Design Engineering

9 Automating design steps

yields huge productivity gains

20 Field Oriented Control boosts

stepper to servo performance

34 Robotic submarine harvests

submerged, formerly lost, lumber

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Contents | Volume 57, No. 6

IN THE NEWS

8

Canadian foundry pioneer mourned

8

Melitron appoints new president

8

Siemens Canada acquires Prairie West Technical

14 CAD Report

CMTS 2011 success signals Canadian manufacturing rebound

20 Motion Control

8

SFU researchers’ Gecko-inspired tank robot climbs walls

22 Power Transmission

10

CAE lands Emirates airline contracts

26 Linear Motion

8

10

RES Canada completes wind farm

10

UofT engineers create flexible, highefficiency OLED

12

BAE invests in Canadian hydrokinetic R&D

12

Canada’s most powerful supercomputer

READER SERVICES Annual Subscription Rate In Canada: $52.00 Outside Canada: $99.00 Single Copy & Directory Rates In Canada: $8.00; $26.00 directory issue Outside Canada: $22.00; $43.00 directory issue Reader Service Contact Information ecallaghan@bizinfogroup.ca T: Toronto 416 442 5600 X 3538 Elsewhere -866-543-7888 Mail: Business Information Group Design Engineering Circulation Dept 80 Valleybrook Drive North York, ON M3B 2S9

Columns

5

10

Automating small, time-consuming design steps results in huge productivity gains.

Field Oriented Control boosts stepper motor performance to servo levels.

Successfully specifying custom components requires forethought and a flexible supplier.

16

Ontario-based steel fabricator solves linear motion challenge.

29 Idea Generator

The latest in industrial products including electrical, fluid power and motion control.

18

Features 18 Game Changing Technologies

As the world grapples with energy issues, Canadian engineering researchers are closing in on potential solutions.

24 Getting It Right, The First Time

26

Markham telecom firm relies on Quebec’s Vicone to ruggedize outdoor equipment.

34 Canadian Innovator

Made-in-Canada submersible robot harvests underwater trees from reservoirs.

34

Printed in Canada

www.design-engineering.com

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Novemember/December | 2011

11-12-13 7:00 AM

6 EditorialViewpoint

Clipped Wings

www.design-engineering.com

W

hen the announcement came that the Canadian government would be scrapping the Avro Aero fighter jet project on 20 February 1959, the day was aptly named “Black Friday” by the Canadian aviation industry.

Beyond the approximately 30,000 laid off employees who were directly or indirectly tied to the Canadian interceptor’s fate and the years of cutting-edge engineering advancement wasted, the Canadian aerospace industry never quite recovered from the blow. Many of the project’s top engineering talent fled to high-flying careers leading NASA’s manned space programs.

Possibly worst of all, nearly all traces of the Aero —including the aircraft prototypes, manufacturing equipment and technical documentation—were ordered destroyed. All that survived of the original CF-105 was a cockpit and nose cone section smuggled out the Avro Aircraft plant in Malton, Ontario by members of the RCAF Flying Personnel Medical Establishment.

As the 53rd anniversary of Black Friday approaches, the fabled Canadian fighter jet—and Canadian aviation history in general—faces yet another indignity. The Canadian Air and Space Museum, which presently houses that smuggled Avro section, is counting down the months until it too is scrapped.

In September, the management of the museum, along with 10 other tenants of the historic Downsview Park building in Toronto, received word that they would have to leave. For one, the beleaguered museum owed $100,000 in back rent and, in any case, Parc Downsview Park, the Crown Corporation that owns the property, had made arrangements to demolish the building to make room for a four-pad hockey arena. Since then, the museum has been looking for a place to store its exhibits.

Among its collection, the museum houses a number of Canadian aviation treasures, including a replica of the Silver Dart, Canada’s first powered flying machine; a rare WWII-era Avro Lancaster Mk. X bomber; and the UTIAS Snowbird, the world’s first powered ornithopter that took its first and only flight in 2006.

Besides the artefacts housed, the building itself is steeped in Canadian aviation history. De Havilland Aircraft—now part of Bombardier Aerospace—built the facility in 1929 where it later built Mosquito fighter bombers and Tiger Moth trainers during WWII. In the 1960s, de Havilland designed and tested the Alouette I, Canada’s first satellite, at the Downsview facility.

For its part, the park’s management has offered to help store the museum’s artefacts until a new home can be found. However, the centerpiece of the museum’s collection—a full-scale replica of the Avro Aero painstakingly reconstructed by volunteers, will have to have its wings removed to fit in storage, the museum’s management says.

The museum has until March before it has to vacate the property permanently.

In a bid to hold that eviction off, it has launched a “Save the Canadian Air and Space Museum” campaign through its Website: www.casmuseum.org. If preserving national heritage is important, show your support. It’s one thing to provide a facility to enhance the national past time, and another still to abandon that which reminds us of why we should be proud to be Canadian in the first place.

Mike McLeod

@

Group Editorial Director Lisa Wichmann (416) 510-5101 LWichmann@canadianmanufacturing.com Editor Michael McLeod (416) 442-5600 ext. 3231 mmcleod@design-engineering.com Technical Field Editor Pat Jones, P. Eng. Art Director Kathy Smith (416) 442-5600 ext. 3215 KSmith@plant.ca Market Production Manager Jessica Jubb (416) 510-5194 jjubb@bizinfogroup.ca Circulation Manager Cindi Holder (416) 442-5600 ext. 3544 CHolder@bizinfogroup.ca BIG Magazines LP Executive Publisher Tim Dimopoulos Vice-President of Canadian Publishing, Alex Papanou President of Business Information Group, Bruce Creighton Publications Mail Agreement #40069240 ISSN number: 0011-9342 Privacy Notice: From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 E-mail: privacyofficer@businessinformationgroup.ca.

Mail to: Privacy Officer, 80 Valleybrook Drive, North York, ON M3B 2S9 Subscriber Services: To subscribe, renew your subscription or to change your address or information contact us at 1-800-387-0273. Subscription Price: Canada $52.00 per year, Outside Canada $99.00 US per year, Single Copy Canada $9.00. Design Engineering, established in 1955, is published 6 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. Published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. Tel: 416-442-5600, Fax: 416-510-5140 80 Valleybrook Dr., Toronto, ON M3B 2S9.

Contents of this publication are protected by copyright and must not be reprinted in whole or in part without permission of the publisher. DE receives unsolicited features and materials (including letters to the editor) from time to time. DE, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. DE accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. DE is indexed in the Canadian Business Index by Micromedia Ltd., Toronto, and is available on-line in the Canadian Business & Current Affairs Database. We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.

I enjoy hearing from you so please contact me at MMcLeod@design-engineering.com and your letter could be published in an upcoming issue.

November/December | 2011

6-ED.indd 6

Publisher Alan Macpherson (416) 510-6756 AMacPherson@design-engineering.com

www.design-engineering.com

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8 DesignNews Up Front Canadian foundry pioneer mourned William Allan “Al” Hunter, pioneer of many of the techniques and machine concepts used worldwide in the foundry market, has died at 89. A giant in the industry, Hunter changed the way sandcasting was done through his invention of the Hunter matchplate molding machine in 1964 and various mold handling systems beginning in 1970.

Born in Wilkie, Saskatchewan in 1922, Hunter joined the Royal Canadian Air Force at 18 and received his BSME from the University of Toronto in 1951. In 1957, he and his family moved to the U.S. where he accepted a position as chief engineer at Beardsley & Piper in Chicago. In 1963, he left B&P to develop his concept for an automatic matchplate molding machine and founded Hunter Automated Machinery Corporation.

During Al Hunter’s professional life, which spanned six decades, he invented and patented more than 80 machinery apparatus or method ideas used every day in foundry operations, including multi-level mold handling systems and automatic coresetters. www.hunterauto.com

CMTS 2011 success signals Canadian manufacturing rebound From standing room only at the keynote address and a show floor that was almost double in size compared to 2009, to an overall 10 per cent increase in attendance and a sold-out technical conference, the success of last month’s Canadian Manufacturing and Technology Show 2011 (CMTS 2011) reflects the growing optimism of the Canadian manufacturing industry in general, say show organizers.

“We took some big steps this year, using the latest in social media to create a more personalized experience for delegates while expanding the show floor to include significant educational and networking components, and our expectations were exceeded,” notes Nick Samain, event manager with the Society of Manufacturing Engineers (SME), organizers of the event, which takes place every two years.

