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16 Autodesk helps expand reach of

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24 Quebec’s InnovMetric speeds 38

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PEO elects new president

Université Laval regains Shell Eco-marathon title

DEX Expo rocks B.C.

Beckhoff relocates to new HQ

BioFuelNet, Airbus and Air Canada partner on biofuel

Queen’s researchers unveil shapechanging smartphone

Combat-ready rechargeable battery scores federal funding

Canadian inventors launch $600 3D scanner

Neptec enters 3D machine vision market

Ballard signs tentative fuel cell bus deal

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Annual Subscription Rate In Canada: $52.95 (1 year) $71.95 (2 year) Outside Canada: $99.95 (1 year) Single Copy In Canada: $10.00 Outside Canada: $22.00 Directory Rates In Canada: $27.00 Outside Canada: $45.00 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

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Contents | Volume 59, No. 3

IN THE NEWS

Columns

16 CAD Report B.C.’s Weatherhaven relies on Autodesk Inventor to design rugged portable shelters 20 CAD Beat Maple-assisted computation helps discover the theoretical Gömböc geometric shape 32 Power Transmission Miniature slides facilitate test of tiny semiconductor wafers

41 Idea Generator The latest in industrial products including power transmission, sensors and motors 46 Canadian Innovator U of T engineering grads create the “most efficient light bulb in the world”

Features 24 A Flare for Design 3D scanning and Quebec-based InnovMetric metrology software turn concept to product in record time. 28 The Future of Automotive Design? Kor Ecologic’s Urbee 2 looks to answer the question of sustainable transport.

36 The Right Tool for the Job SPIROL engineers and a custom disk spring solve DeWALT tool design problem 38 Sharpening the Axes Precisely tuned servomotor technology can boosts productivity and increase accuracy

Printed in Canada

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May/June | 2013

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6 EditorialViewpoint

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www.design-engineering.com

n May, the Harper government announced that the 100-year-old National Research Council, Canada’s center for scientific and engineering research, would be fundamentally reorganized, so as to focus its efforts away from basic blue-sky research and toward scientific investigation with discernable commercial applications. In his announcement of the NRC’s new direction, Minister for Science and Technology, Gary Goodyear, said the organization needs to return to its roots. “The realities of the 21st century economy mean that if Canada is going to continue to compete internationally, we must do it through developing new ideas and new products and opening new markets—in other words, through innovation,” he said. “By helping Canadian businesses develop and bring technically advanced products to market, the NRC is supporting the creation of not just jobs but good-quality, high-paying, long-lasting jobs. Following recommendations presented in a 2011 report by expert advisors headed by Tom Jenkins, executive chairman and chief strategy officer for OpenText, the NRC’s new entrepreneurial focus will see its more than 20 research institutes and projects consolidated into 12 business units that focus on five core areas of research: health costs, manufacturing, community infrastructure, security, and natural resources and the environment. Part of the impetus to reshape the organization stems from the fact that, even though Canada has historically spent more than other OECD countries to foster R&D, through the Scientific Research & Experimental Development (SR&ED) tax credit program, it has comparatively little to show for it. In addition, private sector R&D spending continues to lag behind that of similar industrialized nations. As a result, political leaders see the overhaul as a means to turn the NRC into the business sector’s 1-800 number for industrial-focused research. The move has drawn criticism from all sides. Many in the scientific community see it as the most recent move by a government generally hostile to science. Others liken it to a government subsidy, a bailout of SME’s unable or unwilling to conduct R&D activity themselves. While that may be true, the real problem is that this strategy puts a government-run institution in the position of acting like a for-profit business. If the intent is to drive Canadian innovation—which, by its definition, requires commercialization— then the benchmark of the NRC’s success, inevitably, will be measured in dollars and cents. As a result, the agency could easily become overly timid, taking safe bets on only “sure thing” projects deemed the most likely to show return-on-investment. Never mind that the NRC’s redirection represents a fundamental shift in its culture, but gauging which novel ideas will or won’t be profitable is the domain of entrepreneurs, not research scientists. In the end, the only companies to benefit from this new focus may well be large corporations that don’t need a research handout. What will fall through the cracks are the riskier ideas germinated in small to medium sized firms where true innovation historically takes place.

Mike McLeod

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

May/June | 2013

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Editor Michael McLeod (416) 442-5600 ext. 3231 mmcleod@design-engineering.com Publisher Alan Macpherson (416) 510-6756 AMacPherson@design-engineering.com Group Editorial Director Lisa Wichmann (416) 510-5101 LWichmann@canadianmanufacturing.com Accounts Manager Taebah Khan (416) 510-5230 tkhan@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: 0011-9342 (Print), 1929-6452 (Online) 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 ext.3552. Subscription Price: Canada: $52.95 for 1 year; $71.95 for 2 years; $10 for single copy. Outside Canada: $99.95 for 1 year; $22 for single copy. Directory/buyer’s guide: Canada $27; Outside Canada $45. 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.

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8 DesignNews Up Front PEO elects new president Professional Engineers Ontario elected Annette Bergeron, P.Eng., MBA, as its 94th president during its annual general meeting in April. She holds an honours bachelor of science, material Annette Bergeron and metallurgical engineering, from Queen’s University and a master of business administration from the Schulich School of Business, York University. She has worked as a production engineer at Dofasco Inc.; a lecturer at Queen’s faculty of applied science and engineering and Queen’s school of business; and director, first-year studies, Queen’s engineering. Most recently, she was general manager at Queen’s Alma Mater Society (AMS) Inc. She has also twice served as president and chair of the Ontario Society of Professional Engineers. www.peo.on.ca

JNE Consulting announces new president and CEO JNE Consulting Ltd. appointed John Ng, P. Eng. as its new president and CEO. Ng holds an Honours John Ng Bachelor of Science degree in toxicology along with an Honours Degree in structural engineering from the University of Toronto. As part of his recent achievements, he was recognized as the “2012 Person of the Year” at the Eighth Annual Chinese Business Excellence Awards Celebration. Ng is a licensed professional and consulting engineer in Ontario and Alberta and an active member of the Upper Canada Chapter of the Young Presidents’ Organization. www.jneconsulting.ca

Université Laval regains Shell Eco-marathon title

t the 7th annual Shell Eco-marathon Americas 2013, Quebec’s Université Laval posted the highest mileage ever achieved at the annual fuel-efficiency competition by traveling 3,587 miles on a single gallon of gasoline. This was the fourth year in the last five that the Canadian team has dominated the competition, which attracted more than 1,000 students from across the Americas. Last year’s winner, a team from Mater Dei High School in Evansville, Ind., placed second with a best run of 2,308 mpg on the track through the streets of downtown Houston. Some 131 vehicles competed this year in various categories for the $2,000 first prize, with the Université Laval achievement attaining nearly 1,300 mpg better than Mater Dei’s showing last year. “What the Laval team accomplished is truly remarkable and it underscores the long way our own cars and trucks can go to improve their fuel efficiency,” said Mark Singer, global project manager of Shell Eco-marathon. “Each year, dedicated high school and university student teams astonish us with the advances they make in achieving unheard-of fuel-efficiency improvements.” While impressive, Université Laval’s winning mark – achieved in the Prototype category for internal combustion vehicles – didn’t break the all-time record of 8,914 mpg by a French team in 2003. Besides the Americas competition in Houston, Shell Eco-marathon also occurs annually in Europe and Asia and involves thousands of students from dozens of countries. www.shell.com/ecomarathon

MaRS appoints president and COO

DEX Expo Rocks B.C.

MaRS Discovery District has appointed Euan Robertson to the newly created role of president and Chief Operating Officer. Robertson joins MaRS from the New York City Economic Development Corporation (NYCEDC), where he held the position of executive VP, and the Euan Robertson

By all accounts, the inaugural Design Engineering Expo (DEX) West held this May in Coquitlam (Vancouver), B.C. was a resounding success, surpassing all expectations leading up the to annual tradeshow. Sponsored jointly by Design Engineering and Canadian Metalworking magazines, the one-day tabletop expo featured the latest design, OEM and metalworking technologies in a one-on-one oriented venue. More than 500 local engineers, manufacturing executives, project managers, and purchasing agents toured the show during its first year in Western Canada, and the vast majority came away eager to return

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DesignNews Up Front Center for Economic Transformation, where he served as managing director. At NYCEDC, he oversaw a broad suite of programs, including investment funds, incubators, training and mentorship and advisory services. The newly created role coincides with the organization opening its Phase 2 building, which will more than double the size of its current facilities to more than 1.5 million square feet. www.marsdd.com

