Professional Documents
Culture Documents
Microhydraulics.
Macro capabilities.
So much reliability and performance, in so little space.
Creating high-performance ow control on a micro scale has been
The Lee Companys exclusive focus for more than 50 years. And
its been a successful mission, as evidenced by thousands of applied
Lee Microhydraulics designs ranging from less than 0.10 in. to 1.00 in.
in diameter, and 0.1 to 68 grams, for operating pressures to 8,000 psi.
But small size and light weight are just the beginning.Theres
also absolute reliability built into every Lee component through
100 % testing and inspection. Zero defects. Its a production benchmark
that has enabled Lee to meet demanding application needs in all
sorts of industries. Aerospace, medical instrumentation, automotive,
machine tools and oil drilling, to name a few.
The innovative problem solvers.
We dont just satisfy requirements. We also solve problems
whether by simple modication, or ground-zero design engineering.
The Lee Company is the worlds most capable and proven source
for hydraulic-component innovation. And weve documented this
claim in extensive detail with the Lee Technical Hydraulic Handbook.
An invaluable reference, the Lee handbook contains essential data
on the entire Microhydraulics product line, which includes:
Lee Shuttle Valves. Detented, spring-biased, inverse,
loose ball and zero leak shuttle valves from 50-700 Lohms.
Lee Shuttle
Valve. Shown
actual size.
Designed to
isolate the
normal from
the emergency
hydraulic system. So small,
it ts right
into the head
of an actuator.
Lee Plugs. The best way to seal drilled holes to 32,000 psi.
No O-rings, threads or sealants required.
Innovation in miniature.
Essential reading
for designers of
hydraulic systems.
Send for your
free copy.
Westbrook
Gerrards
Cross
RS# 101
Paris
Frankfurt
Milan
HHP240
Series
Starts at
$408
DPG409
Series
Starts at
$695
Visit
omega.com/hhp240
omega.com
RS# 102
VOLUME 84
ISSUE 17
NOVEMBER 8, 2012
MOTION CONTROL
Rollers with polymer
bearing surfaces work
with aluminum rails, which
cost far less than groundhardened-steel versions.
How to
GET BETTER
MOTION with
plastic parts
Polymer bearing
surfaces resist
wear, dont need
maintenance,
and can run
surprisingly fast.
FEATURES
to get better motion
38 How
with plastic parts
Rollers, cam followers, and other
components used for moving parts can make
good use of polymers to increase speeds,
reduce wear, and resist chemicals and harsh
environments. Theyre also quieter than
metal components.
NOVEMBER 8, 2012
ACHINE
How to
AVOID
ELECTRICAL
HAZARDS with
air logic
Authored by:
Kenneth J. Korane
Managing Editor
Key points:
Air logic functions like relays, switches, and
counters, but uses compressed air instead of
electricity.
Air-logic controls are preferred in wet or dusty
conditions because they pose little danger of
electrical explosion or shock.
Resources:
AOP Technologies, www.aoptec.com
Clippard Instrument Laboratory,
www.clippard.com
D
s
49 MLiterature
Express
NOVEMBER 8, 2012
MACHINE DESIGN.com
38
to design suppression
42 How
circuits for electric
Back-EMF in clutches and brakes may lead to
erratic operation and a shortened life.
38
RS# 621
ESIGN
to avoid electrical
60 How
hazards with air logic
Pneumatic controls are a viable option when
electrical hazards cant be tolerated.
60
MACHINE DESIGN.com
logic can also be used on machines with fluid-power components but no electrical supply.
Air logic does have disadvantages. Most common is
a lack of understanding among maintenance personnel
on how to read schematics and troubleshoot problems.
Also, air logic with long control lines responds noticeably slower than electronics. Thats because control lines
longer than 10 to 15 ft fill and exhaust slowly compared to
near-instantaneous electrical signals. In addition, it takes
NOVEMBER 8, 2012
60
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
MACHINE DESIGN.com
NOVEMBER 8, 2012
%!#%##"%!"%
% %!%!#%##"%
""%$$$
Built-in simulator
software!
H2-DM1
$299
H2-DM1E
Starter Kit
H2-DM1E-START $626
H2-DM1-START $536
www.automationdirect.com
Go online or call to get complete information,
request your free catalog, or place an order.
1-800-633-0405
RS# 103
DEPARTMENTS
ON THE COVER
Photo by R.L.Rubenking
8 EDITORIAL
More green cards, more H-1B visas
10 EDITORIAL STAFF
12 LETTERS
16 SCANNING FOR IDEAS
Liquid cooling for servers also supplies hot water
Gimbal mount expands drones view
20 REPORTERS NOTEBOOK
26 LOOKING BACK
33 SENSOR SENSE
Metal-faced inductive sensors for durability
35 COMMENTARY
Googles got nothing on Cat
36 INVENTORS CORNER
Compact engine packs a powerful punch
68 PRODUCT SPOTLIGHT
Linear actuators
72 PRODUCTS
74 BUSINESS INDEX
76 STATEMENT OF OWNERSHIP
77 AD INDEX
78 CLASSIFIEDS
78 BUSINESS STAFF
79 BACKTALK
MACHINE DESIGN.com
NOVEMBER 8, 2012
S e Over
Save
Ov r $1,200
P r Year
Y r
200 Per
R p i g One
O Outdated
O d d Air Nozzle!
By Replacing
Weve all seen at air nozzles. Some are yellow. Others are orange. The oldest
ones are blue or metal. Those other manufacturers want you to believe youll
save money by conserving compressed air while protecting your workers from
harmful noise levels. In reality, those colorful air nozzles that blow the air out
of holes consume enormous amounts of air. The plastic ones often break o.
Some might even get you an OSHA ne due to the dangerous dead ended
pressures that exist if someone blocks the air exhaust.
EXAIRs award winning 2" Super Air Nozzle has been engineered to replace
those outdated at nozzles. There are no dangerous holes. EXAIRs patented,
award winning design is ecient, maintaining a precise amount of airow
through a thin slot. The result is a forceful stream of high velocity, laminar
airow with minimal air consumption and noise. You can increase or decrease
the force of each at air nozzle using shims to tune it to the application so
youll never waste compressed air.
Flat nozzles from other manufacturers can consume over 30 SCFM
(a refrigerator sized compressor) and arent adjustable. Some manufacturers
oer dierent ow rates but you need to guess at which one will do the job since
you cant adjust them once youve made the purchase. By default, most users feel
bigger is better and go with the highest ow rate, wasting compressed air.
COMPARE
Heres how:
One popular flat nozzle consumes
31 SCFM @ 80 PSIG.
EXAIRs 2" Super Air Nozzle with .015" shim
consumes 21.8 SCFM @ 80 PSIG.
31 SCFM (theirs) 21.8 SCFM (EXAIRs) =
9.2 SCFM compressed air saved/min.
Most large plants know their cost per 1,000
standard cubic feet of compressed air. If
you dont know your actual cost per 1,000
SCF, 25 is a reasonable average to use.
SCFM saved x 60 minutes x cost/1,000 SCF =
dollars saved per hour.
In this case, 9.2 SCFM x 60 x .25/1,000 SCF=
13.8 cents saved per hour.
13.8 cents per hour x 24 hours =
$3.31 saved per day.
$3.31 per day x 365 days =
$1,208.88 saved in one year
(in this 24/7 operation).
83
1.7
Orange
28 SCFM
82
1.7
Blue
26 SCFM
78
1.5
Metal (machined)
29 SCFM
82
1.7
Metal (cast)
31 SCFM
80
1.9
62-81
0.5 1.9
www.exair.com/45/42san.htm
@EXAIR
The
Guarantee
Roller and
conveyor chains
Power-supply site
Mouser Electronics has launched
a new Power Supply site. It contains
technical and design information,
including the benefits of switchedmode power supplies such as high
efficiency, small size, and light
weight. It also provides details on
UPS and ac/dc applications. Content
includes product data, white papers,
a library of technical resources,
and info on products from major
manufacturers. Visit www.mouser.
com/power-supply-technology.
MACHINE DESIGN.com
Bearings info
Kilian Manufacturing, an Altra
Industrial Motion company,
has a new Web site on bearings
and assemblies for demanding
automotive and industrial
applications. It covers products
such as ball, needle, roller, and
thrust bearings, as well as customengineered specialty bearings
and polymer assemblies. Content
included downloadable brochures,
catalogs, industry specific
application profiles, service manuals,
and articles. Visit www.KilianBearings.
com.