Adding to the buzz around this year’s show was the keynote address by Kevin O’Leary, best known as a judge on CBC Television’s Dragon’s Den. O’Leary delivered practical advice for business growth, telling delegates it’s time to look beyond the U.S. to potential export markets in Brazil, India and Asia. He also encouraged ongoing investment in technology, saying: “People think that automation is killing jobs in Canada, when in fact, it’s enhancing the value of jobs you can provide.”

Also of note was a clear message from Take Back Manufacturing (TBM), a campaign launched by the Toronto chapter of SME to get government, education, business and media representatives working together to bring off-shore manufacturing back to North America.

According to reports from Statistics Canada, 322,000 manufacturing jobs disappeared from the Canadian economy between 2004 and 2008, including the production of truly Canadian items like hockey sticks. TBM participants aim to bring those jobs back by promoting a more balanced approach to sourcing of raw materials that keeps manufacturing costs down.

Additional highlights of CTMS 2011 included: A 500-exhibit trade show featuring 150 new products and live demonstrations; demonstrations of some of the latest advances in hybrid and solar cars by Canadian university students; and an international presence, including a 150 exhibitor international pavilion from India, which featured the Canadian debut of the Tato Nano.

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Melitron appoints new president Mike Turner has been promoted to the position of president and CEO of Melitron Corporation, a contract manufacturer of metal enclosures and mechanical and electronic assemblies. Formerly Melitron’s VP and GM, Mike replaces Ted Turner who founded the company and has served as president and CEO since 1995.

Ted will assume the position of chairman and will continue to support Melitron as an executive advisor. Headquartered in Guelph, Ontario, Melitron is a contract manufacturer of precision metal components, electronic chassis, industrial enclosures, frames/racks and self-service kiosks. www.melitron.com

Siemens Canada acquires Prairie West Technical Services Siemens Canada has acquired Regina-based, electrical maintenance firm Prairie West TechniNovemember/December | 2011

8-13 news.indd 8

www.sme.org

SFU researchers’ Gecko-inspired tank robot climbs walls Researchers at Simon Fraser University have developed a tank-like robot that can climb smooth walls without the use of adhesives or magnets.

Drawing inspiration from the gecko, the researchers have been able to create adhesives that mimic the toe pads of the lizard that give it the ability to climb smooth vertical surfaces and shuffle across ceilings.

These dry, but sticky toe pads, also known as dry fibrillar adhesives, were recreated in the lab using polydimethylsiloxane (PDMS) and were manufactured to contain very small mushroom cap shapes that were 17 micrometres wide and 10 micrometres high.

“While van der Waals forces are considered to be relatively weak, the www.design-engineering.com

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DesignNews Up Front cal Services to support its existing mining and oil & gas customers in Saskatchewan and advance its technical capabilities in the region.

Prairie West is one of the largest electrical service organizations in Canada, specializing in engineering solutions for the utility, industrial, commercial and institutional electrical markets.

As part of the deal, Siemens also acquired Prairie West’s state-of-the-art Regina repair facility. Siemens says it also plans to upgrade the existing repair facility in Sudbury, Ontario to the same high-level of capabilities. www.siemens.ca

CAE lands Emirates airline contracts CAE was awarded a contract from Emirates airline for two full-flight simulators (FFSs), one for the Airbus A380 aircraft and one for the Boeing 777. Emirates is the world’s largest operator of both aircraft types.

The contract is worth a total of more than C$34 million at list prices and brings the total number of FFS sales that CAE has announced to date during fiscal year 2012 to 21. The Boeing 777 FFS will be delivered to Emirates’ training facility in Dubai in the first half of 2013. The A380 FFS will be delivered in the second half of 2013. www.cae.com

RES Canada completes wind farm Renewable Energy Systems Canada Inc. (RES Canada), announced the completion of the Greenwich Wind Energy Project on the northern shore of Lake Superior, in Ontario.

The 99-megawatt (MW) project is a limited partnership, in which partners Enbridge and RES Canada have invested $275 million.

The Greenwich Wind Energy Project marks RES Canada’s second Canadian wind energy project to be both developed and constructed by the company. RES Canada’s first project, the 99MW Talbot windfarm, was completed in December 2010.

According to the company, the Greenwich Wind Energy Project is comprised of 43 Siemens SWT-2.3-101MW wind turbines and expected to produce enough power for approximately 33,000 households. www.res-americas.com Novemember/December | 2011

8-13 news.indd 10

thin, flexible overhang provided by the mushroom cap ensures that the area of contact between the robot and the surface is maximized,” said researcher Jeff Krahn. “The adhesive pads on geckos follow this same principle by utilizing a large number of fibres, each with a very small tip. The more fibres a gecko has in contact, the greater attachment force it has on a surface.”

The 240g robot—aka, the Timeless Belt Climbing Platform (TBCPII) — is capable of reliably transferring from a flat surface to a wall over both inside and outside corners at speeds of up to 3.4cm/s. TBCP-II is also fitted with multiple sensors that are able to detect the surroundings of the robot and change its course of action accordingly.

“With an adequate power supply, our robot is capable of functioning fairly independently when it encounters larger-scale objects such as boxes or walls,” Krahn said. “However, we are still developing a control strategy to ensure the robot is capable of fully autonomous functionality.” www.sfu.ca

UofT researchers create high-efficiency OLED display on plastic Engineering researchers at the University of Toronto have developed the world’s most efficient organic light-emitting diodes (OLEDs) in a flexible form factor that is less expensive to manufacture. Currently, OLEDs are produced using heavy-metal doped glass in order to achieve high efficiency and brightness, which makes them heavy, rigid, fragile and expensive to manufacture.

Unlike LCD displays, which require backlighting, OLEDs emit their own light, making them sharper and lower-energy displays and hence popular in advanced electronic devices like smart phones and tablet computers.

The research, which was supervised by Professor Lu and led by Ph.D. candidates Zhibin Wang and Michael G. Helander, demonstrated the first high-efficiency OLED on plastic with performance comparable with the best glass-based OLEDs. Wang and Helander were able to re-construct the high-refractive index property by using a 50-100 nanometre thick layer of tantalum(V) oxide (Ta2O5), an advanced optical thin-film coating material. This coating technique, when applied on flexible plastic, allowed the team to build the highest-efficiency OLED device ever reported with a glass-free design.

The results of Wang and Helander’s work titled “Unlocking the Full Potential of Organic Light-Emitting Diodes on Flexible Plastic” are published online in the journal Nature Photonics. www.research.utoronto.ca

www.design-engineering.com

11-11-24 6:58 AM

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12 DesignNews BAE invests in Canadian hydrokinetic R&D BAE Systems announced an agreement to assist the ongoing technical needs of renewable energy company Instream Energy Systems. The Vancouverbased company specializes in developing and installing hydrokinetic power generation systems, which convert the kinetic energy in moving water into electricity.

The agreement is designed to support the successful commercial development of Instream’s renewable energy technology by granting the company ongoing access to the BAE Systems’ Advanced Technology Centre (ATC).

According to the company, ATC is one of the world’s most advanced R&D facilities, specializing in micro and nano technology, biofutures and robotics. Its backing will allow Instream to further develop its hydrokinetic turbine technology by incorporating the latest materials and manufacturing techniques.

According to BAE, all intellectual property developed as a result of this cooperation will rest solely with Instream.

The company is also currently partnering with Canadian companies, including DEW Engineering, Soucy, Thales Canada and others on priority vehicle programs for the Canadian Armed Forces. www.baesystems.com www.instreamenergy.ca

To help commercialize its hydrokinetic systems, Instream Energy Systems has partnered with BAE Systems.

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Université de Sherbrooke’s “Mammouth” supercomputer ranks as the most powerful in Canada and 41st worldwide.

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According to the international ranking Top500 List of the world’s brawniest supercomputers, the Université de Sherbrooke hosts the most powerful computer in Canada, and the 41st most powerful in the world. Called “Mammouth” — French for Mammoth — it has the combined memory and speed of approximately 20,000 top-of-the-line PCs. Mammouth consists of a total of 39,648 AMD Opteron processor cores, 57,600 GB of RAM and 500 terabytes of data storage. It can perform 240,000 billion arithmetic operations per second (240.3 Teraflops) while executing a single program.

Mammouth is funded mostly by the Canada Foundation for Innovation and the Quebec Ministry of Economic Development, Innovation and Export Trade. Other contributions came from the Natural Sciences and Engineering Research Council of Canada (NSERC).

