l........Shlmpo...............................ll4
l45........SKP......................................5l
lll........SKPGroupHeadquarters...............ll
l37........SmalleySteelRlngCompany...........42
l07........Splrol|nternatlonalCorporatlon......... 8
l28........Stelnmeyer,|nc. .........................33
l30........Stelnmeyer,|nc. .........................35
l83........StockDrlveProducts..................l05
l43........Stratasys................................49
l52........TDK-LambdaAmerlcas|nc..............65
l75........Techno|nc ............................l0l
l76........Trans-Tek|nc..........................l0l
l85........Trlm-LokCompany...................l05
ll6........Turck|ncorporated .....................l8
2l0........v|CControls...........................ll9
l23........veljanHydralrLtd. ......................28
l24........veljanHydralrLtd. ......................29
l25........w.L.Gore&Assoclates|nc ..............30
l26........w.L.Gore&Assoclates|nc ..............3l
l59........wlttensteln.............................79
ll4........ZLRO-MAX.............................l5
RS# 214
BUSINESS INDEX
Thlslndexlncludesallslgnlflcant
referencestoparentcompanles
mentlonedlnfeatureedltorlalmaterlal
wlthlnthlslssueofMACHINEDESIGN.|t
doesntcltecompanlesllstedsolely
lntheProductsandLltSectlon.Page
numbersllstedrefertothepageswhere
theartlclesbegln.
MeltrlcCorp................... 3l
M|CO|nc....................... 90
MllwaukeeCyllnder............ 90
NASA.................... 8,20,54
Nv|D|ACorp. .................. 28
NuageCorp. ................... 95
ObjectManagementGroup.... 42
ParkerHannlfln,HoseProducts
Dlv......................... 88
PlttmanMotors..................6
PolyOneCorp. ................. 96
PrlntedLlectronlcsTestCenter
Network.................... 44
PryerTechnologyGroup ....... 78
PurdueUnlverslty............. 54
Qulckparts.com|nc............ 94
RexnordCorp. ................. 42
Rexnord|nnovatlonCenter.... 42
RexnordTechnlcalServlces
(RTS)....................... 42
SLM| .......................... 62
SaesGetters ................... 37
SalemDeslgnand
ManufacturlngLLC......... 70
SandlaNatlonalLaboratory.... 33
Sauer-Danfoss................. 90
SchottSystemsGmbH......... 95
ShepherdControls&Assoclates 42
Slmrlt......................... 50
Soraa|nc....................... 25
SouthPoleNeutrlno
Observatory................ 47
StarThermoplastlcs............ 97
Stratasys ...................... 92
StruktolCompanyofAmerlca.. 96
SymbloslsPoundatlon......... 60
Synchro-MatLqulpmentCorp.. 40
SyntheonLLC................. 54
T.A.Grlmm&Assoclates|nc..... 92
TLConnectlvlty................ 44
TvSDAmerlca.............. 44
TegraMedlcal................. 42
TeledyneContlnentalMotors.. 40
TrlpollRocketAssoclatlon...... 54
U.S.Dept.ofLnergy........... 62
UC|MU........................ 36
workflowManagement
Coalltlon ................... 42
XenonCorp. ................... 44
AMGeneral................... 40
AMD............................6
AerospaceCorp.,The.......... 48
AgllentTechnologles|nc....... 42
AlrPorceResearchLab......... 54
Altuglas|nternatlonal,
Arkema|nc.................. 97
Amerlchem|nc................. 97
Ansys...........................6
Asslot......................... 37
Assofluld...................... 37
AutomatlonDlrect...............6
AutomatlonDlrect............. 88
AvnetLlectronlcsMarketlng... 44
Avnet|nc...................... 44
BPM.com...................... 42
8eswlckLnglneerlngCo.|nc.... 88
8oschRexroth................. 82
8ureauofAlcohol,Tobacco,
Plrearms,andLxploslves .... 55
Carlbonl....................... 39
CarrollHlghSchool............ 52
Chrysler ....................... 40
Comatrol ...................... 88
CongressofthePutureof
LnglneerlngSoftware....... 48
Cymatlx|nc.................... 42