Mitutoyo Canada Inc. hires sales manager Mitutoyo Canada is pleased to announce the appointment of John Dewar as sales manager. A graduate of McMaster University, Dewar has 25 years of experience in sales of precision measur- John Dewar ing equipment to the manufacturing industry. For the last 15 years, he has fulfilled the role of sales and application specialist for Mitutoyo Canada covering the Southern Ontario region, working with end users and Mitutoyo product distributors. Dewar will report to Peter Detmers, who was named as vice president of sales, overseeing all aspects of Canadian sales and sales support operations in January 2013. www.mitutoyo.ca

next year. Post-event survey results showed that 86 percent of attendees planned to attend next year’s event. Not surprisingly, DEX West’s 62 exhibitors were likewise enthusiastic about the show’s performance and optimistic for its future in the Vancouver area. Nearly all survey respondents (96 percent) said they felt attendees represented a well qualified audience and that they would exhibit again at DEX West next year. “We chose to locate our second DEX tabletop show in British Columbia because we felt the greater Vancouver area was rich in small to mid-size manufacturing companies but vastly underserved by industry events designed to showcase their products and technologies to local OEM buyers and decision-makers,” said Alan Macpherson, Design Engineering Publisher and DEX show manager. “We were very pleased with the response from our exhibitors and attendees alike and we are looking forward to returning to Coquitlam next May with an even bigger show. To be sure, there are other areas of Canada similarly underserved and we plan to expand DEX over the coming years. We’re adding a show in Calgary next year and more locations are in the works.” www.DEXexpo.com

Beckhoff Automation relocates North American HQ Beckhoff Automation LLC has relocated to Savage, Minn. where the company has constructed a modern business complex with over 44,500 square feet in combined office and warehouse space. The new Savage building has more than triple the available space of its previous facility in terms of general office, warehouse and repair center space. The warehouse measures 15,000+ square feet while the Industrial PC repair center is more than 1,660+square feet. Leveraging the company’s own hardware and software for advanced building automation, the building’s lighting, heating/cooling, ventilation and window facades are all automated via PC-based control to reduce energy consumption. www.beckhoff.com May/June | 2013

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BioFuelNet, Airbus and Air Canada partner on biofuel Not-for-profit organization, BioFuelNet, has signed an agreement with Air Canada and Airbus to assess the viability of various Canadian advanced biofuels solutions for aviation. Their research will focus on diverse raw materials, such as municipal solid waste and agricultural and forestry waste, as well as a range of conversion processes available for biofuel production. “Aviation biofuels are one of the most promising ways to reduce the aviation industry’s carbon footprint, making air travel more environmentally-friendly,” Dr. Donald Smith, president of BioFuelNet and McGill University professor says. BioFuelNet was launched in 2012 as part of the Federal Networks of Centres of Excellence program, which funds BioFuelNet through a $25 million grant over five years. BioFuelNet brings together 74 leading researchers working on advanced biofuels in Canada, as well as industry partners and government, to accelerate research, development and commercialization of advanced biofuels. www.biofuelnet.ca www.design-engineering.com

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12 DesignNews

Queen’s researchers unveil shape-changing smartphone Building on its previous flexible electronic creations, the PaperPhone and PaperTab, researchers at Queen’s University’s Human Media Lab have developed a new smartphone, called MorePhone, that changes shape to signal incoming phone calls, text messages or emails. “Users are familiar with hearing their phone ring or feeling it vibrate in silent mode,” says Roel Vertegaal (School of Computing), director of the Human Media Lab at Queen’s University. “One of the problems with current silent forms of notification is that users often miss notifications when not holding their phone. With MorePhone, they can leave their smartphone on the table and observe visual shape changes when someone is trying to contact them.” MorePhone is made of a thin, flexible plastic electronics layer — manufactured by British plastic electronics firm, Plastic Logic -– bonded to an electrophoretic E Ink display as found in eBook readers. Shape memory alloy wires, sandwiched beneath the display, contract and curl the phone’s entire body, to signal an incoming call, or a individual corner, to signal a new text message or e-mail. Corners can also repeatedly bend up and down to convey messages of greater urgency, the researchers say. www.hml.queensu.ca

Canadian combat-ready rechargeable battery scores federal funding Lithium battery system maker, Panacis, announced that it has been awarded up to $613,457 to fund development of its Soldier Sharepack wearable energy storage system targeted at the defense market. The company hopes to commercialize the Sharepack to help militaries deal with the challenges of the modern battlefield. Soldiers carry an increasing number of electronic devices — from standard communications to sophisticated night vision goggles and navigation gear. With that comes the need

for an array of power sources that can weigh a combatant down. Canadian soldiers, for example, currently carry up to seven kilos of double A batteries during a mission. In contrast, Panacis is developing rechargeable battery packs that weigh less, last longer and can be used in extreme cold or hot conditions. In addition, the systems can be customized to integrate into a soldier’s clothing or weapons. Specifically, Panacis’ system is both a battery and an energy management device that uses flexible energy sharing, harvesting and scavenging techniques that allow a user’s movement and renewable sources such as solar to supplement the battery charge and provide reliable power. According to the company, the FedDev Ontario investment has helped Panacis attract another $1,226,916 in private investment from the Capital Angel Network. www.panacis.com www.FedDevOntario.gc.ca

Canadian inventors launch $600 3D scanner A pair of Toronto-based inventors, Drew Cox and Adam Brandejs, and their company, Matterform, have become the darlings of the crowd funding site, Indiegogo, with a small desktop-sized 3D scanner called the Photon that costs less than $600. “The Photon 3D scanner allows anyone to take a physical object and turn it into a digital 3D model on your computer,” says Cox, co-founder of the pair’s invention company, Matterform. “It works by shooting dual laser lines at an object as it rotates 360 degrees, taking pictures with an HD camera along the way. At a current price of $599, this is the first 3D scanner that is affordable for the home consumer market.” The small desktop unit can scan objects up to 190mm x 190mm x 250mm in about three minutes. The Photon has a resolution of 0.43mm at 0.5 degree scans, with an accuracy of +/- .2mm on a 4-inch figurine. With scanning software compatible with all major platforms, the Photon saves files to .STL, .OBJ and point cloud .PLY formats. Launched via a 35-day crowdfunding campaign on Indiegogo, Matterform surpassed its initial fundraising goal of $81,000 in a week. The company has yet to say when the scanner will be available for sale through its web site or how much the final retail price will be. http://matterform.net

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14 DesignNews Neptec enters 3D machine vision market Neptec Technologies Corp., a spin-off of Neptec Design Group Ltd., announced the launch of a line of obscurant-penetrating 3D laser scanners and a software development tool kit that features automatic change detection, object recognition and object tracking. Together, the components are intended to help OEMs create intelligent 3D machine vision applications on autonomous off-road vehicles and for laser-based survey and measurement tasks in harsh environments.

The company says its OPAL 2.0 laser scanners are designed for real-time 3D applications in harsh environments. They incorporate Neptec’s obscurant-penetrating LiDAR technology and have been packaged for the rough conditions typical of off-road vehicles and mapping sensors used in the mining, oil and gas and construction industries. In addition, Neptec says its 3DRi (3D Real-time intelligence) SDK incorporates the company’s 3D data algorithms and real-time software for automatic change detection, 3D data alignment and object recognition.

W u

www.neptectechnologies.com

Ballard signs tentative fuel cell bus deal Ballard Power Systems signed a non-binding Memorandum of Understanding with Azure Hydrogen Corporation of Beijing, China for the development of fuel cell buses. Under the terms of the deal, Azure made a $1 million up-front payment and Ballard will provide a manufacturing license agreement, engineering services, fuel cell stacks and components.

O a c •

•

Mr. Grand Mao, Azure Chairman (left) and Mr. John Sheridan, Ballard President & CEO (CNW Group/Ballard Power Systems Inc.)