Internationally, the top supercomputer spot went to the K Computer, installed at the RIKEN Advanced Institute for Computational Science (AICS) in Kobe, Japan. It achieved an impressive 10.51 Petaflop/s on the Linpack benchmark using 705,024 SPARC64 processing cores. http://rqchp.ca www.design-engineering.com

11-11-24 6:58 AM

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11-11-24 6:58 AM

14 CADReport

Removing Design

BoTTleNecks eliminating the relatively small but time-consuming steps that jam up the design process can result it huge productivity gains.

By Scott Hale

C

aught in traffic, I can see the stalled car up ahead and think about how I am going to miss my first meeting of the day.

A single car preventing hundreds of others from getting to work on time is a significant bottleneck, as well as a reason to think of how many of our clients have a single “car wreck” keeping them from being successful.

As design engineers, we try to solve efficiency problems. They are usually more complex than a traffic jam, and require more than a tow truck to resolve, but they usually start with locating the bottleneck. When I am troubleshooting manufacturing challenges, I apply a mental rule that has repeatedly proven true.

While the general belief is that inefficiencies are hidden in all processes, in reality just 4 percent of the tasks an engineer performs can actually reduce productivity by 50 percent.

This Autodesk Inventor iLogic dialog box, developed by IMAGINiT Technologies, allows Dadanco engineers to configure an ACB 40 Unit in 3D using all of the design rules in effect for that product line.

How can this be true? It turns out that many engineers spend half their time searching for information, repeatedly entering the same information into diverse systems or manually performing complicated engineering calculations—all of which do not add value to the end product. We know from experience that a handful of tasks, like these, can significantly reduce productivity.

The 4/50 Rule I leverage the 4/50 rule regularly when solving customer issues.

To illustrate, let’s take a look at a manufacturing business that has also been working to eliminate inefficiencies. Engineers at HVAC manufacturer, Dadanco, designed a patented induction technology to provide performance advantages in a wide range of HVAC products including active chilled beam, diffuser and November/December | 2011

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induction units. These innovations allow MEP designers to specify custom, energy-efficient HVAC systems.

Dadanco products significantly reduce the amount of primary air required to cool a commercial building. The nature of the chilled beam systems is such that each zone often has unique product configurations. Even rooms of exactly the same size have different properties – depending on their position in the building and exposure to ambient heating from sunlight or another heat source. Combining technology innovation and their unique customization approach allowed Dadanco to capitalize on a growing market opportunity and they increased their business by 300 percent in the first year of operation.

Normally, Growth is a Good Thing To keep growing at that rate, however, the company needed to overcome a bottleneck in the design department. Customization is one of their biggest selling features and often puts them over the top in a bidding war. It also means more time per unit on the design side. With business growing at this pace, the company could simply not keep up with demand.

While many of Dadanco’s HVAC units have only a couple dozen or more components, describing a custom unit requires a full set of custom component and assembly drawings as well as a bill of materials (BOM) for production which is usually outsourced. On average, a set comprises 27 sheets and takes their designer two to three days to produce. For some commercial buildings with more than thirty unit variations, that meant Dadanco was spending up to 60 days just on design.

Engineering knew that they had to speed up the process for developing specification drawings but did not want to increase payroll by hiring more people.

Identifying the Bottleneck The problem was that Dadanco had relatively few standardized Inventor templates for their product lines. They used previous drawings that were “close” to those needed for the new order and made alterations to fit the new order, including mountings, bolts, coils, nozzles, etc. This meant that for each custom product, they had to go through the entire modeling process, part by part.

We began streamlining this repetitive process by creating a prototype template with predefined sheet configurations for Dadanco’s Active Chilled Beams product line—rebuilding each part and then tying them to assembly drawings. To support their customization process, our programmers used iLogic to www.design-engineering.com

11-11-24 6:44 AM

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16 CADReport create a dialogue-driven product configurator. iLogic allowed us to implement rules-based design automation built on the experience and best practices of Dadanco’s engineering staff.

By selecting a product template and providing some details, anyone can now generate a drawing set for a custom unit.

In addition, Engineers weren’t using their design assets effectively until we trained them on the benefits Autodesk Vault for proper drawing storage and version control. Now, instead of hunting for a “look-alike” unit and using it as a base drawing, designers can leverage the dialogue box interface to call up a product line template.

The automation tool then swaps out components as necessary, including mountings, the number of nozzles and coil configurations. Now, 90 percent or more of any drawing customizations required are completed automatically.

Templates Get Them Rolling Again Removing the design bottleneck enabled Dadanco to create an entire set of shop drawings in 30 minutes instead of days. Now, they simply pull the right template and input a few details. This allows relatively few assembly templates to drive hundreds of different configurations. More importantly, the automation has allowed Dadanco to capture their years of expertise and bottle it so that practically anyone can design a custom unit.

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Along with the 3D geometry, this drawing file is automatically created as a result of running the automation tools developed by IMAGINiT.

Many companies grapple with how to ramp up production to meet demand without adding staff. To get started, I recommend making a list of those engineering tasks that are repetitive and time consuming, yet don’t contribute directly to the bottom line. Almost always, people already know where the problems are because it feels just like being stuck in traffic. Removing the bottlenecks to productivity doesn’t have to be painful, and everyone loves flying down an empty highway.

DE www.dadanco.com www.imaginit.com

Scott Hale is the Director Consulting Services, Manufacturing Services Division at IMAGINiT Technologies.

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18 CoverStory

Game Changing TEChNoloGIES

As the world grapples with energy issues, Canadian engineering researchers are closing in on technologies that may hold the solution.

By Mike McLeod

W

hen Thomas Edison invented the first functional light bulb in 1879, and later helped popularize it as a replacement for gas lighting, little could he have imagined the world his vacuum-sealed, electrically heated filament would usher in. Workdays grew longer, night-time leisure activities expanded (at the cost of sleep) and, by 1950, electrically powered machines had transformed nearly aspect of people’s day-to-day lives.

One hundred and thirty years later, the world is struggling to cope with the consequences of pervasive electric power consumption. The issues of growing power demand, dwindling resources and global warming plague most industrialized nations and emerging economies. Into this fray, a few standout Canadian innovators are looking to change the game again, either in the way energy is produced, consumed or in coping with the consequences of having generated it in the first place.

Nano-Tech Solar Cells While silicon-based solar panels hold the potential as a near limitless renewable energy source, they do have their limitations.

For one, the efficiency of typical panels persists at less than 20 percent and, although the cost per watt continues to decrease, building solar farms large enough to replace fossil fuel plants is still too expensive.

UofT’s Tandem Colloidal Enter Professor Ted Sargent, Quantum Dot technology holds and his University of Toronto the promise of cheap and near team, who announced the first ubiquitous solar power. efficient and cost effective tandem solar cell based on colloidal quantum dots, this year.

That discovery holds tantalizing promise for the future of solar for three primary reasons.

The first is that the nano-sized crystals in CQD cells can be variably sized, allowing them to be tuned to specific light wavelengths, including the infrared. This property allows them to November/December | 2011

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convert energy from a wider spectrum of available light.

Also pivotal was the discovery of an effective way to couple multiple layers of CQD together. While other researchers have produced tandem CQD panels previously, the UofT team engineered nanometers-thick materials that allow electrons to efficiently shuttle between the visible and infrared layers. As a result, compared to the 31 percent theoretical limit of conventional panels, tandem CQD panel tap out at 42 percent and could go higher still, as more layers are added.

Most importantly though, Sargent and his team have developed an inexpensive method for manufacturing Tandem QCDs. In fact, they don’t need to be fabricated as panels at all but could be sprayed on, like paint or ink, opening the possibility of turning any surface—billboards, car body, cell phone case—into a power source.

At present, Sargent’s work holds the efficiency record for QCD technology at 5.6 percent. While that may seem low, he foresees reaching the commercially relevant milestone in the next three to five years. “If we can get above 10 percent, because our costs are so low, I think we have something really interesting,” Sargent says. www.light.utoronto.ca

Internet-Connected Electric Socket Within every residence, commercial building and manufacturing facility lurk energy “phantoms” that waste electricity, many times without anyone being the wiser. Although they may see large hydro bills at the end of every month, most consumers have no way of determining how much power their appliances use or which are the least efficient.

Individually, those small inefficiencies don’t account for much, but multiplied by the number of household across a nation or even major city and the cumulative wastage of power, plus the pollution created to generate it, is massive, says Ron Dembo, CEO of Toronto-based Zerofootprint.