NOVEMBER 8, 2012
UPCOMING WEB
EVENTS
BASICS OF MOTION
CONTROL WITH PLCs
AND STEPPERS
Online tutorial videos detail
motion-control theory and
application using PLCs as the
supervisory controller.
A new 11-part Motion Control
video series features the
DirectLogic 05 PLC, SureStep
stepping system components,
and C-more micro HMI. It starts
with the basics of the hardware,
describes typical motion
applications, then moves through
demonstrations using equipment
such as a linear slide.
To view individual segments
of this series, visit http://learn.
automationdirect.com and look
under the Drives/Motors tab.
Four new Do-more PLC videos
focus on using the new CPU with
the latest high-speed counter
module to perform motion
applications using switches or
encoders, as well as details on
hardware setup and software
functions such as trapezoidal
moves.
To view this series, visit http://
learn.automationdirect.com and
look under the PLCs tab for Domore PLC-Live demos.
Or find them all at: www.youtube.
com/automationdirect. Become
a subscriber and get alerts when
new videos are uploaded.
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RS# 106
EDITORIAL
More green cards,
more H-1B visas
Microsoft was recently in the news because it came up with a new scheme
for more H-1B visas. H-1B, of course, lets U.S. companies employ foreign
workers in such highly specialized occupations as science, technology, engineering, and mathematics (STEM). Microsoft not only wants Congress to
permit more H-1B visas but also to reallocate 20,000 green cards for workers
with such technical skills.
In return for boosting H-1B quotas, Microsoft would have Uncle Sam
charge companies $10,000 per additional H-1B worker. It also suggests charging employers $15,000 per STEM green card over the current quota. So far, so
good. Employers should be willing to pay a stiff fee if they feel their needs are
urgent enough to hire outside the U.S. Id even suggest setting the fee at levels
far higher than what Microsoft has in mind as a way of making employers
show they are serious.
But interestingly enough, Microsoft also wants fees collected from greencard permits to be invested in STEM education. Microsoft claims such measures are necessary because it has 3,400 open jobs for scientists and engineers
while the U.S. last year minted only 1,603 new computer science Ph.Ds.
Of course, industry has for decades leveled allegations of shortages as a rationale for letting more foreign skilled workers enter the U.S. But researchers
at the Bureau of Labor Statistics have studied the impact of letting in foreign
Ph.Ds. and concluded that the result is a downward pressure on Ph.D. salaries.
This downward pressure tends to discourage aspiring scientists from pursuing
higher degrees. The result: The smartest of them go where the money is, which,
today, is still in finance. There, new financial engineers can still earn six-figure
bonuses in the first year on the job.
Thus, Microsofts idea for new H-1B fees seems self-defeating. The education it funds would create more workers in areas now being filled by foreigners.
But filling jobs with foreign workers reduces pay scales and makes jobs in that
area less attractive. One might be excused for seeing this whole process as a
negative feedback loop for the process of minting STEM Ph.Ds. in the U.S.
So here is an off-the-wall idea for what to do with U.S. STEM graduates
in an era when STEM jobs get filled by foreign workers: make it easy for U.S.
technical personnel to become Canadians.
Workers with easy access to our Northern neighbor would have more options if salary levels take a hit from an influx of foreign workers. And indications are that Canada might be open to this idea. The Government of Canada
is committed to building an immigration system that actively recruits talent,
said a Canadian minister recently. This is the next frontier in Canadian immigration: looking at opportunities to attract the best talent and going out there
and getting it, he continued.
A representative of the Canadian government even went to Ireland a few
months ago to beg STEM graduates there to try living in Canada. The labor
situation for STEM workers in Canada is so tight that its government officials
are entertaining the idea of instituting special benefits for Canadian STEM
personnel willing to work past the age of 65 not because they lack the money
to retire, but because they are so difficult to replace.
One other point in Canadas favor: Theres no out-of-control financial sector in that country run by individuals making obscene salaries.
Leland Teschler, Editor
RS# 107
NOVEMBER 8, 2012
Our fans for cooling and refrigeration technology are already among the quietest and most efcient in the world.
How can we top that? Easily: with the new AxiTop diffuser. It optimizes air ow at the impeller exhaust, signicantly
increasing efciency. This means up to 7.2 dB(A) of noise reduction and up to 27% lower energy consumption at
the same ow rate for your refrigeration application. Or up to 9 % more air performance with comparable energy
consumption!
If this sounds like music to your ears, visit info.ebmpapst.us/AxiTop for more information.
EDITORIAL STAFF
MANAGING EDITOR
Kenneth J. Korane
ken.korane@penton.com
SENIOR EDITORS
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RS# 109
Leslie Gordon
leslie.gordon@penton.com
Stephen J. Mraz
stephen.mraz@penton.com
ASSOCIATE EDITORS
Lindsey Frick
lindsey.frick@penton.com
Robert J. Repas, Jr.
robert.repas@penton.com
INDUSTRY COVERAGE:
AUTOMOTIVE, PACKAGING,
MEDICAL
Stephen J. Mraz
CAD/CAM, MANUFACTURING
Leslie Gordon
ELECTRICAL, ELECTRONICS
Robert J. Repas, Jr.
FLUID POWER
Kenneth J. Korane
MECHANICAL
Lindsey Frick
Kenneth J. Korane
EDITORIAL PRODUCTION
Denise Greco
Editorial Production Manager
Randall L. Rubenking
Art Director
MACHINE DESIGN.com
RS# 110
NOVEMBER 8, 2012
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LETTERS
MACHINE DESIGN.com
NOVEMBER 8, 2012
RS# 112
LETTERS
keep fixing old equipment when it
clearly is no longer fixable.
It seems theres always that one
guy in the big corner office that
doesnt want to evolve and is just
waiting it out until retirement.
But that same guy will hound every employee for better production rates, less maintenance issues,
and so on. The last thing he wants
is to invest in new equipment to
run leaner and smarter production through modern engineering
ideas and technology. After all, he
might make a mistake.
Paul Pfundtner
Corrections:
Acquisitions The Lord
Corp., Cary, N.C., is purchasing
MicroStrain Inc., Williston, Vt.
(Company News, Oct. 4).
B-2 Bomber The fine news
item on UAVs (More competition for carrier-based UAVs, Sept.
20) has a small but notable error.
Northrop Grumman is the designer and developer of the B-2
Spirit, not Boeing.
Jack Fagan
.com
NOVEMBER 8, 2012
http://nasonptc.com/ttswitch
RS# 113
MACHINE DESIGN.com
800.229.4955 www.nasonptc.com
14
www.schaeffler.us
2012
RS# 114
MACHINE DESIGN.com
NOVEMBER 8, 2012
Servers
vertically
installed in
coolant bath
Evaporative
cooling tower
releases
heat to the
atmosphere
r
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Request free in Web site at
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design.com/rs
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RS# 115
Ball-andsocket
joints
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Harmonic-drive
actuator
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tapered-roller
bearings
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MACHINE DESIGN.com
NOVEMBER 8, 2012
RS# 116
RS# 117
REPORTERS NOTEBOOK
How to
HOT ROD
an
electric motor
Dennis Berubes
Current Eliminator V
electric dragster.
Berube doesnt discuss
construction details of
this, his latest race car,
but an earlier version
hit about 160 mph in
a quarter-mile run of
under 8 sec.
MACHINE DESIGN.com
also claims to be the fastest electric drag racer on four wheels, having piloted an electric dragster he
built to 159.85 mph in a 7.956-sec
run down the quarter mile.
Berube had his first inklings
of how electric motors could be
modified two decades ago when
he got a job repairing and rewinding armatures. While learning his
craft, he worked with a German
engineer who gave me a lot of
good tips about dc motors, he
says. But most of his knowledge
comes from 23 years of experimenting with his own race cars. In
evaluating an idea, you have to be
diligent about documenting your
setups. And you have to try the
idea for one or two months, not
change something after every run,
he says.Thats why I have over
4,000 time slips from quarter-mile
runs with my electric dragsters.
NOVEMBER 8, 2012
Resources:
Brushes
Armature
Armature
windings
Case
Leads
MACHINE DESIGN.com
21
REPORTERS NOTEBOOK
How to convert
technical manuals
Authored by:
James I. Finkel
Engineering Manager
How to build
an airplane at
home
An artists rendering shows
In a trend called personal manufacturing, local
what the MakerPlane
shop facilities like The TechShop have given ev- aircraft will look like.
eryday people access to tools typically available
only to industry. The shops let individuals more easily make everything from
furniture to cargo bikes. Well, hold on to your hats. MakerPlane.org wants
to help DIYers build airplanes at its facilities, dubbed makerspaces, or even
at home. The Web site invites educated visitors to submit improvements to
the basic Light Sport Aircraft open-source design, MakerPlane Version 1.0,
introduced last year. When the final design is complete, MakerPlane engineers will build the craft and the site will let users download plans and 3D
animated instructions for free.