Azure plans to develop fuel cell bus capabilities in China with Ballard’s technical support and funding from Chinese sources, including both private investors as well as various levels of government. If successful, the collaboration could lead to deployment of zero-emission fuel cell buses in China. Ballard fuel cell products are currently powering zero emission fuel cell buses in public transit service in more than 10 countries, including Canada, the U.S., Brazil, India, China and a number of European countries. www.ballard.com May/June | 2013

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16 CADReport

Shelter from the Elements B.C.’s Weatherhaven relies on Autodesk Inventor software to design portable shelter systems for the most rugged environments and remote locations.

ommitted to improving the quality of life for people operating in extremely rugged and dangerous conditions, Burnaby, BC-based Weatherhaven designs and manufactures portable shelter systems for organizations as diverse as NATO, scores of governments and armed forces, and hundreds of resort, exploration, scientific and geographic research companies. The company’s shelters have supported earthquake relief efforts in Haiti, military campaigns in Afghanistan, scientific expeditions in Antarctica and peacekeeping missions in the Sahara desert. In addition, the United Nations has used them for every deployment since 1990. To rapidly deliver shelters that meet the challenging requirements of these customers, Weatherhaven relies on Autodesk Inventor, as well as Autodesk Vault to reuse designs and manage iterations and revisions. As a result, the Canada-based company says it has realized a 100 percent ROI within a short time frame, more quickly produce safer products with improved transportability, and transitioned from manufacturing to a full product development firm. Field Deployment Weatherhaven’s shelters are configured to order. They can include everything from portable sleepers, field kitchens, showers and laundry rooms to gymnasiums, vehicle repair facilities and field hospitals. Given the wide range of specifications and the urgent need for shelters precipitated by natural disasters, health epidemics and military engagements, Weatherhaven adapts its products to make sure they are easily assembled, disassembled and transported, while occupying a very small environmental footprint. “We keep very little inventory, and orders need fulfilling May/June | 2013

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Designed in Inventor, Weatherhaven’s portable shelters see duty in relief efforts, military campaigns and scientific expeditions.

as soon as possible,” says Ray Castelli, CEO of Weatherhaven. “For example, when the Haiti earthquake hit, we were the first to send 140 field hospitals to assist civilian agencies in dealing with the aftermath. It’s critical that our shelters help teams hit the ground running.” Weatherhaven not only must configure and manufacture systems rapidly, but also design its systems to be mobile, redeployable and lightweight so they can be broken down, moved and reassembled with ease when an operation shifts locations. But the design challenges don’t stop there. In recent years, the design team has been tasked with innovating completely new products, helping to transform Weatherhaven from a manufacturer to a product development company. Taking Shelter A longtime AutoCAD user, Weatherhaven now relies on Autodesk Inventor to create the CAD designs of all its products, both new and configured-to-order. With Inventor, it’s easier to find problems earlier in the design process—well before manufacturing, the company says. “With a digital prototype, we can see how systems will work together,” explains Ryan Savenkoff, design engineer at Weatherhaven. “We can even drop digital models from our suppliers into our assemblies and then check for interferences. With Autodesk Inventor, we have much more confidence in our designs and know they’ll be manufactured the way we intend. Digital Prototyping has significantly cut down the time for product development from concept to manufacturing.” “Knowing that the components will work together seamlessly is a real time-saver,” agrees Graham Thompson, design technician at Weatherhaven. “It cuts down on rework tremendously.” In addition, Weatherhaven now builds fewer physical prototypes, relying more heavily on digital prototyping to put designs through their paces. “Our physical prototypes can cost www.design-engineering.com

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CADReport up to US$100,000 to build,” says Thompson. “Autodesk Inventor has already paid for itself—and then some.” Meeting one of its primary design challenges—making lighter, more mobile shelters to facilitate transportability—is now a much easier task. “Autodesk Inventor automatically calculates the weight of various parts and assemblies as we design,” explains Savenkoff. “The lighter it is, the more cost-effective it is. In fact, we can pick up a shelter from a desert location and have it re-deployed to Antarctica two weeks later.” Using the integrated finite element analysis (FEA) feature in Autodesk Inventor software, Weatherhaven can predict stress and deﬂection. Engineers can help ensure they are meeting safety requirements as they optimize the design to lower the overall assembly weight. Inventor’s sheet metal tool helped accelerate the design of Weatherhaven’s MSVS shelters.

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Tackling New Challenges Digital prototyping solidified its value to Weatherhaven when the company partnered with DEW Engineering to win a highly competitive contract with the Canadian military to replace an aging ﬂeet of military trucks with complex container-based shelters. Built on traditional truck bodies, the Medium Support Vehicle System (MSVS) shelters serve as kitchens, dentist offices, showers, washrooms, medical centers, and more. The MSVS project challenged Weatherhaven’s team to design something totally new—and on a very tight timeline. “It was a completely new kind of project for us,” says Castelli. “We had to meet very exacting specifications—and wouldn’t have been able to do it without Inventor.” Savenkoff points to the tools integrated into Inventor, particularly the sheet metal tool, as critical to making the MSVS project a success. “All the useful tools in Inventor helped us move through the design very quickly,” says Savenkoff. “For instance, with the sheet metal tool, you don’t have to spend time calculating bend radiuses. You just pick a material, style

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CADReport 19 and the length of ﬂanges and that’s it. It’s clear Autodesk has thought a great deal about how people work and how to save them time.” Within 12 months of being awarded the contract, Weatherhaven leverage Inventor’s FEA Weatherhaven had a MSVS prototype designed, and weight calculation tools to ensure engineered and tested. “We’d never done anything safety while saving material costs. that fast before, and certainly nothing of that complexity,” remarks Castelli. In addition to the initial contract, Boeing recently awarded Weatherhaven a US$5.6 million contract to modify and convert existing MSVS shelters into portable repair and maintenance shelters for Canada’s CH-147 helicopters as part of the Canadian Medium-to-Heavy Lift Helicopter Program. Even though Weatherhaven dedicates only a handful of engineers to researching and developing completely new products, the company already has made strides and billion-dollar companies around the globe. transforming into a product development company. “We’re a US$100 million company with an engineering Castelli says, “Autodesk Inventor software gives our engineers department that has fewer than 10 people, yet we’re competing the ability to build comprehensive digital prototypes to test with billion-dollar companies,” says Castelli. “With help from out a range of new products. We don’t have our good ideas Inventor software, we’re servicing some of the most sophisticated languishing on the drawing board anymore.” and exacting customers in the world. It definitely gives us a In addition, Weatherhaven is using Autodesk software to competitive advantage.” DE save time during the design phase—and to deploy its shelters www.weatherhaven.com to their rugged destinations more quickly. The result has been satisfied customers and a solid reputation with governments This article was provided by Autodesk.

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20 CADBeat

Theoretical to Practical Maple-assisted computation helps discover the mathematics-based Gömböc shape.

hen the existence of the Gömböc shape was discovered in 2007 by Hungarian scientists Gábor Domokos and Péter Várkonyi, it solved a long standing mystery. For years, mathematicians had discussed, debated and tried to prove its existence using mathematical equations. Vladimir Arnold, a Russian scientist, had conjectured its existence, but it took a decade to prove it conclusively and create the shape. The New York Times called the discovery “one of the best ideas of the year.” Like in many other mathematical developments, Maple played a role in creating the Gömböc. A Gömböc is a convex three-dimensional homogeneous body which, when resting on a flat surface, has just one stable and one unstable point of equilibrium. The Gömböc shape is not unique; it has countless varieties, most May/June | 2013

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of which are very close to a sphere and all have very strict shape tolerance (less than 0.1 mm per 10 cm). The most famous solution has a sharpened top. If you put a Gömböc down on a flat surface, resting on its stable equilibrium point, it will stay in the same position. “Even if you kick it a little, it will come back to its resting position at the stable equilibrium point,” says Domokos, one of the inventors of Gömböc. “If it is put down at a non-equilibrium point, it will start rolling around in a systematic way until it has reached the stable equilibrium position.” Difficult Proofs The invention of the Gömböc is the culmination of a long process of mathematical research and Maple, the mathematical computation engine from Maplesoft, played an important www.design-engineering.com

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CADBeat

role in its discovery. The yet-undiscovered shape was known to be a convex mono-monostatic object — a threedimensional object, which because of its geometry had only one possible way to balance upright. Domokos and Várkonyi identified a two-parameter family of objects, all of which had the desired mono-monostatic property. However, not all of them were convex. Maple was used to identify the convex objects and thus prove the shape’s existence. The process involved a large amount of complex, precise mathematical computation, and Maple’s symbolic computation power made it possible. “The final geometry of Gömböc had to be determined with great accuracy, which meant the details were critical and we couldn’t afford to miss any,” said Domokos. “Maple was very useful www.design-engineering.com

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This formerly theoretical geometric shape, called the Gömböc, was discovered, in part, using Maplesoft’s mathmatics engine, Maple.

in this regard. Using Maple made the calculations more thorough and secure; its computational power can calculate and explore very sensitive details. So it was a trusted companion in our discovery process.” Speaking of the popularity of the Gömböc and the attention it received from the scientific and mathematical community around the globe, Domokos said, “The beauty of Gömböc is its absolute simplicity. It is so simple that high school students can understand it, but it has potentially great impact on the sciences and has several applications in nature. Yet the answer was elusive for 2000 years.” May/June | 2013