“I could walk into just about any home and immediately identify where about 15 percent of the electricity usage is wasted on appliances that aren’t even on,” Dembo says. “For example, take the 160 million DVR, set top boxes and the TVs they are attached to in the United States and multiply that by about 500 watts. That will give you the amount of watts used www.design-engineering.com

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CoverStory 19 just to keep the electronics ‘warm’ so they turn on instantly when you get home.”

To combat the problem, the company has developed a network-enabled electric socket called the TalkingPlug that actively monitors how much power appliances and other devices consume and communicates that information, in real time, to consumers. In addition, via the company’s ZeroMeter software or companion smart phone app, TalkingPlug users can turn individual lights, HVAC systems or ordinary appliances on or off anywhere they can get an Internet connection.

The system works through a series of sensors and transmitters packed into the TalkingPlug’s ordinary looking outlet housing. Cheap Radio Frequency Identification (RFID) tags, attached to plastic sleeves that slip over a gadget’s electrical plug, beam identification information to the TalkingPlug.

The smart-outlet monitors the continuous current flowing to that appliance and transmits the information to a typical wireless Internet router. The information is then processed

by Zerofootprint’s servers and displayed in the ZeroMeter software, where individual appliances, along with their current power usage, are displayed sequentially. To cut the power to an energyhogging appliance remotely, users can simply highlight the it and click a power button.

At present, Dembo says the cost per unit of the TalkingPlug is too high to market as a consumer product. Instead, The TalkingPlug, the company sells to large quantity buyby Toronto-based ers but he estimates the product will hit Zerofootprint, actively store shelves by 2012 once volumes bring monitors the electricity use manufacturing costs down. of individual appliances.

www.zerofootprint.net

Co2 Capture Although the identifiable consequences of greenhouse gas emissions remains a contentious issue, the fact that CO2 levels are steadily growing annually is hard to deny. According to the World Meteorological Organization—the U.N.’s weather agency—2010 figures show CO2 levels are now at 389 parts per million, 39 percent higher than at the beginning of the Industrial Revolution.

More importantly, that number is quickly approaching the 450 parts per million level at which climate disruptions will significantly worsen, researchers say. In fact, the Keeling Curve, a 50-year-old record that tracks monthly atmospheric CO2 levels, predicts the Earth will zip past the 400 ppm mark by 2015 on its way to 450ppm by 2040, if not sooner.

Of course, the best way to deal with CO2 is to capture it at the source. However, more than half of yearly emissions are from mobile sources—including cars, airplanes and residences—making it hard to ameliorate. www.design-engineering.com

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A rendering of Carbon Engineering’s air contactor, part of a system to scrub mass amounts of CO2 from the atmosphere.

Calgary-based Carbon Engineering may have a solution.

Since 2009, the company has been developing a process to remove CO2 in large quantities directly from the air. The system works similar to an evaporative cooler or cooling tower but also leverages chemical processes commonly used in the pulp and paper industry.

In the first stage, large fans in what the company terms an air contactor draw air through a corrugated membrane saturated with sodium hydroxide. Atmospheric CO2 dissolves in the hydroxide to produce a sodium carbonate solution. In the second stage, the carbonate solution is pumped to a recovery system where it is mixed with slaked lime to precipitate limestone. These particles are then heated in a kiln to release pure, compressed CO2 and recapture the slaked lime.

At present, the company is optimizing the air contactor design and recovery chemistry at a small test installation on the University of Calgary campus. According to Geoff Holmes, a research engineer with Carbon Engineering, the company’s next phase will be to build a large-scale test facility, like that shown above, capable of extracting 10,000 tons of CO2 per year. Ultimately, the plan is to build a full scale commercial facility composed of several air contactors capable of more than a million tons annually, an amount equivalent to taking approximately 300,000 cars off the road for a year.

The company isn’t pursuing CO2 capture just for environmental stewardship alone. It plans to sell the compressed gas to major customers, the biggest of which may be oil companies, says Holmes. Through a process called enhanced oil recovery (EOR), CO2 is injected into reservoirs to extract so-called stranded oil, which is unrecoverable by conventional means.

In the process, the CO2 is stored underground. If the greenhouse gas can be extracted from air economically, the business potential could be enormous, as estimates put the amount of stranded oil in the U.S. alone at 100 billion barrels.

At present, the cost to produce compressed CO2 from Carbon Engineering’s method hovers somewhere between $200 and $300 per ton. That cost will have to come down to around the $50 to $100 per ton for its extraction to become a viable business model but Holmes says the company is presently working on an improved chemical process that will significantly cut facility and maintenance costs.

DE www.carbonengineering.com November/December | 2011

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20 MotionControl

Stepping Up Field Oriented Control boosts stepper motor performance to servo levels.

By Mark McCann, B.Sc. Electrical Engineering

W

hile there are many well known advantages to using a stepper motor—including long life, safety, low speed torque and affordability—the more expensive AC synchronous motor (servo motor) is often specified for high performance motion control applications where high levels of speed and/ or position accuracy are required. However, Field Oriented Control (FOC) can bridge this divide and provide an accurate and cost effective solution.

Also known as Vector Drive, Field Oriented Control was the answer for one of our clients, an Ontario-based automated food sorting and grading company that needed a system for a very demanding application with a large inertia mismatch.

Current feedback and the ability to stop on position, fifteen times per second, were critical to achieving their system requirements. The focus for this application was on a 2-phase, permanent magnet stepper, although the theory can, in gen-

eral, be applied to all stepper variants.

A typical 2-phase stepper motor has fifty magnetic poles on the rotor. These poles lead to detent torque, or cogging, which cause undesirable effects on motion speed and positioning as the discrete step tends to snap the rotor from one position to another. Stepper motors provide high torque at low speeds; however, torque speed curves do show a significant decrease in torque at higher rotational speeds.

The more expensive AC synchronous motor has four or eight poles, produces a flat torque line that extends to high speeds and has little issue with vibration or resonance. By implementing Field Oriented Control, we can provide an affordable solution that provides both smooth motion at slow speeds and is efficient at high speeds.

A key aspect of Field Oriented Control is that, to maximise torque, every rotor position has an optimal magnitude and direction of the stator net magnetic field. FOC requires current feedback from both phase windings in the stepper as well

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MotionControl

21

Figure 1: Stator net magnetic field and associated current vectors

as accurate position feedback of the rotor. With this data we can calculate the optimum magnetic field magnitude and direction for the given rotor position (see figure 1).

The application of FOC results in more accurate torque control, higher efficiency and the ability to control stator flux direction and magnitude independently. It also produces good transient and steady state control of the motor, all resulting in smooth and accurate motion. Although a current sensor is required, this is easily realized by placing a low resistance resistor in series with the motor phase winding. Reading the potential drop over the resistor indicates the winding current.

In order to achieve their strict requirements, our client had tested 48V motors but were unsatisfied with the result.

By implementing Field Oriented Control, we were able to run

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at 24V, which was important for their machine certification requirements. They were also able to use a NEMA23 frame size motor, which was critical to their machine design in that they were limited to a very small space envelope.

While Field Oriented Control does add some costs to the motor, it will allow for a smaller motor, use less voltage and run cooler—saving time, space and energy.

DE www.myostat.ca

Mark McCann is the Lead Design Engineer at automation solutions provider, Myostat Motion Control. During his eight years with the company, Mark has worked on hardware, electronic circuit design, software, microcontroller firmware development and windows application programming.

November/December | 2011

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22 PowerTransmission

How to Specify Custom

LEADSCREWS Successfully specing custom components requires forethought and a flexible supplier.

By Tom Solon

F

or many designers and engineers accustomed to the constraints of standard configurations, exploiting the benefits of a custom lead screw can be challenging. Here are some suggestions to help get the most from a custom design.

From a manufacturer’s perspective, a custom lead screw is one that is manufactured to the customer’s specification rather than the manufacturer’s specification. It’s obvious then that the first step is to create a specification for the component you want. But unless you are intimately familiar with the range of customization possible, the best place to start is with a performance specification.

This should include considerations such as how far, fast and precise the motion should be as well as how much load will be involved; the nature of the environment (e.g. temperature, moisture, cleanliness); and where the component will be placed. Other factors include life expectancy of the component; how many will be needed; budget unit price and when they are needed.

