Design Engineering November/December 2016 by Annex Business Media

14 Bricsys bets on the DWG file format for CAD

24 Toronto-based startup develops

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30 Research partnership brings rustfighting technology to market

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Contents | Volume 62, No. 6 5

IN THE NEWS

8 Creaform moves and expands headquarters

Columns

8 Alcoa separates into

8 Design News

8 Renishaw opens

14 CAD Report

two standalone companies

North American AM Solution Centre

Survey shows significant pay boost for Ontario’s engineering techs

Bricsys bets on the DWG file format for CAD

8 Team Waterloop

20 CAD Beat

10 Survey shows pay

24 Canadian Innovator

shows off levitation system

boost for Ontario’s engineering techs

10 Kraken gets IRAP

funding for UMV recovery system

10 Feds invest $54

Million in next-gen aircraft tech

12 Siemens “Expands

Horizons” at Solid Edge University 2016

12 New Flyer begins

testing of industryfirst 60-foot electric bus

SUBSCRIBER SERVICES To subscribe, renew your subscription or to change your address or information contact us at 1-800-387-0273 ext.3552.

Laser welding simulation shortens design cycle and optimizes component design

Toronto-based startup develops exoskeleton fit for children with physical impairments

34 CFPA Corner Fluid Power Challenge goes national to seek future fluid power professionals

40 Idea Generator The latest in industrial products including automation, fluid power and sensors

Features 18 Sustainable Design Diverting e-waste from local landfills and toxic “backyard” operations in developing nations begins with product designers

Renishaw empowers medical device designers with specialized metal AM and design software

30 Dust the Rust Battelle and Xerox Research Centre of Canada bring rust-fighting technology to market

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36 Choosing a Sensor

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26 Pioneering Additive Design

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46 36

www.design-engineering.com November/December | 2016

6 EditorialViewpoint

3D-Printer, Stat!

www.design-engineering.com

oon after London, ON ER doctor, Tarek Loubani, arrived in the Gaza Strip to volunteer his medical skills during the Palestinian/Isreali conflict in March 2012, he discovered that doctors at the Shifa Hospital in Gaza City were running dangerously low on basic medical equipment. Due to blockades of the region and other complicating factors, even seemingly rudimentary instruments like stethoscopes were hard to come by. According to Loubani’s account of his time there, doctors were forced to share two stethoscopes to treat wounded as they entered the hospital’s emergency room. After his return to Canada, his experience inspired him to find a way to not only lower the cost of common medical equipment significantly but also enable doctors in remote or war torn areas like Gaza to produced equipment locally. The result is the Glia Project, Loubani’s open-source medical device design initiative. Not surprisingly, the project’s first device, unveiled last year, is a 3D-printable stethoscope. Using open-source CAD software, Loubani designed the head (the part held to the patient’s chest), plus two ear tubes and earplug molds. More importantly, tests run by the Glia Project’s design team show that it performs acoustically as well as the industry’s gold standard, the Littmann Cardiology III stethoscope. What’s interesting is that, even though the stethoscope was first introduced in 1819 and its design hasn’t evolved much since 1963, instruments like the Littmann Cardiology III still command approximately CAD$200. By contrast, all the CAD drawings, STL files, BOM and assembly instructions of the Glia stethoscope can be freely downloaded from the project’s GitHub page (github.com/GliaX). All told, Loubani says the final bill, including the cost of silicon tubing and earpieces, comes to approximately US$5.00 to make the stethoscope’s components out of ABS plastic on a common FDM printer. Currently, the team is seeking the official blessing (a Medical Device Establishment License) from Health Canada. In the meantime, however, the Glia team has pushed ahead with plans for other common instruments. Among them are low-tech tools, like a needle driver and an otoscope for examining ear canals, as well as comparatively sophisticated equipment like a pulse oximeter to check blood oxygen levels and even a electrocardiogram (ECG) machine. Seemingly a world away from Dr. Loubani’s humble plastic stethoscope, Renishaw plans to pair specialized design software with metal additive manufacturing to create tailor-made, high-tech medical implants, as detailed in this issue’s cover story. On the surface, these two initiatives look very different. One requires little more than a consumer grade 3D printer and some hardware store tubing while the other depends on six-figure AM machines and high-grade metal alloys. In reality, they are two sides of the same coin. Both endeavours strive to resect the complexity, tedium and therefore inflated costs from the traditional medical device development process. Understandably, it will take time for this new paradigm to take hold, and the industry may experience some rejection along the way but, as metal additive manufacturing becomes more precise and cost-efficient, the prognosis for the industry and its customers looks promising.