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22 CADBeat Theoretical to Practical Taking their discovery into the world of natural science, Domokos and Várkonyi discovered a unique application of Gömböc among tortoises. They conducted an extensive study of tortoises using complex three-dimensional models of the shell, created in Maple. Using these models, they discovered that, of the 200 species of turtles in nature, two species had Gömböc-shaped shells. This meant that these turtles had a unique evolutionary advantage in that they had the ability to self-right. “I saw that they were acting like Gömböcs” exclaimed Domokos. Being on their back is a vulnerable and dangerous position for any tortoise. The male tortoise is known to turn over their rivals on their back in an attempt to render them helpless. So any tortoise that has the ability to get back on its belly, under gravity, without having to use its muscle, has a unique advantage, and more power. “It is the Gömböc shape of their shell that gives them this power,” observed Domokos. “This is a classic example of evolution finding the optimal shape for survival.” Continuing his research, Domokos is currently involved in studying the shape of beach pebbles. His research with Gary Gibbons from Cambridge University attempts to describe the shape of pebbles, and their evolution. They are also trying to understand the interaction between pebbles in their collective evolution. Using Maple, Domokos was able to study a system of integrable differential equations. Solving the equation systems gives him unique insights that he otherwise may have missed. He is also studying the balance of friction and collisions in the abrasion process which results in what is called dominant pebble ratios, a phenomenon that makes pebbles in a certain geographical area display similar global geometrical features. Domokos is using Maple to determine the critical friction coefficients which are responsible for the emergence of dominant pebble ratios. Understanding shapes in nature is becoming increasingly important, both on Earth and off it. Recently, NASA’s Curiosity rover sent back images from the surface of Mars that showed an ancient riverbed. The size and shape of the pebbles indicate that water flowed on Mars billions of years ago, and by studying the images of the rock, scientists will be able to learn more about the speed and size of the ancient flow of water. As Domokos continues his research into mathematical shapes and the discovery of natural and scientific phenomenon based on these shapes, Maple will continue to play a significant role in his research. “Maple is my favorite computational tool; it is simple and powerful,” says Domokos. “We are surrounded by geometrical shapes which our brains are not wired to understand. Shapes like Gömböc open a new language to understand such shapes.” DE www.maplesoft.com

This article was provided by Maplesoft. May/June | 2013

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ShopTalk

A Flare for Design 3D scanning and Quebec-based InnovMetric metrology software turn concept to product in record time.

After-market OEM Bushwacker uses 3D scanning and InnovMetric’s PolyWorks software to ensure the ﬁt and function of its fender flares and Trail Armor package for the Jeep JK.

or nearly 40 years, family-operated Bushwacker Inc. has manufactured fender flares and truck accessories for the automotive after-market. The company is committed to style, and they meticulously scrutinize every detail of each design, using the latest standards in design and manufacturing. For Bushwacker, quality can be summed up in three words: Fit, finish and style. However, OEMs continue to raise the bar for vehicle quality in terms of fit and finish, while the body style lines become increasingly sophisticated. To stay in the game, Bushwacker’s products must do the same. “Our customers expect that the accessories will blend with the vehicle’s style lines,” says Bushwacker design engineering, Sterling Logan. “And with the high-quality surfaces that automobile manufacturers produce, the slightest gap or tiniest interference with the vehicle’s style lines is immediately obvious. So we have to deliver a product with a perfect fit.” Crucial to reaching this goal is 3D scanning. After experimenting with alternative solutions and scanning services, Bushwacker acquired a top-end scanning system that includes a seven-axis Romer Infinite 2.0 arm, a Perceptron ScanWorks V5 laser scanner and InnovMetric’s PolyWorks 3D metrology software. Knowing the precise digital data of a vehicle’s surfaces allows Bushwacker to focus its talents on product designs with the confidence that they will fit perfectly. Rapid Response To highlight the rapid response time thanks to 3D scanning, Logan cited the following example. “A customer contacted us a few days before the Specialty Equipment Market Association (SEMA) show with a custom request to design a bumper guard for the Chevrolet Cruze. In a mere three days, we had prototype bumper guards, and we opened the show May/June | 2013

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with a brand-new product.” To complete the product in three days, Bushwacker scanned the Chevrolet Cruze, processed the data using PolyWorks/ Modeler and imported it into Siemens NX, on day one. On day two, they designed the bumper guard and machined a prototype mold. On day three, the parts were manufactured and flown to the SEMA show. In its earlier years, Bushwacker designers would have applied clay to the vehicle and painstakingly sculpted it to the desired design. The resulting shape was then transferred to wood templates so the styling could be replicated in clay on the opposite side of the vehicle. Next, plaster molds were cast from the clay models, and these would be used to manufacture prototype thermoforming tools. According to Logan, this process consisted of many hours of painstaking work. Yet even then, they would be months away from a production-ready mold. “Back when we started the business, our first flares were for the old Jeep CJ.,” Logan reflected. “The clay and plaster process worked fine then because the sheet metal for the fenders was flat. This is definitely not true for the body style of the new Jeep JK.” “Without laser scanning, it may not have been possible for us to roll out the Jeep JK accessories,” he continues. These accessories include several fender flare options and the company’s Trail Armor, which offers hood and corner guards as well as rocker panels.

3D scanning allows Bushwacker to acquire factory mounting points for its accessories. www.design-engineering.com

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26 ShopTalk The Jeep JK was a challenge because of its body style lines and mounting configuration. Even with 3D scanning, Bushwacker spent six months developing its patented pocket-style flares, flat-style flares and Trail Armor. Logan noted that for all other projects, 3D scanning has, on average, slashed product launches to only one or two months after initial concepts. The Jeep JK project also highlighted another advantage of 3D scanning: The acquisition of mounting locations. To facilitate installation, Bushwacker always attempts to use only factory mounting points for its accessories. For the pocket flare, this led to an innovative combination of inner and outer flares; the scanned data provided the exact locations of the mounting points relative to the body panels.

Flat-style fender flare, one of Bushwackers options for the Jeep JK.

The innovative design and attention to detail paid off for the Jeep JK accessories. At SEMA, Bushwacker’s flat flares took the runner-up award in the Best New Off-Road/FourWheel Drive Product category, while its Trail Armor nabbed first place for the Best New Exterior Accessory Product. 3D Scanning at Bushwacker For all projects, Bushwacker combines its laser scan arm, PolyWorks and Siemens NX in a three-step process: Scan, prepare and design. In some instances, the 3D scanning system travels to the target vehicle, but in most instances, Bushwacker drives the vehicle into its facilities. For the first step of the process, Bushwacker uses PolyWorks/Modeler for laser scanner control and live data capture. “With PolyWorks, there isn’t a grueling setup process to get everything communicating before we start scanning,” Logan says, adding that it only takes 10 to 15 minutes to set up and start scanning. “The interface is also intuitive and easy to use,” he adds. “I love the fact that as I scan, the digital model dynamically changes to follow my scan path. It gives me great visual feedback to let me know where I am and what I still need to capture.” When he believes that the scan is complete, he then turns to the PolyWorks comparison tool, which shows scan-to-scan 3D ENGINEERING SERVICES

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ShopTalk deviations. “This is my safety net for the occasional operator error, like a bumped scanner,” Logan said. “I get immediate feedback on what I need to rescan. The result is clean, accurate data.” As a Siemens NX user, Logan also finds that the PolyWorks/ Modeler interface and tools are familiar and quite similar. He makes use of PolyWorks to prepare the files for import to Siemens NX, which he uses for data manipulation and design. “We need powerful modeling tools to create parts and designs that follow the subtle style lines of the vehicle,” he says. “PolyWorks helps us capture the details, and that data is used in Siemens NX to design our parts. For us, it’s a perfect blend.” To prepare the data for Siemens NX, he uses PolyWorks to filter out any noisy data, fill holes, and create splines and NURBS surfaces. “I select an area and let PolyWorks autocreate the splines; then I connect these and create NURBS,” Logan says. “I find that it’s very similar to the process for Siemens NX, so in fact, it’s intuitive. As far as I know, nothing is better.” In Siemens NX, the PolyWorks-generated NURBS become the baseline for accessory design. From the body panels and mounting points, Bushwacker’s vision takes shape. Throughout the process, designers render the accessory and vehicle to visualize form and fit. Each new part goes through a “digital” design review before

any prototype molds are designed and CNC machined. “The high quality surface data that PolyWorks provides allow us to scrutinize the part in CAD for fit and finish before we ever make a real part,” Logan noted. Yet, they still rely on physical prototypes for final evaluation. “Things jump out at you when you mount a flare onto the vehicle for the first time, things you can’t or don’t see on screen,” Logan said. Recently, Bushwacker extended its reliance on PolyWorks to inspection. PolyWorks transforms PolyWorks/Inspector confirms the a digitized model to high quality—for which the company smooth NURBS surfaces. has become renowned—of its molds, prototypes, and first production samples. “PolyWorks/Inspector is extremely powerful. It allows us to bring inspection in-house, which lets us evaluate parts and molds quickly and whenever needed,” Logan said. “In the current economy, we have to stay on the cutting edge, and PolyWorks has helped us do that.” DE www.innovmetric.com

This article was provided by InnovMetric

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28 CoverStory

The

Future Automotive Design? of

Kor Ecologic’s Urbee 2 looks to answer the question of sustainable transport. By Mike McLeod

f there’s one thing Jim Kor can’t abide in automotive design, it’s wasted energy. That’s not to say he’s a zealot. The 60-yearold design engineer from Winnipeg still drives his ‘68 Chevy truck and, over his lifetime, has raced Austin Minis, tinkered on numerous sports cars and even owned an RV or two. Yet, since 1996, Kor and his nine-member team of likeminded engineers at Winnipeg-based consulting engineering firm, Kor EcoLogic, have toiled off and on to design, build and eventually market the Urbee, their vision of the ultimate alternative-energy vehicle. Recently, the company announced it has begun work on the next iteration, named the Urbee 2. Longer and more polished than the original, the next prototype is intended to demonstrate that the “greenest car in the world,” can also appeal to a mass audience.