With as many of these parameters defined as possible, intelligent choices can be made. An analysis of speed, loading and duty cycle will enable material selection based on limiting PV and friction. Environmental conditions will also impact material selection with respect to corrosion risk, chemical and thermal compatibility. Quantity, budget and timing will influence manufacturing methods and tooling investment. Following are some examples of the way requirements can drive customization.

There are different degrees of custom. Learn to recognize the differences. A custom solutions supplier challenges you to answer the question, “What if…”

What if cost was no object, what would the “perfect solution” look like? What if there was no friction, what would the motion profile be? What if the screw could be as long or short as you want? What if the nut could be any shape or size? How can the device work better? How can assembly be easier or use fewer November/December | 2011

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This custom assembly from Haydon Kerk Motion Solutions, includes the lead screw and nut, along with guide features, motor and drive. The guide system is also a structural aluminum rail.

parts? Answering these questions helps define the solution.

Customization of lead screws may include any of these common elements: • Special machining of the screws for bearings, couplings, pulleys, etc.

• Special machining of the nuts for mounting features, size constraints and performance enhancements • Custom injection molded nuts incorporating added functions • Special materials for screws and/or nuts • Special leads and thread forms • Incorporation of guide features • Integration with motors • Consolidation adds value An important step down the path to a custom solution is an evaluation of the next level up. This means looking at all the components connected to the lead screw. It’s often possible to turn the components attached to the nut into the nut itself. Integration with motors and guides is a real opportunity to save space, reduce component count, simplify assembly, and lower total cost. Here are questions to answer: • How will the screw be supported?

• How will the screw be driven?

• What will attach to the nut?

• How can the lead screw assembly be utilized as a structural element?

The answers to these questions will reveal opportunities.

For example, rather than attaching a nut to a carriage, the carriage, nut, guide bushings and sensor flags can all be a single component. Or by utilizing a lead screw as a stressed element, it is possible to simplify a frame structure. Or a nut www.design-engineering.com

11-11-24 6:43 AM

PowerTransmission can incorporate the features of a timing pulley or gear. Or using an integrated, motorized axis rather than an assembly comprising a lead screw, nut, bearings, coupling, and rotary motor; this can even extend to incorporation of a complete guiding structure. Any of these strategies will reduce part count and assembly time. Not only is this a good value, but in many cases, the actual component costs are reduced.

How to “go custom” The challenge will be to initiate the design phase with these expectations and goals. Again, the keys to success are imagination and avoiding constraints at the outset. Here are some common misconceptions: • Custom nuts always cost more.

• Custom parts have long lead times • Injection molds only make sense for huge quantities • An assembly of specialized parts will out-perform an integrated solution • Prototyping custom parts is cost prohibitive Many people have formed these opinions from experiences, so it would be misleading to suggest that all manufacturers are equally positioned to provide custom solutions. But it would be equally misleading to suggest that there is a penalty

23

to be paid to get an optimized product. CAD/CAM, CNC machining, rapid prototyping and lean manufacturing principles allow the same volume-manufacturing processes to be used for moderate runs of custom products. Most manufacturers will claim to offer custom product but there are some simple questions that will reveal the companies who understand and deliver true custom solutions: • Does the company actively promote customization?

• Does the company have strong applications engineering support?

• Are lead times for custom parts similar to those for standard configurations?

• Does the company control manufacturing or simply repackage available components?

Look for attention to the performance specification, not just a part number. Each company has their strengths and weaknesses but all contenders will exhibit a similar approach to product definition. Finding the right partner will provide both high performance and good value. There is no need to settle for off-the-shelf.

DE Tom Solon, PE is an engineering manager at Haydon Kerk Motion Solutions.

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24

Materials

Getting It Right, The First Time Markham telecom firm relies on Quebec’s Vicone to ruggedize outdoor equipment.

D

esigning equipment to stand up to the harsh conditions of a factory floor requires exacting care to shield sensitive components from dust and moisture. However, when the end use of that equipment requires it to be exposed to the elements 24 hours a day for decades without failure, the stakes and component requirements are that much higher.

For Markham, Ontario-based Redline Communications, those considerations are particularly important due to the sensitive electronics of their outdoor systems. The company is a leading producer of specialized outdoor wireless broadband radio systems and its customer base is a who’s who of large enterprises, telecom service providers and government departments across the globe.

Redline’s products are recognized in the industry as being powerful, versatile and reliable. Ruggedized, submersible and marine-ready, the products deliver uninterrupted coverage in harsh weather conditions and in the most challenging urban and industrial environments.

Their performances speak for themselves with an industryleading 29-year Mean Time Between Failures (MTBF) and the lowest documented field failure rate (0.3 percent), which assures maximum uptime from the first minute of service.

“A swift design cycle and production ramp-up is imperative to respond to the evolving telecommunications market,” says Mark Bassett, director of mechanical engineering. “Not having the latest technology equals a sale lost to our competitors. When selecting component providers [for the RedMAX SC-1000, RRH], it is essential that they have first-hand experience, in-depth technical knowledge and the ability to deliver parts on time.”

There were two critical design considerations when developing the RRH, part of the award-winning RedMAX SC-1000 system, a multi-application base station platform. The first was to ensure that the enclosure components met the extreme demands of an outdoor environment; the second, that they would withstand the detrimental effects of transportation vibration. Add to this the need to have the mechanical aspects completed within 24 weeks. Redline’s supplier selection became key to the project’s timeline and success.

“We have specified Vicone as a preferred vendor for our rubber parts,” says Bassett. “They have consistently produced high-quality tooling and trouble-free parts that meet our tolerance standards. Vicone identified and supplied the appropriate material that would meet our demanding specification of a non-standard durometer.”

The tight delivery and timelines also created a unique chalNovember/December | 2011

24 Materials.indd 24

lenge for Vicone. The project required a grouping of three separate moulded articles. Moulds had to be modified rapidly and precisely to get all production parts delivered on time and at the same time.

“Understanding our clients’ technical needs is critical,” says Eric Leclair, president of Vicone. “This project had very specific environmental demands. We had to ensure that the selected material would maintain its inherent properties in spite of the challenging climate demands.”

Markham-based Redline Communications relies on Vicone rubber to help ensure the 29-year MTBF of its outdoor wireless communications systems.

“In our experience, we often found that the choice of material for a specific application may not be optimal and that replacing it with a different material can significantly boost performance,” Leclair adds.

Intrinsic to the success of this project was that the components did not require any tooling revisions or material rework. The product passed the water immersion test (IP67) without issue and the gasket design provided uniform loading on the sealing surfaces. There were no typical product release delays attributed to seal failures. A failed environmental seal can set a project back by four to six weeks, since testing can only be performed after the product is built in its entirety.

“Our production parts from Vicone are always in accordance to specification and, as a result, require minimal support from our quality control staff,” says Bassett. “With Vicone, I am very confident that the parts will be made right the first time and delivered on time.”

DE www.viconerubber.com www.design-engineering.com

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DMR_

This article supplied by Vicone High Performance Rubber Inc.

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26 LinearMotion

An Open and Shut Case Ontario-based steel fabricator solves linear motion challenge.

H

azards lurk around every process equipment design and manufacturing decision. Since not “sweating the small stuff” sometimes backfires, design engineers are wary of simple solutions. Yet, finding a way to make the job easier is the implicit desire of any good design engineer.

That was the case for custom stainless steel equipment fabricator, Pure Ingenuity Equipment Design & Fabrication Group (Formerly E.K. Purdy Ltd.) The Kingston, Ontariobased company manufactures stainless steel processing equipment for the production of well-known brands in the food, cosmetics and pharmaceutical industries around the globe, including Kraft, Nestle, Parmalab, Pfizer, L’Oreal and Clairol, among others.

A solid model of Ontario-based Pure Ingenuity’s 200L jacketed and insulated kettle for cosmetics. The kettle’s 60-pound lid is raised by rods controlled by linear flange ball bushings.

In 2002, Pure Ingenuity was approached by a Kingston, Ontario-area manufacturer that had been ordering lipstickmixing equipment from Italy. When Pure Ingenuity proved it could design and build a jacketed and insulated stainless-steel kettle for cosmetics, Italy lost the business.

This process equipment is specifically for lipstick-making components placed in the kettle. As an agitator runs, the kettle is jacketed with an oil bath to melt the ingredients. Once mixed, the liquid lipstick is dispensed into the molds at the bottom.