DanfossPowerLlectronlcs ..... 42
Darpa ......................... 54
Delcam.........................6
DeltaComputerSystems|nc. ... 76
DeutscheMesse ............... 37
Dunkermotor................ 6,42
LlastoconTPLTechnologles .... 96
LuropeanSpaceAgency....... 20
Lxalr.......................... l8
PAA........................... 54
Pabco-Alr...................... 88
Fabricating.com . . . . . . . . . . . . . . . . .68
PederalHlghwayAdmlnlstratlon26
Pedermacchlne................ 35
PleraMllano ................... 37
PreudenbergSeallngTechnologles
Academy ................... 50
Preudenberg-NOKSeallng
Technologles............44,50
Prost&Sulllvan ................ 42
PutureStrategles|nc........... 42
GatesCorp. ......................6
GermanlscherLloyd........... 44
HoneywellSenslngandControl 90
|ngersollRand................. l6
|nternatlonalHarvester........ 40
1oyGlobal ..................... 48
KralburgTPLCorp. ............. 97
LuxologyLLC.................. 94
MSCNastran.................. 48
Mahle|nc. ..................... 40
RS#2l5
1UNLl4,20l2 MACH|NLDESIGN.com 125
BUSINESS STAFF
l300L.9thSt.,Cleveland,OH44ll4-l503,
Ph:2l6-696-7000Pax:2l6-696-0l77
Mike Hancock
|nternatlonalSalesDlrector,
mlke.hancock@penton.com
Ph:0ll-44-l372-824284,
Pax:0ll-44-l372-824322
United Kingdom, Scandinavia,
France, Spain, Portugal :
Stuart Payne,
stuart.payne@husonmedla.com
Ph:+44(0)l932564999
Pax:+44(0)l932564998
Belgium, Netherlands, Luxemburg:
Rodric Leerling,rodrlc.leerllng@
husonmedla.com,Ph:0ll-3l-229-84l882,
Moblle3l-683-232625,
Germany, Austria, and Switzerland:
Christian Hoelscher,
chrlstlan.hoelscher@husonmedla.com
Ph:0ll-49-89-95002778,
Pax:0ll-49-89-95002779
Italy: Cesare Casiraghi,
CaslraghlPubbllcltaLstera,
Ph:0ll-390-3l-26l407,
Pax:0ll-390-3l-26l380
Tokyo, Japan:
Yoshinori Ikeda,
Paclflc8uslness,|nc.,
Ph:0ll-8l-03-366l-6l38,
Pax:0ll-8l-03-366l-6l39
Advertising Sales
AZ, CA, ID, OR, NV, UT, WA, British
Columbia: Jim Theriault,
jlm.therlault@penton.com,
Ph:408-857-0322,Pax:925-736-8705
AL, AR, FL, GA, KS, LA, NM, MS, MO, OK,
TX: Franny Singleton,
franny.slngleton@penton.com,
Ph:678-947-8563,Pax:9l3-5l4-6884
CO, IA, S. IN, KY, MN, MT, NE, ND,
S. OH, SD, TN, WI, WV, WY:
Dennis Jensen,
dennls.jensen@penton.com,
Ph:952-368-00l8,Pax:9l3-5l4-6627
IL: Melinda Hurley,
mellnda.hurley@penton.com,
Ph:847-784-9825,Pax:847-784-9826
N. IN, N. OH, MI, NY, PA, Ontario:
Bill Rodman,
blll.rodman@penton.com,
Ph:2l6-93l-9636,Pax:2l6-62l-8469
DE, DC, MD, NJ, NC, SC, VA:
Brandy Bissell,
brandy.blssell@penton.com,
Ph:9l9-773-l875,Pax:9l3-5l4-6357
CT, ME, NH, MA, RI, VT, Quebec:
Liz Stott, llz.stott@penton.com,
Ph:857-636-9737,Pax:9l3-5l4-69l4
Bill Baumann,
vlcePresldent/MarketLeader
Dennis Jensen,
AssoclatePubllsher
Larry Berardinis,
8uslnessDevelopmentDlrector
Virginia Goulding,
OnllneSales&MarketlngManager
Julie Ritchie,
ResearchManager
Jane Maloney Cooper,
MarketlngManager
Debbie Brady, Audlence
Development Manager
Carey Sweeten,
GroupProductlonManager,
9l3-967-l823
Courtney Denison,
ProductlonCoordlnator,9l3-967-l738
Denise Donaldson,
AdmlnlstratlveManager/SalesSupport
2l6-93l-9403
Corporate Officers
Bob MacArthur,SenlorvlcePresldent
Nicola Allais,CPO
1UNLl4,20l2 MACH|NLDESIGN.com 126
CLASSIFIEDS
<W)L^MZ\Q[MQV
5)+016-,-;1/6;
ClnssiBods Soction,
contnct Lnrry Bornrdinis nt
(216) 931-9393,
lnrry.bornrdinisponton.con
PRODUCTS/SERVICES
THUMBSCREW
THE ORIGINAL
INSTANT
In most cases, advertisements contained
in Machine Design employment section
indicate that the companies are equal
opportunity employers. The Federal Civil
Rights Act of 1964, and other laws, prohibit
discrimination in employment based on
race, color, religion, national origin, sex, or
for any reason other than lack of professional
qualification for the position being offered.