Blue

It may seem like an idealist’s dream but, to Kor, a vehicle like the Urbee is the inevitable conclusion when you combine an engineer’s drive for the practical with a realist’s understanding of projected auto usage globally and the resulting environmental impact. “There are 1 billion cars on the road now. In 35 years, there are going to be about 2.5 billion new cars, so it’s really about what they should look like,” Kor says. “Too often, I think we listen too much to the economists and not enough to the ecologists, who are telling us we’re in real trouble.” Efficiency at All Costs The prototype version of the tear drop-shaped Urbee (short for Urban electric with ethanol), first grabbed headlines when it entered the Progressive Automotive X-Prize in 2009. Distinctive for its futuristic look and 3D printed body, in reality its shape and plastic exterior shell are simply part of the vehicle’s overall design equation. According to Kor, creating a truly energy efficient car starts with challenging the norms of automotive design.

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CoverStory 29 “People usually ask us if this is an electric or a hybrid; they just want to know the technology,” he says. “Actually, our goal is to create a low-energy car so we can run solely on renewable energy. To achieve that goal, you got to use whatever technology will get you there.” Specifically, Kor says low-energy means a car that has energy requirements so small, its fuel can be produced “off the grid” (e.g. by rooftop solar panels and/or home grown ethanol crop). As a consequence, this imperative has led the Urbee’s creators to make some unconventional design choices. Take, for example, the hybrid’s power plant and drive train. Since the Urbee is intended for city and highway driving, the two-seater relies on a pair of 4-hp DC electric motors to drive its front tires (one per side) coupled with regenerative breaking for the stop-and-go of urban driving. At these lower speeds, the Urbee needs to be as light as possible to overcome inertia. “Over the last 100 years, when an engineer has tried to make a really efficient car, they typically make a three-wheeler,” Kor says. “Our analysis showed that eliminating a wheel doesn’t change rolling resistance much. The reason is that you don’t need the weight of the fourth wheel along with the suspension, break assembly and everything else.” On the highway, at speeds above 70 kph, the three-wheeled The Urbee 2’s small frontal area, low profile and Kamm-back tail combine to give it an exceptionally low .15 drag coefficient.

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hybrid switches over to its 4-cycle diesel engine that can propel the Urbee to a top speed of 120 kph while charging its battery, yet has an output of a scant 5 hp. Making this possible required that the Urbee be as aerodynamic as possible. Consequently, the car has an uncommonly small frontal area (14 sq. ft.) along with a coefficient of drag of only 0.15. “To cut through the air, you don’t need an arrowhead; you want just the opposite: A blunt nose with rounded edges,” Kor says. “Once you burst through the air, you have to bring the air back together again. You can do that at about 15 degrees of taper at the speeds we’re talking about. Any more and the air begins to separate. It looks like a torpedo with a round blunt nose then a tapering off to the pointed tail.” Since a pointed tail is impractical, Kor says, the Urbee’s rear end features a sharply truncated tail, called a Kamm-back or K-tail design, which significantly reduces or eliminates turbulent airflow. “All those backend edges are blindingly sharp because you have to fool the air to keep going,” he says. “If you put even a one-inch radius on it, the air starts to curl as it leaves the car and the vortex causes drag.” Digital Manufacturing To get the organic shape needed to preserve the Urbee’s exceptional aerodynamics, Kor says the team originally planned to make the body out of fibreglass—a material they were familiar with and that could be fashioned by hand. But, from the beginning the Urbee has been a self-funded project, which made the high tooling cost of sheet metal impractical. However, Kor says fibreglass is toxic, generally unpleasant to work with and violated another his design principles—that the materials in the Urbee be largely recyclable. When the team

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30 CoverStory learned that Stratasys’ service bureau division, RedEye On Demand, could print and fuse 3D printed parts into larger structures, Kor decided to try it as simply a prototype body to cover the original Urbee’s chassis. “Once we had a 3D model of the Urbee and we knew it could meet the target coefficient of drag, we met with Stratasys and asked if they could 3D print it,” Kor says. “I looked at because it would give us the sharp edges we needed, which are hard to do in fiberglass.” Based on the success of the first prototype, Kor says the Urbee 2’s body will embrace true digital manufacturing, which will free its designers to create parts that can’t be manufactured any other way. Composed of approximately 30 exterior panels printed on Stratasys’ Fortus machines, the Urbee 2’s body will include an exterior and interior skin, made from recyclable plastic. In addition, all visible interior components of the future prototype will also be 3D printed. As it stands now, the Urbee 2 is still in the design phase. By 2015, however, Kor says the goal is to drive the high efficiency vehicle from San Francisco to New York City using only enough ethanol to fi ll the vehicle’s 10 gallon tank. “We’ve done the calculations but I’m not saying the car can do it; I’m saying it could do it,” Kor says. “I make it clear that its our goal. We fully understand that if we don’t do it

In addition to its exterior body, all the Urbee 2’s visible internal components will be 3D printed.

with very little fuel, why would people compromise to drive a car like this?” In the meantime, Kor and his team are looking to secure funding. As with nearly everything else about the Urbee, financing may take an unconventional route. The company is currently exploring a Kickstarter.com campaign to help it carry the project forward. Once finished, Kor says the next step will be finding a partner who can produce the Urbee for a global market. “It’s completely unrealistic for a small group like ours to make a car,” Kor admits. “The only way the Urbee will have an impact on a global scale, with 2.5 billion cars projected, is if you sell a billion of cars like this. Today, only a car company can make a billion of anything.” DE korecologic.com

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Micro Moves NB miniature slides facilitate test of tiny semi-conductor wafers.

emiconductor labs are billion dollar operations and accuracy in the automated testing of the semiconductor wafers they produce is a critical part of their fabrication process. It’s also a major cost factor. On fabrication of lower cost products, test can account for more 25 percent of the cost of fabrication. As an engineering director for the design and development of automation systems, Mark Filho saw the need for guaranteeing the accurate positioning of wafer testing probes. To this end, he established Newmark Systems, Incorporated. Their first customer, fifteen years ago, needed a compact positioner for semi-conductor wafer probing. Wafer probing occurs before wires are attached in the burn-in process in preparation for the final chip encapsulation. The probe checks circuits or capacitance of the dies, (i.e. chips) in the wafer and tests if the die meets the specification requirements. “What we did was increase the load capacity of a precision positioner,” says Mark Filho, describing the development strategy for Newmark’s first product. “The linear stage we created is a very compact stage for the load carrying capability it has. We’ve been manufacturing the NLS4 for 15 years, and it has been very successful.” The NLS4 runs from 2 inches up to 24 inches using a 9 mm rail system and can carry twenty-five pounds. Its design was optimized for maximum stability and performance with the use of FEA analysis and incorporates NB Corporation’s miniature linear guides — two guides and four blocks. May/June | 2013

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NB Corporation’s Mini SEBS is one of the smallest guides on the market, features zero to minus preload for increased accuracy.

Preload Improves Accuracy Newmark was able to choose from the widest selection of miniature linear slide guides on the market. The standard SEBS guides’ major advantage is that they have a standard radial clearance that is twice as accurate as other standard miniature guides. Most manufactures don’t claim that their preload eliminates all clearance. Their standards are plus to minus, which allows gaps to exist. Minus means there is some preload so there’s no gap. NB’s are from zero to minus as a standard, making for greater accuracy because there is no clearance. Negative clearance means the ball is larger than the space, adding more pressure and greater rigidity. This increased rigidity is desirable in high precision applications. NB’s standard fabrication requires more control in the assembly and manufacturing process in order to adhere to this higher quality standard. Of course, there can be instances where no preload is desired, where one might want to remove all friction and trade off accuracy and rigidity for minimal friction. In such a case, one might want clearance. But the precision positioner was not such a case. Had a different design route been taken, there might have been a deformation of the guide block to consider. For instance, had the positioner been mounted on only one rail on an arm that extended to the side, this would have caused deformation of the block, reducing accuracy. There is a solution to this problem. It is called the SEB-AD. The AD version is stiffer because NB optimizes the machining of the top-mounting www.design-engineering.com

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PowerTransmission

Cutaway of MSL, the microslide linear stage, showing its single miniature rail and block which travels from 25mm to 200mm. Since the carriage is supported over the entire travel of the stage, it has good cantilevered load capacity.

surface of the guide block that attaches to the table. This withstands the extra moment load that could have caused some clearance due to deformation.

bearings. SER comes in all stainless steel. It has non-retained rollers and is available in the same block sizes and configurations as the SEBS ball bearing miniature guides. All NLS4 series stages are machined from 6061 aluminum alloy to provide a light yet stiff and stable linear stage. The drive system utilizes a stainless steel ACME leadscrew with internally lubricated plastic drive nut. The drive nut offers zero backlash operation that automatically adjusts for wear to insure zero backlash for the life of the stage. For more reliability and durability, the ways and leadscrews are protected with a strong, machined cover and the encoder is mounted internally directly to the leadscrew rather than being exposed to shock and contamination when mounted in the rear of the motor.