During this process, the machine operators need to lift the lid four or five times a day to add ingredients or inspect the process. Since the lid is twenty-four inches in diameter and made of stainless steel, it is quite heavy—weighing fifty or sixty November/December | 2011

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pounds. Therefore, lifting the lid the 20 inches required has to be done mechanically using rods that raise the lid along with the mixing paddles that are attached to it.

Solving a Vertical Challenge After considering alternate solutions, Pure Ingenuity decided against bearings that required a great deal of time and effort to mount and they certainly didn’t want to have to make their own housing to mount a bushing.

They decided on the linear flange ball bushing so that they could just bore a rough hole, tap it, and then bolt the linear flange ball bushing down to the top of the base that the tank is mounted to. Because the bushing is supported by the linear flange, the bore-through hole – the main hole that the bushing slides in – doesn’t need to be accurate or tight against the bushing, so the machining is much easier.

“We needed a bearing to help us move a couple rods up and down that could bear the weight of the lid,” explains Steven Dean, a project manager with Pure Ingenuity. “The linear flange ball bushing we chose does that. We use two bushings to raise the lid. We started using it about eight years ago. In all these years, we’ve not had to replace them in our customers’ kettles.

The linear flange bushing is easy to work with. You might say, compared to mounting a non-linear flange bearing, that they are effortless.”

RotoPrecision Inc., a Canadian specialist in precision linear motion products and design, helped Pure Ingenuity specify the SWF 20 GWUU manufactured by the NB Corporation of America. The linear flange ball bushing they chose is about four inches and can travel 30 inches for clamping. It’s a linear flange double-wide bushing with resin retainer that has seals on both sides.

Synchronizing Movement The two ball bushings in one cylinder give it the strength and uniformity of movement needed to handle the weight of the heavy lids. Uniform movement keeps the movement smooth and prevents shaking and rattling as the lid goes up and down.

For the ultimate in vertical movement precision, some companies, such as those that manufacture measuring tables, use four linear flange ball bushings – ensuring complete rigidity. But, the linear flange bushing advantage for measuring tables isn’t the weight they can bear; it’s their accuracy. An uneven measuring table won’t yield accurate measurements.

All four sides have to be going down equally to be able to measure precisely. This is also why linear flange ball bushings are frequently specified for mating molds for injection molding machines and moving stamping die sets. For these applications, www.design-engineering.com

11-11-24 6:42 AM

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28 LinearMotion linear flange ball bushing precision is critical.

If Pure Ingenuity eventually designs a larger jacketed and insulated kettle with, say, a one hundred pound lid, the triple wide cylinder with the additional space between its two bushings would be the linear flange ball bushing for the job. It can handle extremely high moment loads.

1200 Choices Bushings are, typically, sized by bore/shaft diameter. In NB’s line of twelve hundred linear flange ball bushing combinations, the smallest inner diameter – which dictates the shaft diameter to be used – is 6mm. NB bushing inner diameters are precisely controlled to eliminate unwanted clearance between shaft and bushing. The inner diameter is controlled from zero to 5 microns or larger depending on the size.

NB linear flange ball bushings range in size from 19mm in length up to 310mm. Single, double-wide, triple-wide or center mount configurations are available. Linear flange types are available in inch, Asian or European metric dimensions.

NB also offers the “Fit Series” because choosing proper “linear shafting” is critical. The Fit Series is a combination of NB shaft and NB ball bushing as a set, appropriate when customers don’t have to use their own shafting. Both NB supplied linear flange bushing and shaft are precisely controlled to fit together. This

In total, NB Corporation offers 1,200 linear flange ball bushing styles, ranging in size from 19mm in length up to 310mm.

avoids mismatches such as using a non-hardened, non-linear grade shafting that would not take advantage of NB ball bushings’ precision. The Fit Series assures customers that their shaft and bushing combinations’ fit tolerance is precise. This is essential since, if shaft diameter is not properly fitted to a ball bushing’s inner diameter, the motion control will not be accurate.

DE www.rotoprecision.ca

Linear Rail Linear Rail Systems Systems

SBC SBC

Montreal Phone (514) 685-6006 montreal@ringball.com Montreal Phone (514) 685-6006 montreal@ringball.com Vancouver Phone (604) 294-3461 vancouver@ringball.com Vancouver Phone (604) 294-3461 vancouver@ringball.com

November/December | 2011

26-28 linear.indd 28

Winnipeg Phone (204) 694-1455 winnipeg@ringball.com Winnipeg Phone (204) 694-1455 winnipeg@ringball.com Edmonton Phone (780) 465-3311 edmonton@ringball.com Edmonton Phone (780) 465-3311 edmonton@ringball.com

Linear Rail System Ball Screw Linear Rail System Support Unit Ball Screw Linear Bushings Support Unit Cross Roller Guide Linear Bushings RobotRoller Carrier Guide Cross Guide LinearCarrier Actuator Robot Guide Linear Actuator

www.ringball.com www.ringball.com

Toronto Phone (905) 826-1100 toronto@ringball.com Toronto Phone (905) 826-1100 toronto@ringball.com

www.design-engineering.com

11-11-24 6:42 AM

IdeaGenerator 29 Electrical Power Supply Pepperl+Fuchs has added four new power supplies to the company’s family of K- and H-System intrinsic safety solutions. Singlechannel KCD2-STC-Ex.1ES and KFD2-STC4Ex1.ES power supplies are assembled to the 35 mm DIN mounting rail with power rail. HiC2025ES and HiD2025ES transmitter power supplies are mounted on prewired termination boards. These modules provide internal diagnostics information using a single failure signal and are designed for intrinsically safe applications up to SIL 3 according to EN61508. KCD2-STCEx.1ES and KFD2-STC4-Ex1.ES modules measure 12.5 and 20 mm wide, respectively, and offer active and passive 4…20mA output signals as well as 1…5V for the control level. The HiC2025ES and HiD2025ES transmitter power supplies are 12.5 and 18mm wide respectively and are both compatible with existing termination boards in the system. www.pepperl-fuchs.us

Voltage-to-Frequency Converters WAGO Corporation introduced two new 0–10VDC 859 series Voltage-toFrequency Converters that provide output frequencies of 0–1.5KHz or 0–25KHz for pulse generation.

WAGO’s VFCs mimic motor encoders to generate pulse inputs for controlling lighting or machine speed. The two 859 Series VFCs can be factorytuned to a customer-specified frequency within three ranges: 0–1.0KHz, 0–1.5KHz or 0–25KHz. Based on WAGO’s industryproven 859 Series Relays, the VFCs employ CAGE CLAMP Spring Pressure for connections that resist vibrations and current-induced temperature cycling. Operating temperatures range between 0°C to +40°C. www.wago.us

IEC Contactors and Overloads Carlo Gavazzi introduced its range of IEC contactors, overloads and accessories. The CC Series Contactors are available in eight frame sizes, ranging from 25 to 900Amps AC1 (up to 600 hp at 480VAC). Contactors are available with a selection of AC and DC coil voltages, choice of screw or lug terminals on larger contactors, dual coil terminals for easy looping and at least one set of auxiliary contacts. Matching GT Series Bimetallic Thermal Overloads provide class 10 trip protection for motor loads. Standard features include a set of auxiliary contacts, test button and manual or automatic reset www.design-engineering.com

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direct mounting or an optional separate mounting bracket. More advanced motor protection is available with the CGE Series of electronic (overload) motor protection relays. www.gavazzionline.com

Power Supply SolaHD has extended its line of SDN-C series power supplies by introducing 5 amp SDN (5-24-480C) and 10 amp (SDN 10-24-480C) three-phase DIN rail models. Combining a small footprint with high efficiency, the new units take up approximately 32 percent less space along the DIN rail than previous generation models, plus generate far less heat, the company says. They also offer sag immunity, power factor correction and universal voltage input. In addition, the units feature diagnostic LEDs to show input and output status and come equipped with standard screw terminal connections.