Mike McLeod

Publisher Alan Macpherson (416) 510-6756 amacpherson@design-engineering.com Editor Michael McLeod (416) 442-5600 ext. 3231 mmcleod@design-engineering.com Associate Editor Lindsay Luminoso (416) 510-5233 lluminoso@design-engineering.com Account Manager Ron Salmon (416) (905) 713-4362 rsalmon@design-engineering.com Art Director Mark Ryan (416) 442-5600 ext. 3241 mryan@annexnewcom.ca Account Coordinator Cheryl Fisher (416) 510-5194 cfisher@annexnewcom.ca Circulation Manager Beata Olechnowicz (416) 442-5600 ext. 3543 bolechnowicz@annexnewcom.ca Vice President Tim Dimopoulos (416) 510-5100 tdimopoulos@canadianmanufacturing.com President & CEO Mike Fredericks Design Engineering, established in 1955, is published by Annex Business Media, 6 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. Printed in Canada Publications Mail Agreement #40065710 ISSN: 0011-9342 (Print), 1929-6452 (Online) Subscriber Services: Canada: $55.00 for 1 year; $88.00 for 2 years; $10 for single copy. Outside Canada: $102.95 for 1 year; $22 for single copy. Directory/buyer’s guide: Canada $28; Outside Canada $46. Add applicable taxes to Canadian rates. Customer Service: email: stelian@annexnewcom.ca Tel: 416-442-5600 ext 3636 Fax: 416-510-5170 Mail: 80 Valleybrook Drive, Toronto, ON M3B 2S9 From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you prefer not to receive this information, please contact our circulation department in any of the four ways listed above. Annex Privacy Officer: privacy@annexbizmedia.com Tel: 800-668-2374 No part of the editorial content of this publication may be reprinted without the publisher’s written permission. ©2016 Annex Publishing & Printing Inc. All rights reserved. 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 of the Department of Canadian Heritage.

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 | 2016

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8 DesignNews

Team Waterloop shows off levitation system

University of Waterloo team unveiled its entry to the SpaceX Hyperloop Pod Competition hosted by Tesla’s Elon Musk. Of the 22 competitors scheduled for the event, Team Waterloop is the only Canadian entry. The final leg of the competition is set for January 2017 on a one-mile test track at the SpaceX headquarters in Hawthorne, California. Toward that goal, the Waterloop team showed off a functioning pneumatic levitation system, in November, on a test track facility at Kitchener’s Lot 41 innovation center. The demonstration used nothing but air to float the test objects. The Waterloop vehicle was designed with four air casters supplied by two onboard scuba air tanks that enable the vehicle to levitate. Presently, the team is working towards constructing a half-scale prototype. “Our design philosophy embraces simplicity, enabling us to build a safe, high performance and cost effective Hyperloop pod,” the team says on its Kickstarter campaign that has already raised more than $32,000 for the project. www.teamwaterloop.ca

The University of Waterloo’s award-winning Hyperloop prototype design. A team of over 120 engineering student volunteers successfully demonstrated a working levitation system for their ambitious Hyperloop prototype, dubbed the Waterloop.

UP FRONT Renishaw opens North American AM Solution Centre

Creaform to move and expand its headquarters

Alcoa separates into two standalone companies

Creaform announced that it plans to move its headquarters to a new expanded location at the Lévis’ Innoparc. The 3D measurement technology company says its $20 million investment will help triple its production capacity and fill more than a dozen new job positions. In addition, the new facility is double the size of its existing building (38,000 to 76,000 sq. ft.). For the past 10 years, Creaform’s present HQ at rue SaintGeorges in Vieux-Lévis, has housed its R&D, manufacturing and assembly operations, engineering services, sales and marketing and administration staff. Creaform was initially founded Lévis, which was a major reason why the company decided to invest in the town. Creaform will be moving to its new headquarters, at 4700 rue de la Pascaline, in November 2017. www.creaform3d.com