Until now, a big problem has been that nearly three out of four aircraft
projects started by home builders either from kits or from parts are
abandoned before they ever fly, says MakerPlane founder John Nicol. Reasons include poor instructions and complicated assembly, plus it takes more
tools and skills than many people realize. So we decided to use collaborators
from around the world to develop a design that would let home builders
take advantage of modern personal-manufacturing equipment such as CNC
machines and 3D printers. This makes sense because makerspaces are cropping up almost everywhere.
Nicol points out that MakerPlane does not intend that people build structural components using 3D printers, just items like door handles and knobs.
And in terms of safety, We are not letting just anyone make design changes
to the aircraft, he says. Our aeronautical engineer, JefResources:
frey Meyer, acts as a gatekeeper for all design activities
MakerPlane,
and, as such, must approve changes.
makerplane.org
In addition, every experimental aircraft must be approved and inspected before it flies. In the U.S., the FAA
Submit your ideas for
handles this. It sends an FAA staffer to your house and
the plane design or
instruments through
they check your aircraft for compliance. It is up to you as
the online forum or
the pilot and builder to be safe, says Nicol. But there are
at IdeaForge (under
all sorts of regulatory hurdles to overcome before you
Tools) on the Web site.
can fly. You must even have a pilot license.
To sustain itself and maybe
Authored by:
make a profit, MakerPlane
What you get in
will sell kit sets, avionics, and
James I. Finkel
return is a CAD file
other parts. Users can also
Engineering Manager
Wallace Cranes
in the new native
source parts from anywhere.
format. And this file Malvern, Pa.
There will always be people
can be edited. To be
who will build the aircraft
sure the file is absolutely free of any extrafrom scratch and who have all
neous data, you can select the new CAD
the resources they need, says
geometry and place this in an empty file.
Nicol. But there will be others
While you want the geometric fidelity, the
who want to shorten the time
last thing you want to import in a live file
it takes to build a craft by usis extraneous data, or in the case of a docuing a kit or parts.
ment file, extraneous formatting.
MakerPlane intends to
The hazard of this whole process is that
have a nonflying prototype
when you re-create the assembly, you will
at the AirVenture air show in
likely see errors as the parts might not
Oshkosh, Wis., July through
quite match. Finding and fixing these error
August 2013. It hopes to have
is an entirely different problem. MD
an aircraft flying at the 2014
show. MD
RS# 119
NOVEMBER 8, 2012
REPORTERS NOTEBOOK
Resources
U. S. Navy Research
Lab, www.nrl.navy.mil
RFID vs.
Barcode:
Which track and
trace technology is
askTURCK.com
RS# 120
We Mold Ideas
Into Reality.
www.mnrubber.com
RS# 121
REPORTERS NOTEBOOK
LOOKING BACK
10 YEARS AGO 2002
Practicing to the extreme: If
you ever wanted to learn extreme
sports such as skateboarding,
snowboarding, or surfing, nows
your chance. Pivit LLC, Franklin
Lakes, N.J., has designed a durable
fiberglass balance board called Pivit
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Made in USA
A
Misalignment
7 angular .025 radial .050 axial
Phone 1-888-260-7466
Fax 516-771-6444
sales@ondrivesUS.com
www.ondrivesUS.com/ServoBeam
26
MACHINE DESIGN.com
NOVEMBER 8, 2012
polymer ex member
.US Corp.
ersion
hort v
s
10,000 RPM
300 in-lb torque
High torsional stiness
Low weight to size ratio
Short and long versions
Flex member available in
420SS or Engineered Polymer
tick tock
Power. Precision.
Performance.
PUMPS
VALVES
POWER UNITS
RS# 122
REPORTERS NOTEBOOK
COMPANY NEWS
ACQUISITION
Lord Corp., Cary, N.C., has purchased MicroStrain Inc., Williston, Vt. MicroStrain will continue
to operate at that location as
MicroStrain, a Lord Co.
Lord specializes in adhesive,
coating, and motion-manage-
INNOVATION
MAKES
GGB THE
PRODUCT
LEADER
PROGRAMMING PLCs
Omron Automation and Safety
is offering PLC
programming
training courses
that let attendees complete
basic and intermediate levels
in one week. The
training will be
at Omrons headquarters in Schaumburg, Ill.
Dates for the
Fall schedule
are: Nov. 29-30 Advanced PLC
Programming (Course #IA-TRNOES118); Dec. 35 Basic PLC
Programming (Course #IA-TRNOES110); Dec. 67 Intermediate
PLC Programming (Course #IATRN-OES112)
Go to http://www.omron247.
com/Industrial-Automation/Store/
OmronTrngOmronUniversityView_1_10051_10051?location=US for
registration information.
EXPANSION
The Global Leader in High
Performance Bearing Solutions
GGB listens to our customers.
The result is superior bearings
that eliminate problems.
To learn more, visit
ggbearings.com or scan
the QR code below.
NEW SERVICE
28
MACHINE DESIGN.com
RS# 123
NOVEMBER 8, 2012
RS# 124
REPORTERS NOTEBOOK
COMPANY NEWS
SOLUTION FACTORY OPENS
SKF USA Inc., Lansdale, Pa., has
opened its SKF Solution Factory
in Highland Heights, Ohio. It is the
second to open in the U. S., joining
17 others worldwide. Services the
facility offers includes bearing
application support, customized
AWARD
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PERSONNEL
New England Wire Technologies,
Lisbon, N.H., has appointed
Kelly MacKay as Sales Director,
and Nick DAgostino as Business
Development Manager. New
England Wire Technologies
develops, designs, and
manufactures technologically
advanced wire and cable products.
SOFTWARE INTEGRATION
SpaceClaim, Concord, Mass., and
First Trace, Phoenix, Ariz., have
integrated SpaceClaim Engineer and
Kinnosa. SpaceClaim is a provider 3D
software for engineering design and
manufacturing, and First Trace offers
Kinnosa, an Engineering Document
Management (EDM) system for
managing complex CAD documents,
Office files, and business processes.
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30
MACHINE DESIGN.com
RS# 125
NOVEMBER 8, 2012
AS9100 REV C
CERTIFICATION
BEI Sensors, Goleta, Calif., has
been awarded the AS9100 Rev C
quality standard for aerospace.
The company met the nearly 100
additional rigorous criteria required
to meet the stringent, complex,
and unique demands of aerospace
manufacturing, from commercial
to defense aviation. BEI Sensors
provides speed and position
sensors. MD
TOGGLE CLAMPS
EXCLUSIVELY MADE IN THE USA
You can count on Carr Lane to provide you with top quality,
American made toggle clamps in a variety of types, sizes and styles.
Free 3D solid CAD drawings
New, optional safety locks
on some styles
Fast shipping
RS# 126
Pepperl+Fuchs Inc.
Twinsburg, Ohio
330.486.0001
www.pepperl-fuchs.com
RS# 127
5)&"#*-*5:508*5)45"/%
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SENSOR SENSE
Metal-faced
inductive sensors for durability
In quick review, an inductive sensor generates an electromagnetic wave at
a specific tuned frequency. The tuned circuit inside the sensor has a high
impedance at that frequency, creating a high ringing voltage. When any
metal is brought near the output coil of the sensor, the coil becomes detuned. This shifts the oscillator frequency and, more importantly, reduces
the ringing voltage in the sensors tuned oscillator circuit. The lower voltage triggers the output that indicates the presence of the metal target.
Most metal-detecting inductive sensors use plastic sensing faces. Plastic facings are inexpensive and do not interfere with the metal-sensing
ability of the sensor. These
products are an option when a
sensing area is relatively benign.
But plastics lack of durability
may create problems in some
situations.
Inductive sensors feature
comparatively short sensing
ranges, often under a half-inch.
Such close proximity to the target means even slight variations
in target clearances or vibration
may subject the sensor to damaging physical abuse. The life
span of a plastic-faced sensor
After a 20-hr abrasion test by a wire brush on
is greatly reduced under these
plastic and metal-faced sensors, the metalcircumstances.
face sensor on the left shows wear but still
If an inductive sensor is to be
works while the plastic-face sensor on the
used in abusive environments
right is totally destroyed.
where impact and abrasion are
commonplace, its now more common for the inductive sensor to have a
metallic face specifically, stainless steel.