The metal outer case delivers full power in a temperature range from -25°C to +60°C. www.solahd.com

Fluid Power Pnuematic linear actuator Festo introduced the CDNA, expanding its range of pneumatic linear drives. Manufactured in Canada, the actuator features anodized aluminum construction and nitrocarburized tie rods and gland. It comes in configurations from 1-1/2-inch to 12-inch bore sizes and stroke lengths from 0.125 inch to 120 inches. Additional features include dual rod and dual piston seals, flexible end position cushioning and NFPA interchangeability. www.festo.ca

Air Process Circulation Heaters Omega’s new AHPF series heaters are used to heat low flows of air, gas, water, or aqueous solutions with air/ gas flow up to 15 CFM and air/gas out temperature up to 430°C (800°F). This 316 Stainless Steel constructed heater can handle pressures up to 100 psi and 50 watts per square inch. Applications include those where clean air is necessary, as in laboratories, environmental testing areas, packaging and sealing. The heaters are designed for the automotive, petroleum and manufacturing industries. www.omega.ca Novemember/December | 2011

11-11-24 2:21 PM

30 IdeaGenerator Duplex Filter Schroeder Industries introduced its RLD Series Top-Ported Duplex Filter for return line applications. Constructed of lightweight aluminium, the filter integrates a pressure equalization valve allowing switch flow from one filter to the other, so element change out can be performed with virtually no service interruption. The RLD Series is offered in two element lengths in either synthetic Z-Media or metal mesh media. The filter housing has standard Viton seals, as well as upstream and downstream pressure ports. It can sustain pressures of up to 350 psi and flows up to 100 gpm. www.schroederindustries.com

Piston Valve The Fluid Control Division of Parker Hannifin introduces an enhanced model of its 810 Series Angle Body Piston Valve that features stroke limitation while maintaining the standard optical valve position indicator. The product line includes valves with up to 3-inch port connections, has temperature rating options up to 430°F (221°C) and features various-sized metal actuators that meet operating pressure ratings of up to 580 psi (40 bar). The valves are constructed with 316L stainless steel or bronze bodies and come standard with NPT porting; other connection options are available. www.parker.com

Large Air Nozzle EXAIR introduced its 1 NPT Stainless Steel Super Air Nozzle that delivers 6.6 pounds of strong blowing force. The aerodynamic design of the 1 NPT Stainless Steel Super Air Nozzle directs compressed air to a single point of convergence, delivering a concentrated stream of high velocity airflow with hard-hitting force. Safe operation is assured since the airflow cannot be blocked (as required by OSHA standard 29 CFR 1910.242(b)). At 80 psig, the air consumption is 135 scfm and the sound level is 99 dBA, meeting the OSHA standard for two hours of use per day without hearing protection. www.exair.com

Motion Control AC Drives Rockwell Automation has extended the power range of its PowerFlex 755 AC drives to 900 kW/1350 hp and added 600/690 volt ratings. Like all PowerFlex 755 drives, this latest frame size includes an embedded Ethernet port and five option slots. Option modules include I/O, feedback, safety, additional communications and an auxiliary power supply. In addition, a firmware upgrade provides interior permanent magnet motor control and a “Stop Dwell” feature. Rockwell says the next version of RSLogix 5000 software will include a feature that automatically configures the drive upon installation. www.ab.com

DesignSolutions Clippard Offers Miniature Pneumatic Products Catalog for Scientific/Medical Applications A leader in miniature pneumatics, Clippard provides the scientific/medical industry a variety of products and solutions. The product range is illustrated in a color brochure featuring the most complete line of miniature fluid power products for the medical, pharmaceutical analytical and dental fields. To get your copy today please visit our website at the address printed below.

Contact: sales@clippard.com Visit us at: www.clippard.com/scientific-a

Shock Absorbers plus New Gas Springs ACE Controls catalog features deceleration and motion control products. Includes: industrial, safety, PET & GLASS industry shock absorbers, feed controllers & hydraulic dampers.

Also includes: AGS Gas Springs providing counterbalance motion control for lifting and lowering lids, hoods, hatches, panels and more. Made in USA. Contact: shocks@acecontrols.com Visit us at: www.acecontrols.com

To advertise your solution in this section call Alan Macpherson at 416.510.6756 Novemember/December | 2011

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www.design-engineering.com

11-11-24 2:21 PM

IdeaGenerator 31 Stepper Motor Controller Haydon Kerk Motion Solutions has introduced its RoHS compliant PCM7539X IDEA programmable stepper motor drive capable of a 75VDC input voltage and a max output current of 3.85A RMS. This unit is designed to control the company’s larger-size stepper motor linear actuators, particularly its size 23 and size 34 units. Like all Haydon IDEA drives, the PCM7539X is fully programmable with a patent-pending graphic user interface.

The drive features programmable current control, 8 digital I/O points and memory for up to 75 stored motion control programs. www.idea-drive.com

Motion Coordinator Trio Motion has expanded its Motion Coordinator range with two new motion and machine controllers based on the latest 533MHz ARM11 processor. The MC403 will control two servo axes with a master encoder input, or three stepper axes. The MC405 has a choice of four servos plus a master encoder or five step and direction axes. The 6MHz servo encoder ports are selectable for incremental linear or rotary feedback. The maximum stepper output frequency is 2MHz. Any combination of servo and stepper axes is possible. The controller features clock frequency of 533MHz, a servo update rate from 125 to 2,000 microseconds and a maximum data table size of 512K. In addition, the double floating point precision processor delivers servo loop accuracy with 64-bit real-number mathematics and 64-bit integer position registers. www.triomotion.com

Single-Axis Controller Galil Motion Control rolled out the latest generation of its DMC-300xx Pocket Motion Controller Series, which combines a single-axis Ethernet motion controller and a 800 watt sine drive. Using a 32-bit RISC processor and improved power technology, the DMC-300xx is twice as fast as the previous generation, the company says, with a 125 microsecond servo loop update time.

Other features include PID compensation with velocity and acceleration feedforward; non-volatile memory for user programs, multitasking for simultaneously running up to four programs, and I/O processing for synchronizing motion with external events. Modes of motion include point-to-point positioning, position tracking, jogging, contouring, electronic gearing, ECAM, and PVT. www.galilmc.com

Remote HMI access AutomationDirect launched its C-more remote HMI application for the iPad, iPhone or iPod touch. Available through the iTunes App Store, the app requires a C-more panel with remote connectivity but isn’t dependent on third party remote desktop VNC-type applications.

Multilevel logon security is provided for up to three remote access user accounts that are configured and stored in the panel project. Multilevel access control allows each of the user accounts to be configured in one of three levels of access: full control access, view only access and view and screen change only access. http://c-more.automationdirect.com www.design-engineering.com

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IdeaGenerator Motors Brushless DC Motors Ametek unveiled its ROTRON 64 Frame brushless DC condenser and evaporator motors designed as drop-in replacements for most existing brush DC motors up to 2.0 hp. Both the condenser and evaporator motors are environmentally sealed and electronically protected to resist hot water spray, rain, humidity, salt, fog, shock, and vibration. The condenser motors can achieve torque up to 24 lb-in. and speeds up to 2,340 rpm. The evaporator models can develop torque up to 32 lb-in. and speeds up to 2,800 rpm.

Both incorporate rare-earth magnets for high torque/weight ratio, provide protections against reverse polarity and voltage surges, and are sealed with O-rings as standard. www.ametektechnicalproducts.com

High Torque Actuators Wittenstein introduced its TPM+ family of actuators that integrate a servo motor and gearhead. The High Torque version of the actuator has been upgraded to match the rest of the rotary family and is capable of resisting almost any externally applied forces without yielding. According to the company, the actuator features up to a 40 percent reduction in

length and weight and 90 percent higher torsional rigidity compared to standard gearbox/motor combinations. Available upgraded sizes include the new TPM+ 010 with lengths from 183mm. www.wittenstein-us.com

Planetary DC Gearmotor Midwest Motion Products released its model MMP-D33-655D-36V GP81-019 DC gear- motor. Accepting any 36 Volt DC source, including battery power, motor measures just 3.2 inches in diameter by 11.3 inches long and has a keyed output shaft of 19mm diameter by 40mm long. The reversible gearmotor output is rated for 155 in-lbs. continuous torque, at 188 RPM, and 1,062 in-lbs. peak. Despite its compact size and weight of approximately 14 pounds, it requires 14 amps at 36 volts DC to generate its full load torque. Motor windings for 12V, 24V, 28V, 42V, 48V, 60V and 90 volts are available. The motor is rated at an IP 54 protection level for operation in harsh environments. www.midwestmotion.com

Linear Induction Motor H2W Technologies introduced its LMG-06-650-SSE, a linear induction motor (LIM) able to generate 2,900 N (651 Lb) of thrust, at a 3 percent duty cycle and operating at 400VAC, 75 Hz, with synchronous velocity

DesignSolutions DILBERT™ CONTROLCAT NEW HORIZONS® Catalog Version No. 28 Contains over 150 full color pages of state-of-the art products separated into 7 sections: Automation, Sanitary, Temperature, Electric Heaters, Wireless/Data Acquisition, Pressure/Strain/Force, and Flow/Level/Environmental. A user-friendly index is available for easy product search, economical choices, popular models and accessories. Also featured are 105 classic Dilbert Cartoons, easy ordering options including online shopping, technical assistance, and fast delivery.