Alcoa finalized its separation into two standalone companies – Arconic Inc. and Alcoa Corporation – on November 1. While Alcoa will continue to produce raw aluminum, Arconic will specialize in precision engineering and advanced manufacturing for the aerospace and automotive industries, the company says. Last year, the businesses that now comprise Arconic recorded revenues of approximately $12.5 billion. According to the company, it has already solidified its position as a leader in the aerospace industry with the recent announcement that Airbus selected Arconic for a multi-year $1 billion agreement to provide aluminum sheet and plate for the Airbus A320 family of aircraft. This agreement makes Arconic the sole supplier to Airbus for specific applications including some wing, fuselage and structural components. www.arconic.com

November/December | 2016

Renishaw officially opened the doors of its North American Additive Manufacturing Solution Centre in Kitchener, ON. Marc Saunders, Director, Global Solutions Centers at Renishaw, took to the Marc Saunders, stage to explain the comRenishaw’s Director, pany’s plans to push into Global Solutions the additive manufacturCenters ing market and show off new additive technology, the RenAM 500M system. Saunders spoke to the crowd about how designing for additive manufacturing opens new opportunity for expansion and success. Afterwards, attendees were treated to presentations of two practical additive manufacturing applications by Tony Parraman, Head of Sponsor Liaison for the Bloodhound SSC rocket car, and Paul Guerrier, Additive Manufacturing Center Manager for aerospace parts manufacturer, Moog Inc. The day ended with a tour of the new facility and its additive capabilities. Renishaw’s new facility is located at 41 Ardelt Place, Kitchener, ON. www.renishaw.com www.design-engineering.com

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DesignNews Survey shows significant pay boost for Ontario’s engineering techs

The Ontario Association of Certified Engineering Technicians & Technologists (OACETT) Salary Survey 2016 reveals that compensation for Ontario’s engineering technicians and technologists continues to eclipse the national inflation rate. Conducted by Environics Research Group and based on responses from more than 3,400 members, the survey shows salaries have bumped up seven percent in the past two years, rising from $75,436 in 2014 to $80,725 currently. The report does note though that certified professionals earn a premium in compensation, which can add upwards of $14,000 to $20,000 in salary alone. In comparison, their non-certified counterparts report an average of $65,565. “This study confirms that certification pays dividends in compensation, career growth and employability for engineering technology professionals,” says OACETT President Bob van den Berg, C.E.T. According to the Salary Survey, six out of ten employers said they would be more inclined to hire OACETT members knowing they must engage in mandatory Continuing Professional Development to maintain their membership. A full 80 percent agreed that employing certified employees contributes positively to their organization’s quality and competitiveness. “We are pleased to see the extent to which our members are valued in the workforce,” adds van den Berg. “With a high rate of job satisfaction and highly sought after skills, engineering technology professionals occupy a sweet spot in the Canadian economy.” www.oacett.org

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Kraken receives IRAP funding to develop UMV recovery system

St. John’s, NL’s Kraken Sonar Inc. announced that its subsidiary, Kraken Sonar Systems, will receive up to $485,000 from the National Research Council of Canada Industrial Research Assistance Program (NRC-IRAP). In addition to technical and business advisory services, the funding is being used to develop Kraken’s Autonomous Launch and Recovery Systems (A-LARS)

Computer-generated image of Kraken’s Autonomous Launch & Recovery System (A-LARS) with the KATFISH Synthetic Aperture Sonar underwater towbody. November/December | 2016

for Unmanned Maritime Vehicles (UMV). The initial A-LARS is being designed to support Kraken’s KATFISH Synthetic Aperture Sonar underwater towbody. According to the company, launch and recovery is a high risk operation that its autonomous launch and recovery system is designed to safely and efficiently perform. Next-generation surface vessels will carry a variety of unmanned vehicles and modular mission packages that will require specialized launch and recovery equipment. The NRC funding will be used to expand Kraken’s Handling Systems Division, based in Dartmouth, Nova Scotia. This group is led by Bill Spencer who was recently the Engineering Manager at Rolls-Royce Naval Marine and responsible for the development of advanced launch and recovery systems used by a variety of military, commercial and ocean science customers.