The question arises, How does the sensor detect the metal in the target, yet ignore the metal at the tip of its own housing? To understand
how requires a quick look into electrical physics. The trick hinges on the
oscillator frequency and the wavelength of the signal it produces.
Metals such as copper, aluminum, and stainless steel tend to block or
shield electromagnetic waves. The waves travel along and around the
surface of the metal by a process known as skin effect. By reducing the
frequency, the electromagnetic field no longer stops at the sensors metal
surface, but extends beyond the surface into the surrounding space. Sensors with a stainless-steel face use such low-frequency alternating fields
that their detection area extends well through the metal face of the sensor
to detect metallic objects on the other side.
Laboratory tests compared the survivability of plastic and metal-face
products to metal-brush abrasion and hammer impacts. The tests showed
stainless versions withstood exposure levels more than 20 beyond their
plastic-face counterparts. Considering stainless models cost only 25 to
30% more than plastic, they can be an economical replacement over an
extended time with no trade-off in durability versus sensing distance. MD
Pepperl+Fuchs (www.pepperl-fuchs.us) supplied information for this column.
Edited by Robert Repas
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RS# 128
NOVEMBER 8, 2012
gd-thomas.com/md11.
RS# 129
COMMENTARY
Googles got
nothing on Cat
Kenneth J.
Korane
Much has been made of Googles self-driving cars. Fitted Managing Editor
with AI software and an array of sensors, the computercontrolled fleet recently surpassed 300,000 road miles
without an accident. The company says robot drivers
react faster than humans and dont get sleepy, distracted,
or intoxicated, and would boost road capacity by letting cars drive more
safely and be spaced closer together. But right now, the experimental vehicles
require a human in the drivers seat. Most experts say practical autonomous
cars are years away from affordability and mass production.
With less fanfare, several mining operations have been running autonomous haul trucks with considerable success. Caterpillar is operating a few
small fleets in the U.S. and abroad, and will soon have 45 unmanned haulers at an iron-ore mine in Australia. Komatsu has likewise deployed such
vehicles in Chile and Australia. It expects to have 150 driverless trucks at a
Rio Tinto mine in Western Australia within the next four years, run from an
operations center in Perth, nearly 1,000 miles away.
These ultraclass dump trucks the size of a small house and carrying
payloads up to 400 tons rely on sophisticated controllers, GPS, obstacledetection systems, and a wireless-communications network. Software algorithms tell the machines where to go and what to do, while seamlessly and
safely working with and around other equipment and personnel.
Its mining of the future, today. Driven by a booming demand for minerals, autonomy is seen as a way to get more ore out of the ground quickly and
efficiently. Trucks can be programmed to back under a shovel to within a few
inches of the same spot, all day long, to speed loading. Cycle times are always the same, with no time lost from operator fatigue, rest breaks, and shift
changes. And consistently operating trucks within design specs can maximize fuel economy, lessen mechanical breakdowns, and improve tire life.
While up-front costs are higher, these benefits offer potential savings in
the millions, say OEMs and mine operators alike. Autonomy also addresses
a growing shortage of skilled workers as mine sites move into more remote
areas. It may attract a new generation of employees who have grown up with
powerful computers, video games, and the Internet and would otherwise
never consider a career in mining.
Users are learning lessons as they gain experience. One is that humans
intuitively sense surroundings in ways that todays smart machines cannot.
For instance, a driver who hears an unusual noise or sees a broken component can stop the truck or call maintenance. Computers cant monitor in the
same way. Condition-monitoring systems help, but safety checks are needed
at regular intervals.
Another aspect is dealing with mine regulations that werent written with
unmanned vehicles in mind. For instance, MSHA codes say cab windows
must be kept clean, and mobile equipment cannot be left unattended unless
the brakes are set. Obviously, they make little sense with unmanned vehicles.
Cat has had to work with local agency officials to overcome these hurdles.
Granted, mining trucks arent dealing with the same level of complexity as
Googles cars, but theyre actually getting work done and growing ever-more
sophisticated. The ultimate goal: completely autonomous mines with not
only unmanned haulers, but drill rigs, shovels, and loaders, too. Some say
that could happen within the next 5 to 20 years. MD
NOVEMBER 8, 2012
An Illustration
in Innovation
The innovative 2450Z BLDC
pump is perfect for medical
and other applications
requiring a small lightweight
pump with a high performance
to weight ratio.
Efficient, variable speed brushless
DC motor conserves power by
matching output to requirement
Lightweight 6.8 lbs. vs. 9.5 lbs
with AC motor
Small footprint 8.32" x 6.75"
x 4.08"
Oil-less design
Maximum flow 3.3 CFM @
2200 RPM
Maximum pressure 35 PSIG
RS# 130
MACHINE DESIGN.com
35
INVENTORS CORNER
Edited by Leslie Gordon
Compact engine
packs a powerful punch
MACHINE DESIGN.com
Paul Karlan first thought up his Karlan Cam Engine for surface vehicles about
50years ago when he was trying to figure out a different way to change the reciprocating motion of pistons to rotary motion. Instead of using a crankshaft, his engine
uses two cams attached to the output shaft. The engine has four cylinders, two
banks of two cylinders each, parallel to the output shaft. Both the opposite cylinders
fire every 180 (both sides), for four cycles/rev, as opposed to a crankshaft engine,
which is two cycles/rev. A disc valve is keyed to the output shaft between the two
cylinder banks. The disc valve meters the four cycles in and out of the cylinders. The
pistons connect to the connecting plate which rides on the cams. The cam lobes are
tapered to provide true rolling motion between the cam followers and the cam. The
connecting plates on each side of the cylinder blocks reciprocate equal and opposite to each other, giving balanced motion.
According to Karlan, his barrel engine is the only one with two cams and four cylinders. The only other barrel engine he knows about the Hermann engine has
one cam that sits in the center of the output shaft, and two banks of six cylinders on
each side of the block. The Hermann engine design has disadvantages, says Karlan.
It uses poppet valves, which have intake/exhaust overlap. The Karlan engine has a
disc valve with little intake/exhaust overlap. The clearance between the disc valve
and the cylinder heads in the Karlan engine is just a couple of tenths. This minimal
clearance is maintained by floating seals i.e., the thin layer of air so there is
no friction and almost no compression leakage. This patented feature has been well
tested in the running prototypes.
Another advantage pertains to side pressure, says Karlan. Piston side pressure on
the side of the cylinder wall is what turns the output shaft on the power stroke. The
connecting plates on the Karlan engine reciprocate on bronze bushings with hardsurfaced, lubricated guide rods, which take all the side pressure, with little sliding
friction. And, there is no side pressure on the pistons. True, a significant weight goes
back and forth, but the momentum of the reciprocating plate goes into the flywheel,
says Karlan. The only energy lost is in the friction of the slides and there is little
friction. His special cam followers have high-speed, heavy-duty radial and thrust
bearings mounted in an aluminum housing (not needle bearing cam followers). His
engine output shaft, thus, provides low rpm with high torque.
In addition, the length of the connecting rod determines the compression ratio. Users can, thus, adjust the compression ratio. Karlan believes his
engine is more efficient than current designs because it entails almost no
intake/exhaust overlap and less internal sliding friction. Although the working prototype has not yet been tested for extended operation, Karlan says it
shows no inherent weak spots, and is a sturdy mechanism.
The Karlan Cam engine has a low and long configuration which could
apply to aircraft and more. Karlan feels his engine could be an alternate to
the polluting turbojet engine, which many scientists link to global warming.
Propulsion could be by ducted fan or gasoline electric.
The engine can have pistons with small or large diameters, up to 10 in. or
more. Karlans prototype engine, which is running on gasoline on a bench,
shown at http://tinyurl.com/9setjoa, has 2-in. bores. The Karlan Cam Engine Car,
shown at http://tinyurl.com/9gcbhnd, has 31/8-in. bores.
The Karlan engine has relatively few parts. It has no gears, no timing belts, no
springs, and no gaskets. The engine can be air or water cooled. The Karlan Car was
water cooled and had a pressurized lubrication system. Karlan plans on applying
several improvements, including a special supercharger. Karlan can be reached at
cam511boy@optonline.net. MD
NOVEMBER 8, 2012
RS# 131
MOTION CONTROL
How to
GET BETTER
MOTION with
plastic parts
Polymer bearing
surfaces resist
wear, dont need
maintenance,
and can run
surprisingly fast.