Tiny Guides Even Smaller For the smallest applications, there is an extra compact block There are for lesser loads – SEBS-BS (size 2), which is shorter than the standard length block and only has two holes instead of four. Either retained-ball (whose elements allow for easier handling since the guide block may be removed from rail without ball loss) or low-cost non-retained-ball lines are available. A unique miniature guide that provides the greatest rigid- A cut-away CAD rendering of the NLS4, which provides precise linear ity is the SER. It uses crossed-roller bearings, which give more positioning from 25 mm to 1.5 meters and rides on four linear guide AH1212H_CSG_Aerotech_Automation_7x4_875_AGR_halfpage.qxd rigidity. Crossed-rollers have greater contact areas than ball 4/2/2013 blocks on4:26 two PM rails.Page 1

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PowerTransmission some applications that need a greatly reduced footprint – robotic applications ranging from pick-and-place in factory and lab automation to medical devices. So Newmark created a linear stage with a single bearing – a single guide instead of two guides – with a single block. The carriage is supported over the entire range of travel using a single preloaded NB Corporation miniature linear guide bearing. This positioner, the MSL, is tiny yet it can lift 15 pounds. Its maximum velocity is three to four inches per second. It offers travels from 25mm to 200mm, has two leadscrew pitches: 2mm and 10mm and comes standard with a high-torque, size-17 stepper motor. End of travel limit switches come standard on the MSL linear stage. The drive system utilizes a stainless steel ACME leadscrew with internally lubricated plastic drive nut. The drive nut offers zero backlash operation that automatically adjusts for wear to insure zero back-lash for the life of the stage. For vertical movement, again, the positioners use the mini guide as in a linear stage except they have a wedge. When the wedge is pushed, it creates lift. The guide moves horizontally to push the wedge and that is what causes the

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This vertical positioner, Newmark’s NVS-1, displays the two miniature guides, used with a wedge to elevate small payloads precisely.

vertical movement. When the wedge is pushed against a second wedge, it will lift, but you have to guide that up and down. The NB bearings are used vertically, horizontally and on an angle. Positioned For The Next Innovation Newmark just moved their 16 employees to a bigger, newer place with more power. Since they do everything in-house, including all machining to control quality, their power needs keep growing. There is irony in their getting bigger as their products get smaller. And, Mark Filho is confident that innovations in miniaturization of automation will lead to ever more growth going forward. www.nbcorporation.com

This article was provided by NB Corporation. 5021MP_3.375x4.875 DE (QR)

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36 Fasteners&Adhesives

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The Right Tool for the Job SPIROL’s application engineers and a custom disk spring solve DeWALT tool design problem.

eWALT, a subsidiary of Stanley Black and Decker, is a brand with a reputation for providing high quality professional power tools and accessories. But when the company’s lead design engineer for drills was tasked with designing a high power right angle drill that was also lightweight, compact and portable, the solution required more than off-the-shelf components and product knowledge. According to the design specs, the drill would incorporate a mechanical clutch built to limit maximum torque output to 70 ft-lbs. Absent the clutch, with the huge gear reduction of 75:1, the drill would be capable of producing a lock rotor torque at the spindle of 175 ft-lbs, transmitted directly to the operator of the tool. Early in the design phase, it was determined that the clutching thrust required in the space available could only be achieved by a disc An exploded view of the DeWALT drill’s mechanical clutch assembly showing the two spring design. Compared to conventional coil custom SPIROL disc springs stacked in series. springs, disc springs offer a higher load capacity in less space. Additionally, longevity and reliability is a high theoretically calculated the initial disc spring design but measure of quality for professional tools used on a daily basis. initially choose to work with a low cost disc spring supplier. Therefore, the life and performance warranty of the tool was The first prototype built failed, with the new design achieving reliant on the disc spring design. less than half the targeted cycle life. Analysis indicated the During development, DeWALT’s engineers developed and disc spring’s premature fatigue failure was due to higher than expected stress, lesser quality material and a less than ideal manufacturing process. Determined to find a solution, the lead engineer contacted SPIROL to discuss the disc spring design. SPIROL’s application engineering team evaluated the design and quickly determined they could not be met by a standard disc spring. SPIROL essentially became an extension to DeWALT’s team and focused specifically on the disc spring portion of the design. Ultimately, SPIROL recommended a custom disc spring design that had alternate dimensions, material and secondary operations. For this demanding and high performance application, these special features added significant value and ended A cut-away of DEWALT high performance up costing only pennies more compared to the product offered industrial drill showing the placement of by the original supplier. SPIROL’s disc springs. DeWALT tested SPIROL’s recommended disc spring and the tool far exceeded the cycle life requirement. By partnering together, DeWALT and SPIROL determined the best disc spring design for the new angle drill, minimizing costly development time for both companies. DE www.dewalt.com

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MotionControl

Sharpening the Axes Precisely tuned servomotor technology can boosts productivity and increase accuracy. By Scott Carlberg

hoosing the appropriate servo technology can make all of the difference when it comes to maximizing the potential of a machine design. Each individual application has a unique set of requirements that could be satisfied in a number of different ways. The ability to identify the key application requirements coupled with the knowledge of available servo technologies can help the designer achieve the best automation solution. The following applications illustrate some unique challenges and how the automation solution was optimized by leveraging the most appropriate servo technology.

High resolution feedback devices on the servo motors coupled with tuning algorithms eliminated significant vibration from this plasma cutting application.

2-Axis Planar Shape Cutting Cutting a two dimensional pattern out of a sheet of material is a common application with a number of important requirements. Whether the cutting is being accomplished with laser, plasma or water jet technology, it is crucial for the planar motion of the X and Y axes to be coordinated smoothly to ensure an optimized finished cut. For example, in a plasma cutting machine that cuts patterns out of sheet metal stock, the X and Y axes are coordinated to move the cutting head through the path of the designated pattern. Each axis is actuated with a standard rotary servomotor coupled to a ballscrew assembly. Depending on the size of the machine, the length of travel for each axis can be relatively long (in this case the travel length of the X-axis is 76 inches and the Y-axis is 49 inches). During operation, a machine of this size and nature can be subject to a few different types of resonant frequencies and vibrations. As a result, the tuning of each servo axis becomes critical to the cut quality on the finished part. During the commissioning of this particular machine, significant amounts of vibration on both X- and Y-axes were being reflected up through the cutting head. The effect of this vibration May/June | 2013

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can be seen in both the Y-axis scope plot and the picture of the finished part. Some of the higher end servo systems available today have built-in functionality to account for these types of mechanical disturbances. This built-in functionality consists of high resolution feedback devices on the servo motors coupled with advanced tuning algorithms in the servo electronics. In this application, the servomotors used on the X and Y axes of the machine are equipped with 20-bit (1,048,576 counts per revolution) feedback devices. This high resolution feedback is utilized by an advanced vibration suppression algorithm in the servo amplifier to effectively eliminate the machine vibrations. By analyzing the feedback on the motor and comparing it to the commanded motion, the servo amplifier is able to obtain a mechanical signature of the machine. Due to the high resolution of the feedback devices, the amplifier can detect machine disturbances in extremely small increments. The servo amplifier processes this information and injects a signal that is 180 degrees out of phase with the detected resonances and vibrations, thereby eliminating the disturbances. Glass Cutting Another example of 2-axis planar shape cutting is the application of glass cutting. In this application, the diamond cutting head of a machine cuts patterns out of large glass sheets in the X and Y axes. The key requirements for this application were to improve the machine throughput and accuracy as well as increase the machineâ&#x20AC;&#x2122;s flexibility and ease of use. When throughput and accuracy in linear motion are of primary importance, linear servomotor technology can be a very good solution. A linear servomotor has the same design concept as a traditional rotary servomotor with the exception that the motor is laid out flat. A significant advantage of this technology is that mechanical transmission is required to convert from rotary to linear motion. Complicated mechanical designs involving ballscrews, belts and A linear servomotor increased the pulleys and other types of throughput of this glass cutting gearing can be avoided. application by 33 percent. www.design-engineering.com

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MotionControl As a result, linear motor systems, with a high resolution linear feedback device, can be extremely accurate and achieve speeds and accelerations that are magnitudes higher than rotary servomotors used in conjunction with mechanical actuators. In the glass cutting example above, the machine builder replaced a complicated mechanical design comprised of pneumatic actuators, ballscrews and gearheads with linear motors for the actuation of the X and Y axes of the cutting machine. As a result, the overall machine throughput increased by 33 percent. Cutting speeds were increased to 3 meters per second and cutting acceleration was increased to 1.0 G. All of these improvements equated to a yield of 200 cut pieces per hour. The finished part quality was improved due to a doubling of system accuracy (0.05 mm on glass thickness ranging from 2 to 6 mm).