Contact: info@omega.com Visit us at: www.omega.com

Clever Ideas To Improve Production Efficiency! Look to Seal Master® Inflatable Seals.

Solve difficult, awkward design problems with Seal Master® Inflatable Seals. Custom-built, fabric reinforced for strength, fully molded, these elastomeric seals and other pneumatic specialties offer flexible, close tolerance capability and resistance to compression. Use anywhere a positive seal is needed between opposing surfaces. Actuators and grippers are also featured. Design assistance is offered.

Contact: info@sealmaster.com Visit us at: www.sealmaster.com

To advertise your solution in this section call Alan Macpherson at 416.510.6756 Novemember/December | 2011

29-33 Idea.indd 32

www.design-engineering.com

11-11-24 2:21 PM

IdeaGenerator 33 of 17 m/sec. The linear induction motor is designed for high-speed operation; however, it can also be operated at stall (zero speed) in order to produce static thrust. The LIM’s 3-phase coil assembly can be directly connected to the AC line for single speed applications or to an adjustable frequency drive for variable speed control. Additionally, linear induction motors are reversible and can also be dynamically braked. www.h2wtech.com

Sensors Subminiature Shock Accelerometers Meggitt Sensing Systems has introduced the Endevco model 71M series, a family of piezoresistive accelerometers. With available g ranges of 2K, 6K, 20K and 60K, the etched silicon chip includes both the inertial mass and strain gages arranged in an active four-arm Wheatstone bridge circuit, complete with an on-chip zero balance network. The element is housed within an epoxy-sealed subminiature surface mountable package, weigh-

ing 0.06 gram, for minimized mass loading effects. The low mass, small size and unique construction of the MEMS sensing element allows for high resonance frequency, low output impedance, 3x over-range and zero damping. www.meggittsensingsystems.com

High resolution machine vision Teledyne DALSA announced its Falcon2 high performance area scan camera series. The series is comprised of three models: the Falcon2 4M, delivering 4 Megapixels at 168 frames per second; the Falcon2 8M, delivering 8 Megapixels at 90 frames per second; and the Falcon2 12M, delivering 12 Megapixels at 58 frames per second. The 8M and 12M Falcon2 cameras come with selectable aspect ratio. All three models come with embedded image processing, including FFC correction and sensor cosmetics enhancement. In addition, all Falcon2 cameras are GenICam compliant and available with a Camera Link interface. Color versions of the Falcon2 series will be available in January 2012. www.teledynedalsa.com 5000MP_3.375x4.875

Advertisers Index Advertiser

Website

Page

Automation Direct

www.automationdirect.com

Baldor Electric Company

www.baldor.com

36

Baumer Electric Inc.

www.baumer.ca

12

Beckhoff Automation

www.beckhoff.ca

11

Canadian Standards Association

www.shop.csa.ca

20

Clippard Instrument Laboratory Inc. www.clippard.com

7

9

Daemar Inc.

www.daemarinc.com

25

Encoder Products

www.encoder.com

28

GTC Falcon Inc.

www.gtcfalcon.com

23

Henkel Canada Corp.

www.loctite.com

35

Master Bond Inc.

www.masterbond.com

33

Omega Engineering Inc.

www.omega.ca

3

Parker Hannifin Corp.

www.parker.com

17

Proto Labs Inc.

www.protolabs.com

15

Reid Tool Supply Company

www.reidsuply.com

31

Ringball Corporation

www.ringball.com

28

Rosta Inc.

www.rostainc.com

21

RotoPrecision Inc.

www.rotoprecision.ca

16

Schaeffler Canada Inc.

www.ina.com

Schneider Electric Canada

www.schneider-electric.com

www.plm.automation.siemens.com 2

Stratasys/Dimension

www.dimensionprinting.com

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www.masterbond.com Novemember/December | 2011

11-11-24 2:21 PM

34

CanadianInnovator

Submarine Lumberjack Made-in-Canada technology allows for underwater tree harvesting from reservoirs.

B.C.-based Triton Logging’s Sawfish and SHARC (inset) Harvesters salvage submerged logs, otherwise unrecoverable.

By Treena Hein

W

hen the founders of Triton Logging heard there were millions of trees still standing in hydro dam reservoirs around the world – trees that could be harvested, thereby reducing the impact of land-based logging—the idea of an underwater logging company was born.

“Having been involved in the salvage of sunken logs, we could see the potential to do water-based logging on a large scale,” says Jim Hayhurst, vice president of business development and global services at Triton, which is based in Saanichton, BC. The company was founded in 2000 with the aim of creating technology that could overcome the three biggest barriers to making underwater logging work: Making it safe for the environment and people; getting at trees sitting at depths where divers can’t work; and ensuring it’s economically feasible.

Triton’s team of engineers went to work and, by 2004, the company’s first underwater system, the Sawfish Harvester, was patented. “The Sawfish is a remotely-operated vehicle (ROV) system designed specifically for deep water operation, and based on proven components used in sub-sea industries such as oil and gas, scientific surveying and marine construction,” says Hayhurst.

“It is now being used in remote northern Canadian reservoirs, deep U.S. lakes and tropical reservoirs in Southeast Asia.”

Triton has used its next generation technology, the SHARC Harvester (which rests on a sectional barge platform) in Canada, and is now operating one in Ghana at the company’s Volta Lake concession, the world’s largest underwater logging licence.

“Triton does not sell its technologies, but uses them for its own licences and also works as a contractor for reservoir managers, utilities and governments,” Hayhurst explains. Triton is responsible for all aspects of underwater timber management, from volume/value assessments, licence formulation and environmental planning to customized harvesting, timber recovery and marketing of eco-certified wood.

Both of Triton’s systems are highly specialized. Video, sonar and GPS on the Sawfish, for example, guide a barge-based operator by way of six computer monitors. Power, communications and compressed air are delivered to the Sawfish through a tether. It uses seven manoeuvring thrusters (that leave lake beds undisturbed) and an airbag lift system that can retrieve up to 50 trees before resurfacing. Its grapple and saw are capable of cutting a wide range of tree diameters.

November/December | 2011

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Triton’s patent-pending SHARC system is a barge-mounted tree harvester designed for shallower reservoirs. “We developed it over the past two years,” notes Director of Engineering Stan Worsley, “integrating proven marine and forestry components that are standard and generally replaceable throughout the world from numerous global suppliers such as Caterpillar, BoschRexroth and SATCO.” The SHARC is equipped with three thrusters and an integrated ‘Dynamic Positioning System’ (DPS). “The DPS uses satelliteguided thruster inputs that automatically keep the SHARC stationary, allowing the operator to focus completely on harvesting trees efficiently and safely,” says Worsley. Trees are placed in floating side bunks, which when full, are towed to shore by tugboats. The unit’s telescoping boom is capable of reaching 25-meter depths, which is the depth to which the vast majority of trees are submerged in key tropical reservoirs. Subsequent versions of the SHARC will likely be built for depths up to 37 meters.

In terms of design changes over time, Hayhurst says they’ve made the Sawfish more powerful, more manoeuvrable and capable of harvesting larger trees, which involved things like adding more airbags. Similarly, the next-generation SHARC will be able to cut bigger trees at greater depths than the first.

“The biggest design challenges for the Sawfish included making it robust – traditional ROVs aren’t meant for being bashed around underwater – making it simple to pilot, and ensuring that it could harvest at any depth,” says Hayhurst.

The SHARC was challenging in that the design team had to integrate all of the systems – communication, video, sonar, navigation, cutting, retrieving – into a one-operator platform.

“This keeps costs down and efficiencies high,” Hayhurst explains.

“We also had to make it easy to ship around the world.”

Hayhurst says they will always be improving their designs as they learn. “As an environmentally-focussed company, we would also love to begin integrating other green aspects such as biofuels and solar power,” Hayhurst notes. “What excites us most is that we’re able to go to work every day and harvest beautiful wood that would otherwise be lost forever. We’re proud to be helping solve one of the world’s great resource challenges.” DE www.tritonlogging.com

Treena Hein is a Pembrook, Ont.-based freelance writer. www.design-engineering.com

11-11-24 6:46 AM

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