MACHINE DESIGN.com
NOVEMBER 8, 2012
Ultra-High-Performance Stages
Precisely
The Way
You Want
Them
Get Your
Free
Catalog
Steinmeyer-USA.com/stages
or call 781-273-6220
RS# 132
NOVEMBER 8, 2012
MOTION CONTROL
8IFO
JUNBUUFST
80
70
60
50
40
30
20
10
0
Nylon 6
Nylon 6.6
Nylon 11
0
Power-Core
4
6
8
10
Moisture content (%)
Power-Core nylon does not absorb much water and, as a
result, it is more dimensionally stable than other plastics.
2
80
70
60
50
Nylon 6.6
40 Power-Core
30
Nylon 6
20
10
0
0
1.5
3
6
9
Moisture content (%)
Power-Core components also maintain their
tensile strength by not absorbing water.
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RS# 133
&.*("4,&54"/%
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Plastic components
improve a rotary table
NOVEMBER 8, 2012
(03&8JSFBOE$BCMF
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RS# 134
8*3&"/%$"#-&
How to
DESIGN
SUPPRESSION
CIRCUITS for
electric clutches
and brakes
The past decade
has seen a
growing trend
toward powering
electromagnet ic clutches
and brakes with
programmablecontroller outputs.
Clutch and brake
manufacturers make
power supplies and controls for their products
that are designed to integrate
cleanly into many applications.
But some applications need only a
programmable controller to do the job almost
as well as the OEM hardware. It is the almost in that
statement that is the area of concern.
Before proceeding, let me provide a quick review
of electromagnetic clutch and brake operation. Electromagnetic clutches and brakes work on dc power.
Power supplies convert ac power to dc power through
a rectification circuit. Typically these supplies provide
an on-off function: either full power or no power.
42
MACHINE DESIGN.com
NOVEMBER 8, 2012
Authored by:
Greg Cober
Product Training Manager
Warner Electric LLC
South Beloit, Ill.
Edited by Robert Repas
robert.repas@penton.com
Key points:
Electric brakes and clutches operated directly
from PLCs frequently lack proper suppression
circuitry.
Without proper suppression, the operating
life of an electric brake or clutch may be
drastically reduced.
Suppression circuits can be made using offthe-shelf components.
Resources:
Heavy-duty clutch/brake, machinedesign.
com/article/heavy-duty-clutchbrake-warnerelectric-0527
Warner Electric LLC, www.warnerelectric.com
Controller
Linear or Rotary Actuator
Solutions Available
Amplifier
Motor
Actuator
MACHINE DESIGN.com
43
Switch
signal
Brake
coil
CIRCUIT A
+
24 V 1N5368
90 V 1N5378
Brake
coil
Model
1N4004
Switch
signal
ERS-26
ERS-42
ERS-49
ERS-57
ERS-68
CIRCUIT B
24 V
90 V
30
50
70
110
160
30
60
80
110
200
40
100
150
150
200
Brake-release
time (msec)
40
100
150
150
200
10
10
20
20
30
10
20
20
20
30
Airpel
The Anti-Stiction
RS# 136
44
MACHINE DESIGN.com
NOVEMBER 8, 2012
Air Cylinder
www.fabrico.com
RS# 137
NOVEMBER 8, 2012
MACHINE DESIGN.com
45
MATERIALS
How to
RIDof FOAM
petroleum
Mushroom-based foam is
the new polystyrene.
Authored by:
Lindsey Frick
Associate Editor
lindsey.frick@penton.com
Key points:
Mushroom roots digest
and bind agricultural waste
to form a cohesive material
that acts like polystyrene.
The method to grow and
form EcoCradle material
consumes less energy
than the process to make
expanded foams.
EcoCradle material can be
custom formulated to serve
a variety of applications
like protective packaging
and insulation.
Resources:
Center for Alaskan Coastal
Studies, akcoastalstudies.
org
MACHINE DESIGN.com
NOVEMBER 8, 2012
Eco Cable
Lighte
r
le
cy
Re
Toug
b
la
her
&20,1*)$//
Visit www.alphawire.com/
ecocable for free samples and more.
2012 AlphaWire
RS# 138
MATERIALS
Fungus in action
MACHINE DESIGN.com
NOVEMBER 8, 2012
NOVEMBER 2012
V
V
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[
(
H
U
X
W
D
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/LW
FLOYD BELL INC
51
53
51
53
ADVANCED ANTIVIBRATION
COMPONENTS
51
51
51
QUALITY TRANSMISSION
COMPONENTS
55
http://www.machinedesign.com
Going to Electronica?
The Design Engineering and Sourcing Group, featuring Electronic Design,
Microwaves and RF and Electronic Design Europe has some exciting things planned.
Make sure to come to Hall A5, Booth 279 at the show and
enter to win an ipad every hour.
Sponsored by
download on www.electronic
design.com
Smalleys new catalog combines existing Spirolox Retaining Ring and Smalley Wave
Spring selections with series recently released from Smalley. Now a single catalog
includes new: Hoopster Rings, Metric Wave
Springs, Constant Section Rings and more. Over
10,000 standard parts in carbon and stainless
steel; free samples available. Specials manufactured with No-Tooling-Costs from .200-120.
Tiny (approx.1x1) piezoelectric alarms provide LOUD output with a supersleek design. Available in variety of voltages and output up to 103dB! Rugged, tamper-proof, lo-profile panel mount
design is IP68 and NEMA 4X. Optional
manual volume control offers increased attenuation. ISO 9001:2000 registered company all products made in the USA.
(614) 294-4000
Fax: (614) 291-0823
Email: sales@oydbell.com
Web: www.oydbell.com
(847) 719-5900
Email: info@smalley.com
Web: www.smalley.com/getcatalog
(614) 294-4000
Fax: (614) 291-0823
Email: sales@oydbell.com
Web: www.oydbell.com
(614) 294-4000
Fax: (614) 291-0823
Email: sales@oydbell.com
Web: www.oydbell.com
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Email: shocks@acecontrols.com
Web: www.acecontrols.com
The industrys largest selection of piezoelectric whoops, warbles, sirens, beeps and more. Available in variety of voltages and output up to
103dB! Rugged panel mount products are
IP68 and NEMA 4X when used with optional gasket. ISO 9001:2000 registered
company all products made in the USA.
MACHINE Design.com
8
51
The NEW
Engineering Channels
Recent Videos
Only our patent pending iCamFollowers offer all these advantages: plastic tire eliminates rail wear; no lubrication is required in the bearing or on the rail; reduce noise
up to 10dB; absorb shock and vibration; high
load capacity; ball bearings permit higher linear
speeds; lighter weight reduces inertia; are suitable for use in clean rooms; wash downs; work
well in subzero temperatures (-40F). For load ratings and sizes go to www.intechpower.com/icam.
Intech Corp.
250 Herbert Ave., Closter, NJ 07624
(201) 767-8066
Fax: (201) 767-7797
Web: www.intechpower.com
FOR A FREE COPY, CIRCLE NUMBER
13
The domestic source for perfect meshing timing belts and pulleys. BRECOflex CO., L.L.C. is
announcing their new pulley catalog B216 for made-to-order and stock pulleys. The new
domestic CNC state of the art pulley manufacture allows for very precise machining
standards, leading to superior product quality and quick product availability. BRECOflex CO.,
L.L.C., is providing finished precision pulleys made-tospecification and stock pulleys with pilot bores, for
immediate delivery. Made-to-order pulleys are available with
normal backlash, reduced backlash SE or zero backlash
0 tooth gap design.
Helicals 28-page catalog features miniature flexible couplings, u-joints, power transmission couplings and machined springs. Couplings are available in high strength
17-4PH stainless steel or 7075-T-6 aluminum.
Quick-reference, product summary chart highlights features and technical data. Easy-touse part number builders make ordering easy.
10
ELECTRIC CYLINDERS
RACO Electric Linear Cylinders with ballscrews or acme screws are an environmentally safe
and low maintenance replacement for hydraulic or pneumatic cylinders. Thrusts to 200,000
lbs., speeds to 30/second, and strokes to 20 ft. Modular system allows custom built units using the special high torque RACO actuator motor or servo and
stepper motors. Cylinders are built for heavy duty industrial applications. Other types of cylinders are available
for high speed, high positioning accuracy applications.