Without mechanical components, performance on this turntable increased to the full bandwidth of the direct drive servo.

Rotary Table Indexer A rotary table indexer is a classic material handling application where a work piece gets rotated to multiple locations in a circular path. In many instances, direct drive servomotor technology is a practical solution for this type of application. Direct drive servomotor design allows for the load inertia to be coupled directly to the motor’s rotor. This motor design eliminates the limitations associated with common mechanical components (e.g. couplings, gearheads, ballscrews, belt & pulley, etc).

Once the mechanical compliance is removed, the servo system tuning gains can be increased to a point where you can take full advantage of the total bandwidth capabilities of today’s most advanced servo electronics. The table was designed to handle three large solar panels, each measuring 49 in x 40 in. When the 3.8 meter diameter table is fully loaded with three solar panels, the total load inertia (the load that is rotated by the motor) is 400 kg-m2. To index a load this large with a conventional rotary servo motor, a significant amount of gearing would be required. A direct drive motor was used in this application. The inertia of the rotor of the direct drive motor was 0.31 kg-m2. This resulted in a load to rotor inertia mismatch of 1300:1. Due to the table’s rigid design Our encoders are built to perform, even in the most extreme conditions of and that it was directly coupled to the direct heat, cold, moisture and anything your requirements dictate. Whatever drive motor, the system was able to perform a reasonable move profi le regardless of this your industry, we’ll satisfy your expectations for superior quality, value, incredibly large inertia mismatch. A target service and reliability, always eager to earn your confidence with our move time of 5 sec for a 120 degree move FIVE-YEAR WARRANTY. was achieved (with a settling window of 10 Count on more from counts) in this application. The bearings IEC...we’ll deliver. in the motor were able to support the entire fully loaded moving structure. It is important to note that the pole count, feedback resolution and torque constant of this particular direct drive motor were chosen to optimize performance for this application. The key thing to take away from this application example is that when applied properly, direct drive motor technology can result in performance that cannot be matched with any other motor technology. DE

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13-06-10 2:28 PM

IdeaGenerator 41

DieQua offers more gearboxes

Automation Multi-Axis Gripper SCHUNK rolled out its LEG multi axis gripper, with fixed center jaws, fingers made of carbon fiber reinforced plastic and a pneumatic ejector. The gripper, which pre-adjusts its position as the robot approaches, palletizes between 15 and 60 units per minute, at a clamping accuracy of less than 0.1 mm. Due to the universal servo-electric drive concept, the gripper fingers can be separately controlled, and articles can be laid down separately. Moreover, the gauge for bore holes between the fingers can be defined individually. The gripper weighs 60 kg without chuck jaws. Depending on the article and weight, solutions with minimum clearances between 3 and 10 millimeters are possible. Depending on the size, the LEG multi axis gripper clamps up to 100 kg forcefit, and up to 150 kg form-fit. www.schunk.com

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Wireless Ethernet Gateway WAGO Corporation introduced its IP65-rated WLAN Wireless Ethernet Gateways designed to replace Ethernet network cables. The 758-916 (2.4 GHz) and 758-917 (5 GHz) Wireless Ethernet Gateways (WEGS) transmit data up to 1,300 ft (400M) line-of-sight. The WEGs wirelessly transmit ETHERNET protocols (e.g. MODBUS/TCP, EtherNet/IP or PROFINET). With a IP65 housing, the gateways feature an integrated antenna (circularly polarized for heavily metallic environments) and on-unit LEDs for ata-glance diagnostics/operational status updates. In addition, the Industry Canada and FCC-approved units feature M12 cables to provide power and Ethernet connectivity. www.wago.us

Planetary Gearheads • Precision or Economy • Inline or Right Angle • 40-155mm Frames • Low Backlash • 1 and 2 Stage Ratios • Lubricated for Life

Servo Worm Gearheads • 3 Backlash Levels • Shafts or Hollow Bores • Single or Dual Outputs • 11 sizes, 25-200mm CD • Capacity: 10-7000 Nm • 20,000 Hour Ratings

Z-Axis Nanopositioners Aerotech introduced a line of ANT-L-Z crossed-roller, Z-axis, nanopositioning stages, offered in two models (ANT95-L-Z and ANT130-L-Z) and two accuracy grades. Utilizing non-contact direct-drive technology, the ANTL-Z stages provide nanometer performance in a large travel format (25 mm, 35 mm, 50 mm, 60 mm travels). The line also features high resolution (2 nm), repeatability (75 nm) and accuracy (300 nm) with in-position stability of less than 2 nm, assisted by anti-creep, crossedroller bearings. The ANT-L-Z stages use a nearly frictionless counterbalance mechanism to maintain performance levels while minimizing motor heating. The counterbalance is user-adjustable from 0 to 10 kg, depending on stage model. www.aerotech.com

Spiral Bevel Gearboxes • 9 Sizes • 1-250 HP Capacity • Low Backlash Option • Ratios from 1:1 to 6:1 • Output Shaft Options • Machined Housings

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Power Transmission Belt Drive Actuators MISUMI USA introduced its MSA Series Belt Drive Actuators, configurable to carry loads up to 227 kg (500 lbs), with travel speeds ranging from 1200 to 10,000 mm/ sec, and standard lengths up to 6.25 meters. The pulleys used feature precision-machined www.design-engineering.com

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42 IdeaGenerator one-piece steel construction and nickel plated with an integral shaft. The timing belts are made of steel cords molded into highly flexible polyurethane material. All MSA Series Actuator models have been tested over tens of millions of cycles with no failures and all have a repeatability of +/-25 µm or better. MISUMI offers a line-up of eight standard MSA Belt Drive Actuators, with selection depending on each user’s specific application requirements. www.misumiusa.com

Linear Rail Haydon Kerk Motion Solutions introduced its BGS06 linear rail, which integrates an IDEA Drive. The linear rail also utilizes a size 17 single stack or double stack stepper motor linear actuator with an integrated and fully programmable stepper motor controller. The BGS06 has a maximum stroke length of 24-in (610mm) and a maximum horizontal load of 135 lb (600N). The rail’s RoHS-compliant IDEA drive system has an input voltage range of 12-48VDC and maximum current of 2.6A RMS with a current

boost capability of up to 30 percent during ramping. The component has four digital inputs and outputs. In addition, the rail features USB and RS-485 ports for communications. www.HaydonKerk.com

Lever Actuated Shaft Collars Stafford Manufacturing Corp. has expanded its Staff-Lok line of lever actuated shaft collars, which can be opened, moved, and re-clamped by hand for use in larger, non-rotary applications. The collars feature an integral hinge with a conformal cam lever for clamping and a knurled nut for adjusting the clamping preset, which makes it easy to move by lifting the lever, moving the collar, and clamping it by hand. Machined from steel with a smooth bore, Staff-Lok Shaft Collars come in three body and round bore size combinations: 2-1/8 inches O.D. with 1/2-, 5/8-, 3/4-, 7/8-, and 1-inch bores; 3-1/4 inches O.D. with 1-1/8-, 1-1/4-, 1-1/2-, and 1-3/4-inch bores; and 4-1/4 inches O.D. with 2-, 2-1/4-, and 2-1/2-inch bores. www.staffordmfg.com

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IdeaGenerator 43 Sensors Inductive Proximity Sensors Carlo Gavazzi announced that its ICB Series Proximity Sensors have been certified for use in hazardous environments. By division, the certification includes hazardous locations with presence of flammable gases or vapours (Class I) includes; hazardous atmospheres only present under fault conditions and only for very short periods of time (Div 2) and Groups A, B, C, and D of explosive gases (Acetylene, Hydrogen, Ethylene and Propane). The sensors feature the same microprocessor design and AirCore sensing coil, along with a potting process that allows users to install the sensor in heavy duty applications. There are no new part numbers involved, as the Class I, Div 2 rating is an enhancement to the existing ICB Series. www.gavazzionline.com

Magnetic Positioning Sensor SICK USA launched its MPA magnetic positioning sensor that feature analog current from 4 to 20 mA and an analog voltage between 0 and 10V. With measuring lengths from 107 to 1,007 mm, the MPA provides high-resolution, non-contact position measurement. The sensor is enclosed in a IP 67-rated aluminum housing that can be mounted on various cylinders, including T-slot, round and tie rod. The MPA includes a teach pad, a 4-color LED display and several mounting accessories. www.sickusa.com