It should be noted that employment
advertisements in Machine Design are
published for the readers convenience and, in
no way, to the best of our knowledge, promote
unlawful discrimination.
375 METRIC HANDLES
for a c|eaner env|ronment
All Metric Small Parts
T. 516.302.0152 F. 516.302.0153
www.amsp.biz
RoHS
COMPLIANT
Request
your free
catalog
BACKTALK
Live like the
Flintstones
PredPllntstoneneverhadltthlsgood.
whoknewthatDlckClarkllvedlnahouse
remlnlscentofthecavemaneraITheMal-
lbuhomerecentlyhltthemarket,andlf
youeverwlshedtollvellkePred,heres
yourchance.1ustdlgout$3,500,000and
thebeautlfulhomelsallyours.
The Pllntstone-lnsplred home slts
atoparemotebluffof22.89acreswltha
360vlewofthePaclflcOcean,Channel
|slands,8oneyMountalns,Serranovalley,
andLosAngeles.
Archltecturallyspeaklng,ltlsawork
ofartwlthmasslveamountsofglassto
bestshowcasethelmpresslvevlewsseen
fromeveryroom.vaultedcelllngslnthe
llvlngroomanddlnlngroomopenup
thespace.Surprlslngly,therelsonlyone
bedroomwlthaflreplaceandtwo
bathrooms
AllthatsmlsslnglsDlnoyabba-
dabba-do.MD
RS#2l7 RS#2l6
1UNLl4,20l2 MACH|NLDESIGN.com 127
BACKTALK
READER SERVICES
Letters to the editor: Please
lncludeyourname,address,
anddaytlmephonenumber.
Lettersmaybeedltedforbrevlty
andtofocusonessentlalpolnts.
Mail: Letters,MACHINEDESIGN,
l300L.9thSt.,Cleveland,OH
44ll4-l503,Pax:2l6-62l-8469
E-mail, Editorial:
mdedltor@penton.com
Online forums: Tocomment
onartlcles,edltorlals,andother
englneerlngtoplcs,gotohttp://
community.machinedesign.com/
forums/157/ShowForum.aspx and
logln.
Questions about articles:
DenlseGreco,2l6-93l-9402,
denlse.greco@penton.com,
Paxquestlonsaboutreleases
&llteratureto9l3-5l4-6694
Subscriptions: Porasubscrlptlon
quallflcatlonform,seeourweb
pageatsubmag.com/sub/mn.
Subscription problems or
questions: Contactacustomer
servlcerepresentatlveat
866-505-7l73ore-mall:
machlnedeslgn@halldata.com.
Order a paid subscription:
847-763-9670
Circulation:
machlnedeslgn@halldata.com.
Editorial reprints: Contact
PentonReprlnts,l-888-858-885l,
e-mallatreprlnts@pentonreprlnts.
comorvlsltpentonreprlnts.com.
List rentals: Marle8rlgantl,
877-796-6947,
mbrlgantl@merltdlrect.com
SIGN IN TO PLAY THE
2012 WORLDS SMARTEST DESIGN ENGINEER CONTEST AT:
WWW.SMARTESTDESIGNENGINEER.COM
RS#2l8
Real parts. Really fast.
Receive
FirstQuote
interactive
quote.
Part ready
for shipping.
Parts ready
for shipping.
Machining begins.
Finalize options, order
with credit card or P.O.
Computerized automated
toolpaths sent to CNC Machine.
Upload
3D CAD le.
115 Days
13 Days
A product development team needs parts
to meet its rapidly approaching deadline.
Receive a
ProtoQuote
interactive
quote.
Finalize
quote and
submit P.O.
Mold design
and milling.
Receive order
conrmation with
gate and ejector
layout. Approve.
Part
production.
110 parts
1010,000+
parts
How Many
Parts?
Check out
our demo quote!
Visit www.protolabs.com/parts today
and request your FREE book. Enter code MA12C.
Proto Labs 2012 ISO 9001:2008 Certied ITAR Registered
Its easy to work with Proto Labs. Just upload your
3D CAD model and choose the best process for your project: CNC
machining in 13 days or injection molding in 115 days. Real parts
in real materials, in daysnot weeks. And thats the real story.
Call 877.479.3680 or visit www.protolabs.com
RS# 219
When I need something fast, I go to With tools like a 3D CAD Congurator
and an Advanced Search Engine, nding the right solution is more efcient than ever.
And, with access to experts through Live Chat, I get all my questions answered ASAP.
For an online experience that keeps my projects moving forwardit better be Bimba.
I AM ACTUATION
PNEUMATIC t HYDRAULIC t ELECTRIC t WWW.BIMBA.COM
RS# 220