Santa Maria, CA
Toll Free: (888) 211-9589
(805) 928-3851
Fax: (805) 928-2369
Web: www.Heli-Cal.com
FOR A FREE COPY, CIRCLE NUMBER
O-Seal System valves and fittings are rated for heavy-duty liquid or gas services and provide
years of reliable leakproof operation. The unique O-Seal System design allows operators to
change out valves and other ocmponents for maintenance with the simple turn of a union
nut. The flat-faced fittings are joined with a resilient O-ring in a close tolerance groove -- so
the higher the pressure, the tighter the seal. These fittings are rated for 6,000 psi, at temperatures from -20
to 225 F.
CPV Manufacturing
Philadelphia, PA
(888) 278-8339, FAX: (215) 387-9043
Email: sales@cpvmfg.com
Web: www.cpvmfg.com
11
Deublin Company
Cincinnati, OH
(513) 772-1242
Fax: (513) 772-9080
Email: fgorman@astromet.com
Web: www.astromet.com
12
15
Deublin, the leading manufacturer of rotating unions,has a new, updated 56-page catalog that
includes complete information for selecting unions for a variety of applications, from water and
steam, to air and hydraulic, oil and coolant. Both operating data and dimensional specifications are provided in one comprehensive catalog, along
with installation and service information. This reference catalog provides detailed information on over 50
application categories and over 500 models. The catalog is available free via reader response, phone or email.
14
MACHINE Design.com
16
53
(QJLQHHULQJ
(9(5<:+(5(
,6
DQGZHUHDOORYHULW
Electronic Design | Machine Design | Microwaves & RF | Medical Design | Source ESB | Hydraulics
& Pneumatics | Global Purchasing | Distribution Resource | Power Electronics Technology | Mobile
DevelopmentandDesign|EnergyEfficiency&Technology|DefenseElectronics|MotionSystemDesign
| Auto Electronics | Electronic Design Europe | Electronic Design China | Engineering TV | Fluid Power
Expo | Medical Silicone | Medical Prototyping | One Powerful Day | Combating Counterfeit Conference
Intech Corp.,
250 Herbert Ave., Closter, NJ 07624
(201) 767-8066
Fax: (201) 767-7797
Web: www.intechpower.com
FOR A FREE COPY, CIRCLE NUMBER
17
New 528-page catalog Q420 has technical specs for 3,800+ standardized stock metric
gear components, including spur, helical and internal gears, straight and helical racks,
straight and spiral bevel gears, worm and worm
gears, ratchets, splines and gear couplings in modules 0.5 to 10. Materials include carbon & chromemoly steel, brass, bronze, nylon and cast iron.
18
913-967-1823
Courtney Denison Production Coordinator
913-967-1738
Corporate Officers
David Kieselstein Cheif Executive Officer
Bob MacArthur Senior Vice President
Nicola Allais Chief Financial Officer
19
An economy line of check valves and checked orifices which can be installed
in female threads in sizes 6/32, 10/32, 1/420 and 5/1618. Comparable
metric sizes are M3.5, M5, M6 and M8. Valves
are available in all metal construction, brass or
stainless steel or also with resilient seating Buna
N or Viton.
&$7$/2*7&9
MACHINE Design.com
20
55
INDEX TO ADVERTISERS
ADVERTISER. . . . . . . . PAGE
ACE CONTROLS . . . . . . . . . . . . 51
INC.. . . . . . . . . . . . . . . . . 53
COMPANY . . . . . . . . . . . 51
COMPONENTS . . . . . . . 51
TRIM-LOK INC. . . . . . . . . . . . . . 55
ALTECH CORP . . . . . . . . . . . . . 56
QUALITY TRANSMISSION
ADVANCED ANTIVIBRATION
COMPONENTS . . . . . . . 55
While every effort has been made to ensure the accuracy of this index,
the publisher cannot be held responsible for any errors or omissions.
MACHINE Design.com
NOVEMBER 8, 2012
21
MATERIALS
its expertise with living fungus to create reusable circuits. In a recent TEDx talk, Ecovative cofounder Gavin
McIntyre describes studying the natural formation of
mushrooms around toxins as a way to develop a reusable
circuit.
Research started with an abandoned open-pit copper
mine in Montana called the Berkeley Pit, which spans one
mile long by half a mile wide. A natural spring fills the pit
Lubriplate .com
SPECIFY THE
SYNTHETIC
ADVANTAGE ...
LUBRIPLATE
PGO SERIES
POLYALKYLENE GLYCOL
(PAG)-BASED GEAR OILS.
Advanced PAG-Based Formula
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operating under the most demanding conditions.
They Reduce Friction, Wear, and Thermal Build-Up
(Reductions up to 15F in Worm Gear Reducers).
Exceeds 12 Stages of FZG Test.
Lubriplate
Mushrooms are naturally composed
of an insulative biopolymer called
chitin. When mushrooms are grown
with conductive copper solution, the
mushroom works like a circuit.
Synthetic Lubricants
Contact: Ellen Girard / OEM Marketing Analyst
Tel: 973-465-5731 / E-mail: egirard@lubriplate.com
For Equipment Recommendations and Lubricant Specications
RS# 141
NOVEMBER 8, 2012
MACHINE DESIGN.com
57
MATERIALS
with about 900ft of water laden with heavy metals and dangerous chemicals that leach from rock. Mushrooms form
around the Berkeley Pit because fungi grow naturally around
metal toxins. They grow around metal toxins because the
mycelium within the fungi contain complex proteins that
bind to surrounding materials and store toxins within their
cell walls. When fungi grow on materials without the presence of a metallic solution, toxins are stored outside their cell
Custom
formulated
EcoCradle
material
can insulate
commercial
and residential
buildings.
2012 COMSOL.
58
MACHINE DESIGN.com
RS# 140
NOVEMBER 8, 2012
RS# 139
CONNECTED.
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How to
AVOID
ELECTRICAL
HAZARDS with
air logic
Authored by:
Kenneth J. Korane
Managing Editor
Key points:
Air logic functions like relays, switches, and
counters, but uses compressed air instead of
electricity.
Air-logic controls are preferred in wet or dusty
conditions because they pose little danger of
electrical explosion or shock.
Resources:
AOP Technologies, www.aoptec.com
Clippard Instrument Laboratory,
www.clippard.com
RS# 621
MACHINE DESIGN.com
NOVEMBER 8, 2012
logic can also be used on machines with fluid-power components but no electrical supply.
Air logic does have disadvantages. Most common is
a lack of understanding among maintenance personnel
on how to read schematics and troubleshoot problems.
Also, air logic with long control lines responds noticeably slower than electronics. Thats because control lines
longer than 10 to 15 ft fill and exhaust slowly compared to
near-instantaneous electrical signals. In addition, it takes
06')4#6'&16+101.76+105
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
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48 HOUR
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.groshcopp.com/specs or call (800) 829-4135 and
ask to speeak with a regional account manager.
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800.829.4135
(712) 722.1445
sales@groschopp.com
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Groschopp Inc.
420 15th St. NE
Sioux Center, IA 51250-2100 USA
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RS# 142
IN D US T RY -L E ADING
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GET
IT ALL
FROM
PMD
Molding composites
CHIPS
CARDS
DRIVES
DEVELOPERS KITS
RS# 143
PERFORMANCE MOTION DEVICES, INC.
80 CENTRAL ST. | BOXBOROUGH, MA 01719
P: 978.266.1210 | WWW.PMDCORP.COM
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RS# 144
Servo Gearheads
Air-logic controls
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Precise pumping
Precise metering was a key objective when the Patriot was developed.
It ensures a catalyst-to-resin variance
ratio of 1% or less. A pneumatic motor drives the resin pump which, in
turn, is connected by a slave arm to
the catalyst pump. In this way, the
catalyst pump is directly slaved to the
resin pump, ensuring accurate metering as both catalyst and resin are
delivered to the mix head.
The air motor driving the pumps
uses line-pressure pilot valves, which
shift a four-way valve spool to reverse
the pump. Keys for quickly reversing the pump are a light spring load
on the pilots and large exhaust ports
on the valve. Also, the air cylinder
has a 2-in. stroke that minimizes
Avago Encoders
From Miniature Modules to
Complete Housed Encoders
RS# 146
COATED
INDUSTRIAL
DEVICE
The Leader
in Coating
Industrial,
Medical, and
Aerospace
Components.
Innovative design
The Innovator II is based on
controls originally built in the
United Kingdom for a specific
model of MVPs meter/mix equipment. That unit used European-standard components and metric tubing.