High-Resolution Encoders AutomationDirect announced that it has extended its line of Koyo medium duty encoder to include high PPR (Pulses Per Revolution) models. Available in Totem Pole (Push-Pull) or line driver (differential) configurations, the encoders feature a 50mm diameter body with a 35mm depth. Models are constructed with an 8mm diameter solid or hollow shaft and offer incremental resolutions of 3000, 3600 or 5000 PPR. The encoders are also fitted with a two-meter cable with tinned ends and are available with either 5 VDC or 5 to 30 VDC inputs; the high-PPR encoders provide up to 200 kHz response frequency. www.automationdirect.com

Hygienic Sensors Baumer announced that it now offers a range of sensors designed to withstand chemicals and/or high pressure washdowns. Baumerâ&#x20AC;&#x2122;s OADR 20 series of laser sensors provides resolutions from 5 Âľm and carry an IP68/IP69K rating. Baumer Series 14 hygienic photoelectric sensors are available in standard models as well as a version featuring SmartReflect, a light barrier that operates without a reflector and has a sensing distance of 800 mm. Baumer CleverLevel sensors are certified according to FDA, EHEDG and 3A guidelines and offer 1.4404 stainless steel housings, matching PM023 weld-in boss and PEEK plastic sensor tips. LBFS versions feature standard output configurations and operate from www.design-engineering.com

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May/June | 2013

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IdeaGenerator -40 to +115°C, while LFFS versions withstand operating process temperatures from -40 to +200°C. The company’s IFBR and IFRR series of inductive sensors are Ecolab-tested and EHEDG-certified. Baumer’s UNAR 18 series of ultrasonic sensors feature stainless steel housings with a parylene coating for increased chemical resistance. www.baumer.com

Motors Washdown Duty Motor Baldor Electric Company introduced its Super White Washdown Duty motor designed for humid and moist environments in the food and beverage industry. Its autophoretic autodeposition exterior surface preparation method makes the white epoxy finish coat of this motor five times more

resistant to corrosion and chipping than previous methods. The shaft, hardware and nameplate are all 300 series stainless steel, to prevent rust and corrosion. The motor line also includes labyrinth seals on each end of the motor, enhanced sealing around the lead exit, same size bearings on each end and a moisture resistant insulation system. Neoprene rubber gaskets on the conduit box ensure a tight, waterproof seal. It also features a maintenancefriendly drain design with four condensation drain plugs. A notched fan cover allows access to condensate drain plugs without removing the fan cover. Baldor Super White Washdown Duty motors are NEMA Premium efficient and are available from 1 to 20 HP, 56°C through 256°C. www.baldor.com

All-in-One Stepper Motor Oriental Motor introduced its PKA Series, a line of integrated stepper motors, drivers and controllers. The All-in-One motor features a built-in controller (stored

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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

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IdeaGenerator 45 data) type, microstepping driver and a 0.72° stepper as the base motor. The built-in positioning function ensures that the traveling amount, speed, and other operating data are retained in the motor. The motor is also equipped with a variety of other operation functions in addition to the positioning operation, such as continuous operation and a return-to-home operation. The PKA Series has DC input and available in 42 mm (1.65 in.) and 60 mm (2.36 in.) frame sizes. www.orientalmotor.com

Process Centrifugal Pumps KSB Canada released the latest generation of its Movitec highpressure centrifugal pumps. The series features laser welded hydraulics and are available with a range of material and seal options. With seal variants rated for temperatures from -30°C to +140°C, these standardized centrifugal pumps are designed to handle a huge variety of media, ranging from water

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(including acidic and alkaline solutions), alcohol and vegetable oils to petroleum products and condensates, liquid CO2 and LPG. A new addition to the product range is the tri-clamp coupling, designed for pharmaceutical and hygienic food or beverage applications. They are rated for volumes of up to 113 m3/h (498 gpm) and discharge pressure of up to 2,496 kPA (362 psi). www.ksb.ca

Solenoid Valve Festo introduced the VZWF valve, a force pilot operated solenoid valve that can be used with water, air and neutral media. This new valves utilize relatively small solenoids to control high pressures with large nominal diameters. The units can switch at pressures as low as 0 bar and close automatically in the case of a pressure loss in the circuit. These valves can be applied in closed media circuits. The VZWF series is generally suitable for applications in which the medium can be vented downstream of the valve into the atmosphere or a tank. The VZWP is used for gaseous and liquid material flows up to a viscosity of 22 mm²/s. www.festo.ca

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46 CanadianInnovator

From left: U of T engineering graduates—Gimmy Chu, Tom Rodinger, Christian Yan—with their high-efficiency LED lightbulb, the NanoLeaf.

Light of a New Age U of T engineering grads create the “most efficient light bulb in the world.” By Treena Hein

t was some time ago that the big global electrical product companies saw the “lighting” on the wall. The need for a greener light bulb – one that’s much more energy efficient and lasts a long time but is still economical and environmentally-friendly to produce – was clear. Experienced teams at these gigantic companies set to work, with huge budgets at their disposal. But a small, independent trio of engineers, all University of Toronto alumni, also took a stab at the problem – and have achieved astonishing levels of energy efficiency that surpass what anyone else has produced thus far. Meet Tom Rodinger, Gimmy Chu and Christian Yan, creators of the Nanoleaf light bulb, an LED lightbulb that its creators say is as bright as conventional bulbs but lasts much longer. The Nanoleaf’s journey began during the trio’s time as part of the University of Toronto “Blue Sky” solar car racing team. Their experience with the car’s electronics and circuitry gave them great familiarity with efficient circuit design. “We’ve all been really passionate about developing green energy products for the planet for a while,” says Chu. “Our current focus is in May/June | 2013

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green energy products such as solar and LED technology.” The bulb’s design features small LEDs mounted onto a folded PCB circuit board so that a bulb shape is achieved, and uses only 12 watts of electricity to produce the light output of a 100W bulb. It turns on instantly and will last for about 20 years. That’s about 30,000 hours of usage, which is equal to that of 30 incandescent bulbs or four compact fluorescent. “Our signature product, the 12W NanoLeaf, produces 1600 lumens (133 Lm/W) which is hard to achieve with LED light bulbs,” Chu explains. “Some of the bigger brands have just started coming out with 1600 Lm bulbs, but they use much more electricity – 20W for the Sylvania and 23W for the Philips model.” The LED bulb that won the 2012 U.S. Department of Energy’s “L Prize” achieves only 93.4 Lm/W. It gets better. “Many LED bulbs have the issue where, if used in an enclosed fixture, heat will cause the bulb to burn out within a few months,” says Chu. “These bulbs need a large heat sink to dissipate the heat.” The Nanoleaf solves this problem through over-temperature circuitry protection, so in a fullyenclosed fixture, it will automatically dim to prevent damage. It helps that the NanoLeaf also runs fairly cool compared to other LED light bulbs – yes, you can touch it while it’s on. www.design-engineering.com

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CanadianInnovator “Eventually we will pursue the Energy Star certification,” adds Chu. “At the moment, we’re focusing our efforts in some of the other required certifications for getting the product onto store shelves in various countries.” The team hasn’t yet done the testing to see what extreme outdoor temperatures will do to the lifetime of the bulb, and therefore currently recommend it for indoor use only. Support for the Nanoleaf has been impressive from the start. In January, the team used crowd-funding web site KickStarter to raise funds for production of a first batch, with a goal of $20,000. By March, they had generated over ten times that amount: $270,000 from over 5,700 backers all around the world. “It was incredible for us to find so many like-minded people so supportive of our work, says Chu. “There’s still a constant stream of people placing pre-orders every day.” One of the most challenging aspects of the entire journey was the manufacturing. “We needed to define a process where folding of the circuit board wouldn’t cause any damage to the circuitry,” Chu explains. “This has not been done by any other manufacturer before, but through making the initial batch of 5,000 bulbs, we are ironing out the issues and we’re confident we’ll have a process that can be expanded to a larger scale.”

47 Hammering out the design and manufacture was also challenging geographically. The three have lived in three different countries (Canada, the U.S. and China) for a while, and each do a lot of travelling, which made collaboration interesting. “We had to constantly call each other across various time zones and plan trips to continue working on the project,” says Chu. “But we are a great team, and we each bring a specialty to the table. We’re all working day and night to make this product a success.” While at U of T, the team members found inspiration in attending the Electrical & Computer Engineering program’s entrepreneur speaker series, where alumni come and talk about building their start-ups. Coming full circle, Rodinger, Chu and Yan have been invited to be present next year. By then, they’ll be able to tell the next generation of engineering students how they worked to build a global distribution network and describe their work to launch other light bulb models, including one that is dimmable. “Our goal with the NanoLeaf is to facilitate the global transition to LED lighting, and we’re on the way to reaching that goal,” says Chu. “It’s been a great ride so far.” DE www.thenanoleaf.com

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