We wanted an Americanized version for North America with Clippard valves, standard tubing, and
other components that are readily
available, says Austad.
And MVP wanted the controls to
work with a variety of its equipment.
Looking to build greater versatility
and functionality into the controls,
engineers from MVP and Clippard
distributor AOP Technologies, Auburn, Wash., made key improvements, notes DeLuca. We changed
all the control lines to 1/8-in. OD to
get faster reaction times on the circuits. All of the valves that actually
control outside sources were upsized
to allow for more flow so that we
could use longer trigger lines outside
the box, he says.
Using stand-alone brass valves
from Clippard, we arranged valves
into banks. Four of the valve banks
are essentially complete circuits, to
ease troubleshooting. The fifth is an
overall control circuit with flow controls for system tuning. Some redundancies were removed and common
valves were used when possible to reduce the number of different parts,
notes DeLuca.
Another important feature: the
RS# 147
NOVEMBER 8, 2012
MVPs
Innovator
II controls
are shipped
worldwide
and built for
durability
and low
maintenance.
Ensuring reliability
Although the box is designed primarily for the North American market, MVPs machines are shipped
worldwide. This makes reliability,
along with minimal maintenance, essential, according to Austad. From
MVPs standpoint, we have used
Clippard products in our pumping
systems for many years, with good
results, he says. The design relies on
standard components and Clippard
has worldwide distribution. So in
case there is a problem, users can go
to their local distributor and get it repaired and up and running as soon as
possible.
Because of the proven reliability
and durability of Clippard air-logic
valves, we expect these systems to be
trouble-free for many years, adds
DeLuca. Other than cleaning the air
filter, no maintenance is required.
MD
RS# 148
RS# 136
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RS# 150
SPOTLIGHT LINEAR
High-force linear
actuator
The High Force Linear Actuator Model
LA100-93-000A packs a 500-lb peak
force a level that typically requires two
actuators and a continuous force of
292lb with 2-in. total stroke. The device
features a semihoused construction with
built-in shaft and bushings that orient
the coil assembly concentric to the field
assembly, which makes actuator
mounting fast and easy.
The unit measures
10in. in diameter
and 9.3in. long
at mid stroke.
BEI Kimco
Magnetics,
1499 Poinsettia Ave., Suite
160, Vista, CA
92081, (800)
572-7560, www.
beikimco.com
RS# 446
ACTUATORS
Linear units
First in the companys new family of Actuatorline
products, the ELM Series linear units feature highspeed and low-noise operation
The units come in several sizes offering a range of
stroke lengths, load capacities, and shuttling speeds.
ELM units are made of anodized aluminum extrusions
for high mechanical strength and low weight, and
have a steel-reinforced polyurethane timing belt with
either an AT pitch or parabolic profile. The units have
polyurethane sealing strips to protect internal parts
against dust and foreign matter, with an optional bellows for critical environments.
The units feature a maintenance-free ball bearing
guide within the extruded body and offer speeds to
5m/sec, high-load capacity and bending moments,
low friction, and a 20,000-km service life without relubrication. Measuring 50 50 mm to 110 110 mm,
the units maximum axial loads range from 530 to
2,650 N, with stroke lengths from 100 to 3,700 mm,
depending on the model. All units support loads in
any direction and may be installed in any position.
Units may be fitted with a variety of drive systems
based on application needs, with the driving pulley
attached to the reduction gear shaft by a tapered
coupling for high accuracy and long life. For highly
68
MACHINE DESIGN.com
NOVEMBER 8, 2012
EZ INDEXER
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Nickel Conductive
Adhesive Cures Rapidly
at Room Temperature
EP76MF Epoxy System
Low volume resistivity
High bond strength
Chemically resistant
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www.masterbond.com
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RS# 152
RS# 151
www.tech-etch.com/photoetch
,62
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SPOTLIGHT LINEAR
ACTUATORS
Linear-motion platform
The SIMO (Simultaneous Integral Milling Operation) Series linear-motion
platform lets design engineers meet multiple application requirements
within a single platform. Its consistent geometry creates a platform of
interchangeable options, including.
MACHINE DESIGN.com
RS# 154
NOVEMBER 8, 2012
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PRODUCTS
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Request free in Web site at
Reader Service
c
design.com/rs
ww w.machine
Hypoid gearmotor
The PowerSTAR is a hypoid, maximumefficiency, right-angle gearmotor
capable of energy-efficient operation
for applications include packaging equipment, conveyors, light industrial equipment,
and food processing.
The gearmotors improved energy efficiency and maximum
power density allow for a compact profile without compromising performance, unlike conventional worm and competing hypoid gearmotors. Additional features include ground gearing for whisper-quiet operation, low backlash
precision, external finned edges for cooler operating temperatures, and multiple
mounting configurations to support easy interchangeability.
The gearmotor includes both / and /-hp, single-phase 115-V, and threephase 230-V inverter-duty motor options on the 725 gearbox in 13 standard
ratios with output torque from 59-878 lb-in.
Bison Gear and Engineering, 3850 Ohio Ave., St. Charles, IL 60174, (800) 2824766, www.bisongear.com
RS# 465
RS# 158
MACHINE DESIGN.com
NOVEMBER 8, 2012
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8 AXES in ONE
MSEP
8-axis Controller
for
Approx.
60% smaller
California: 800-736-1712
www.IntelligentActuator.com/MSEP
Illinois: 800-944-0333
Georgia: 888-354-9470
BUSINESS INDEX
Agilent Technologies . . . . . . . . . . . . 6, 28
AOP Technologies . . . . . . . . . . . . . . . . . 60
Asurian. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AutomationDirect . . . . . . . . . . . . . . . . . . 6
BEI Kimco Magnetics. . . . . . . . . . . . . . . 68
BEI Sensors . . . . . . . . . . . . . . . . . . . . . . . . 30
Boeing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Boerhaave Museum . . . . . . . . . . . . . . . 79
Bridgestone/Firestone . . . . . . . . . . . . . 12
Bureau of Labor Statistics . . . . . . . . . . . 8
Caremark. . . . . . . . . . . . . . . . . . . . . . . . . . 12
Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . 35
Caterpillar Financial. . . . . . . . . . . . . . . . 12
Center for Alaskan Coastal Studies . 46
Christies . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Clippard Instrument Laboratory. . . . 60
REAL PRODUCTS
for real problems
solutions with advanced pneumatic technology
Pneumatic
Linear Slides
Precision linear slides withstand side loads
SE Series Linear Slides are designed to fit precision motion applications where
overall length is limited. A bearing block houses four pre-loaded, sealed linear
bearings that support hardened guide shafts attached to a front toolbar. An integral, repairable air cylinder at the rear of the bearing block powers the toolbar.
Adjustable strokes
1245 lb. maximum thrust rod locks
Precision machined toolbar surfaces
Slip fit dowel hole & slot mountings
Multiple mounting surfaces
Magnetic position sensing
Limit switches & electronic sensors
Cylinder bores: 1/2" to 31/4"
Guide shaft diameters: 1/4" to 11/2"
Tandem cylinder options (3 position)
Multi-Power options yield thrusts
to 31/2 times that of standard cylinders
74
MACHINE DESIGN.com
RS# 162
NOVEMBER 8, 2012
RS# 164
RS# 163
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STATEMENT OF OWNERSHIP
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MACHINE DESIGN.com
NOVEMBER 8, 2012
ADVERTISER INDEX
RS#. . . . . . COMPANY. . . . . . . . . . . . . . . . . . . . . . .PAGE
109. . . . . . . .Airfloat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
136. . . . . . . .Airpot Corp/Airpel . . . . . . . . . . . . . . . . . . . . . .44
169. . . . . . . .All Metric Small Parts . . . . . . . . . . . . . . . . . . .79
138. . . . . . . .Alpha Wire Company . . . . . . . . . . . . . . . . . . .47
103. . . . . . . .Automationdirect.com . . . . . . . . . . . . . . . . . . 3
105. . . . . . . .Automationdirect.com . . . . . . . . . . . . . . . . . . 6
146. . . . . . . .Avago Technologies U.S. Inc . . . . . . . . . . . .65
139. . . . . . . .Avnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
171. . . . . . . .Baldor Electric Co . . . . . . . . . . . . . . . . . . . . . .IBC
110. . . . . . . .BEI Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
172. . . . . . . .Bimba Manufacturing Company . . . . . . BC
147. . . . . . . .Boyd.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
126. . . . . . . .Carr Lane Manufacturing Co. . . . . . . . . . . .31
151. . . . . . . .Centricity Corporation . . . . . . . . . . . . . . . . . .69
106. . . . . . . .Clippard Instrument Laboratory, Inc. . . . . 7
140. . . . . . . .Comsol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
122. . . . . . . .Continental Hydraulics . . . . . . . . . . . . . . . . .27
145. . . . . . . .Diequa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
156. . . . . . . .Dynaflo, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
165. . . . . . . .Dynetic Systems . . . . . . . . . . . . . . . . . . . . . . . .75
160. . . . . . . .Eagle Stainless & Fabrication, Inc. . . . . . . .73
108. . . . . . . .EBM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
17 . . . . . . . . .Epson America Inc . . . . . . . . . . . . . . . . . . . . 115
104. . . . . . . .Exair Corporation . . . . . . . . . . . . . . . . . . . . . . . . 5
116. . . . . . . .Excel Gear Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .18
135. . . . . . . .Exlar Corporation . . . . . . . . . . . . . . . . . . . . . . .43
162. . . . . . . .Fabco Air, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . .74
137. . . . . . . .Fabrico. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
123. . . . . . . .GGB Llc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
142. . . . . . . .Groschopp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
131. . . . . . . .Haydon Kerk. . . . . . . . . . . . . . . . . . . . . . . . . . . .37
144. . . . . . . .Helical Products Company, Inc. . . . . . . . . .63
161. . . . . . . .IAI America Inc. . . . . . . . . . . . . . . . . . . . . . . . . .73
148. . . . . . . .Innovate3d . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
158. . . . . . . .Intech Corporation . . . . . . . . . . . . . . . . . . . . .72
149. . . . . . . .KNF Neuberger, Inc.. . . . . . . . . . . . . . . . . . . . .67
101. . . . . . . .Lee Company. . . . . . . . . . . . . . . . . . . . . . . . . . IFC
141. . . . . . . .Lubriplate Lubricants Co. . . . . . . . . . . . . . . .57
152. . . . . . . .Master Bond, Inc. . . . . . . . . . . . . . . . . . . . . . . .69
154. . . . . . . .Metal Powder Ind Federation. . . . . . . . . . .70
166. . . . . . . .Minalex Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .77
121. . . . . . . .Minnesota Rubber. . . . . . . . . . . . . . . . . . . . . .25
111. . . . . . . .Moog Components Group . . . . . . . . . . . . .11
113. . . . . . . .Nason Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
112. . . . . . . .National Instruments Corporation. . . . . .13
167. . . . . . . .Novotechnik U.S., Inc.. . . . . . . . . . . . . . . . . . .77
102. . . . . . . .Omega Engineering Inc . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . .Ondrives.us . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
127. . . . . . . .Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . . .32
128. . . . . . . .Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . . .33
143. . . . . . . .Performance Motion Devices, Inc. . . . . . .62
150. . . . . . . .Peter Paul Electronics Co. Inc. . . . . . . . . . . .67
131. . . . . . . .Pittman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
159. . . . . . . .Quality Bearings & Components. . . . . . . .73
163. . . . . . . .Quality Transmission Components . . . . .75
114. . . . . . . .Schaeffler Group USA. . . . . . . . . . . . . . . . . . .15
118. . . . . . . .Schneider Electric Motion.. . . . . . . . . . . . . .22
119. . . . . . . .Schneider Electric Motion.. . . . . . . . . . . . . .23
164. . . . . . . .Seal Master Corporation . . . . . . . . . . . . . . . .75
125. . . . . . . .Setco USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
170. . . . . . . .Shimpo Drives Inc. . . . . . . . . . . . . . . . . . . . . . .80
117. . . . . . . .Smalley Steel Ring Company . . . . . . . . . . .19
107. . . . . . . .Spirol International Corporation. . . . . . . . . 8
132. . . . . . . .Steinmeyer, Inc.. . . . . . . . . . . . . . . . . . . . . . . . .39
124. . . . . . . .TDK-Lambda Americas Inc. . . . . . . . . . . . . .29
153. . . . . . . .Tech-etch Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .69
129. . . . . . . .Thomas Division . . . . . . . . . . . . . . . . . . . . . . . .34
130. . . . . . . .Thomas Division . . . . . . . . . . . . . . . . . . . . . . . .35
157. . . . . . . .Trim-Lok Company . . . . . . . . . . . . . . . . . . . . .71
120. . . . . . . .Turck Incorporated . . . . . . . . . . . . . . . . . . . . .24
168. . . . . . . .Vesco Plastics Sales . . . . . . . . . . . . . . . . . . . . .79
155. . . . . . . .VIC Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
133. . . . . . . .W.L. Gore & Associates Inc . . . . . . . . . . . . . .40
134. . . . . . . .W.L. Gore & Associates Inc . . . . . . . . . . . . . .41
RS# 166
Linear Position Sensors With
Attachment Options
Novotechniks TEX Series has the
mounting and connection
configurations needed to be
plug-in compatible with
your existing or new
application. The TEX Series is designed
for use in tough environments like industrial, off-road automotive and others.
The TEX Series is available in stroke
lengths of 10 to 300 mm. Repeatability is better than
0.01 mm and the TEX Series has outstanding linearity
to 0.05%. A wide range of standard configurations for
mounting are featured including:
return spring
bolt through flanges
bushing mount
RS# 167
CLASSIFIEDS
BUSINESS STAFF
EDITORIAL
PRODUCTS/SERVICES
THE ORIGINAL
INSTANT
THUMBSCREW
A R T D E PA R T M E N T
CREATIVE DIRECTOR: DIMITRIOS BASTAS
GROUP DESIGN DIRECTOR: ANTHONY VITOLO
dimitrios.bastas@penton.com
tony.vitolo@penton.com
PRODUCTION
GROUP PRODUCTION DIRECTOR: CAREY SWEETEN
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ONLINE
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CLIENT SERVICES COORDINATOR: JOANN MARTIN
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5)+016-,-;1/6;
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78
MACHINE DESIGN.com
NOVEMBER 8, 2012
david.kieselstein@penton.com
nicola.allais@penton.com
bob.macarthur@penton.com
BACKTALK
300-year-old
thermometer resurfaces
Daniel Gabriel Fahrenheit had a strong interest
in natural science and a fascination with new
inventions. In 1714, he invented the mercury
thermometer. It divided the freezing and boiling
points of water into 180.
The top of the 300-year-old brass instrument,
thought to have been lost to history, resurfaced
when it went up for sale at Christies in London.
In a private collection for more than 40 years, it is
one of only three known examples in existence
today. The 4-in.-tall instrument sold for more
than 67,000 (~$107,386,00 in U.S. dollars). The
scale on the thermometer is marked from 0 to
132F and is so small that the numbers had to be
written on both sides of the mercury tube.
James Hyslop, speaking on behalf of Christies, said,
Until now, only two originals were thought to exist.
And these are both in the Boerhaave Museum in the
Netherlands. So to have this one emerge is very exciting. It is impossible to pinpoint exactly when it was
made, but one in the museum is dated 1718, and this
was probably made between 1715 and 1730.
He made barometers with thermometers on the
Vesconite
Hilube
Up to ten
times the life
of bronze
No grease needed
Ideal in dirt and
underwater
Small to XXL sizes
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RS# 168
NOVEMBER 8, 2012
RS# 169
MACHINE DESIGN.com
79
BACKTALK
studies and experimentation in the
field. He later moved to the Dutch
Republic, where he spent the rest of
his life. He died in The Hague in 1736.
The Celsius scale was invented
in 1742 by Swedish astronomer
Anders Celsius. The scale has 100
between the freezing point (0C)
SIGN IN AT
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WORLDS SMARTEST DESIGN
ENGINEER CONTEST!
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80
MACHINE DESIGN.com
RS# 170
NOVEMBER 8, 2012
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RS# 171
WE SET
THE STANDARD.
NOW WEVE
DOUBLED THE LIFE.
RS# 172
After leading the way for more than 50 years, the best just got better. Clocking in at
an industry-leading 3000+* miles of travel, the new Bimba Original Line cylinders are designed
to leave the competition in the dust. These new, non-repairable, round body cylinders are
also lubricated for life to ensure less hassle for the long haul. To follow the new OL on its
cross-country road trip and register for a free sample, visit bimba.com/OLroadtrip
PNEUMATIC t HYDRAULIC t ELECTRIC t WWW.BIMBA.COM
* This life estimate may not include cylinders with design modications, those exposed to harsh operating conditions or any unintended applications.