Feds invest $54 million in next-gen aircraft tech

The Canadian government has announced plans to boost the aerospace industry with a $54 million investment. The funding will be shared by a consortium of 15 Canadian companies and academic institutions led by Bombardier. Other partners include Rolls-Royce, Thales, OPAL-RT, Quaternion Aerospace, FusiA, Liebherr, Axis, and Microturbo (Safran). According to the Minister of Innovation, Science and Economic Development, Navdeep Bains, the goal of the investment is to develop the latest in aircraft technology, while creating the well-paying middle-class jobs of the future. “The Government of Canada is proud of the made-in-Canada innovations that have made our country’s aerospace industry a global success,” Bains said. The consortium will develop state-of-the-art electric and advanced aerodynamic systems in a push to make more energy efficient aircraft. Officials say the innovations in aerospace design and engineering that result from this industry-led collaboration will strengthen the skills and knowledge of Canadians working in the aerospace sector. It’s hoped the initiative will also position the industry to adopt new advanced-manufacturing platforms that provide a foundation for future jobs. www.ito.ic.gc.ca

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12 DesignNews Siemens “Expands Horizons” at Solid Edge University 2016

In October, more than 500 Solid Edge users flocked to the home of the Indy 500 to attend Solid Edge University and check out the latest from Siemens PLM. This year’s event was one of the largest and offered users a chance to learn ST9 and Catchbook, a companion mobile app the company released this year to help designers sketch ideas quickly via a mobile device’s touch interface. The event kicked off with a welcome address by John Miller, Sr. VP and General Manager, Mainstream Engineering, Siemens PLM Software. Miller explained the company has added some significant features to its latest software release to address customer concerns. According to a survey conducted by Siemens PLM, working with imported CAD data was users’ number one CAD challenge and just under half said rapidly creating initial designs was a significant concern. In addition, 1 in 5 users ranked responding to change requests a top challenge while 90 percent of users said they deal with late stage changes. Beyond extolling the virtues of its modeling software, Siemens PLM also stressed its new licensing options as a means to attract new users. For example, Siemens introduced “Solid Edge for Startups,” an initiative that allows U.S. and UK startups (young businesses with less than $10M in revenue and $1M in funding) to obtain a free year of Solid Edge Professional for each engineer. In addition, the company announced cloud-based licensing that allows engineers to validate the software via the Internet rather than being tied to a single install. During the three day event, guests were given the opportunity to “expand their horizons” with expert panel discussions, how-to sessions and best practice advice. Siemens also took the

Dan Staples, VP of product design for Siemens, demonstrates the latest features of ST9.

opportunity to show off their expanding portfolio that includes design, simulation, manufacturing, data management and application enhancements. www.siemens.com

New Flyer begins testing industry-first 60-foot electric bus Winnipeg-based New Flyer Industries’ U.S. subsidiary, New Flyer of America Inc., announced that it has begun testing the industry’s first 60-foot electric heavy-duty transit bus at the FTA’s proving grounds in Pennsylvania. New Flyer’s XE60 battery-electric bus, and its sister XHE60 hydrogen fuel cell bus (pictured), are both powered by Siemens electric motors with rechargeable lithiumion batteries and incorporate a two-axle drive system for added traction. The XE60 version features either extended range batteries or en-route fast charging capability. The XHE60 model incorporates a small hydrogen fuel cell operating as an on-board battery charger. Both the XE60

November/December | 2016

and XHE60 are built on the company’s Xcelsior platform, which has more than 8,000 buses in-service in North America. The company says the XE60 and XHE60 will be deployed initially at the Los Angeles

County Metropolitan Transportation Authority (METRO) and the AlamedaContra Costa Transit District (AC Transit), respectively. www.newflyer.com

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14 CADReport

EVOLVING Bricsys bets on the DWG file format for CAD (and all else). By Ralph Grabowski

rawings stored in AutoCAD’s DWG format are so prevalent that Belgiumbased CAD vendor Bricsys is pinning its success on using the aging format for every aspect of its CAD software. In the opinion of the company’s officers, users shouldn’t endure more than one file format just to use CAD systems specialized for MCAD, ECAD, BIM or GIS. For Bricsys CEO Erik de Keyser, DWG is sufficiently flexible to handle all the extra data needed by 3D MCAD and BIM models (see Figure 1). His BricsCAD software accomplishes this by storing the unique data sets in these areas of the DWG file:

• Extended entity data (a.k.a. xdata) • X records (like xdata but not limited in size) • Extension dictionaries (for documentlevel definitions) • Named object dictionaries (for objectlevel definitions, a.k.a. tables) • Custom entities (for defining entities not available in plain AutoCAD) These parts of DWG are not secret; Autodesk provides APIs (application programming interfaces) so that thirdparty developers can write and read data into these locations. It’s a simple matter

Figure 1: BricsCAD modeling a tripod through an assembly of 3D parts November/December | 2016

www.design-engineering.com

CADReport 15

NGDWG for Bricsys to combine the data locations with documented API calls to extend DWG to many disciplines of CAD. Bricsys embraced and extended AutoCAD’s APIs, specifically LISP, DCL (for designing dialog boxes), Diesel (used for menu macros and the command line), the all-powerful ARx (which Bricsys calls Brx), Tx (licensed from the Open Design Alliance), .Net, COM, ADS (obsoleted by Autodesk but still supported by Bricsys as SDS), and VBA (licensed from Microsoft). Bricsys figures it has the solution to a problem Autodesk created for itself and its MCAD and BIM customers. Users who

deal with a half-dozen file formats would prefer a single format, he thinks. At one time, Autodesk recognized the problem when it showed a nascent universal file format that held data from many of its CAD programs. It was based on Navisworks, but then work stalled as Autodesk acquired and launched more products with their own file formats.

Autodesk’s Move Away from DWG It wasn’t always this complex. Autodesk’s first releases of MCAD ran on AutoCAD – Mechanical Desktop (MDT) and AutoCAD Mechanical. They employed DWG files with custom objects, for which Autodesk provided “object enablers” so that non-MDT users could view and edit the specialized drawings. But then Autodesk developed Inventor to replace MDT, and an entirely new file format – well, four of them, actually: .ipt files to store 3D parts in Inventor; .iam for assemblies; .idw for 2D drawings; and .ipn for presentations. The formats were designed to make a fundamental break from AutoCAD. That was okay at the time because, in the late 1990s, DWG was seen as yesteryear’s file format, destined to fade away. Years later, the company realized it misread DWG’s decline; a multiplicity of emerging AutoCAD clones made DWG more prominent. Autodesk spent years giving Inventor and AutoCAD an ability to read each other’s drawings. The same sequence of events befell Revit, also developed in the late 1990s. More recently, Autodesk decided to begin replacing the Windows-bound Inventor with a new MCAD program that could operate online, Fusion. Users faced new file formats designed for today’s multiuser, multi-server world. The same compatibility crisis affected Dassault Systèmes, whose mid-range Solid-

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www.design-engineering.com November/December | 2016

16 CADReport

Figure 2: BricsCAD-made 3D model opened in AutoCAD

works software is data-incompatible with its high-end 3DExperience line. The compatibility problem is sufficiently complex that after ten years of effort, Dassault has not solved it to its satisfaction. Bricsys management saw the contortions taking place among their competitors and wondered if the solution could be the reverse: Not abandoning DWG but extending it to meet the needs of parts and assemblies, BIM, sheet metal, GIS and more. A single file format meant no disruption due to translation between CAD systems and project engineers. Modeling and editing techniques developed for one discipline (MCAD, say) could be reused for others, such as BIM. No need for multiple teams of programmers working on silo’ed software. Autodesk Will Do It Differently The reason Autodesk didn’t stick with DWG is probably technology-related; it’s simply easier to write a new file system from scratch than to adapt 22-year-old DWG. Even so, Autodesk now says it will also go with a single file format for its future design software, although to call it a “file format” is inaccurate. At Autodesk University 2016, the company said its future lies in what it calls Project Quantum, currently in pre-alpha. In terms of data storage, that translates to a database that runs in the cloud. On the application side, design software like Revit will be rewritten as a group of collaborative “apps” that perform specific functions. These apps would then access the data they need from a shared, online storage system, while users have their own workspaces. For Bricsys, it’s also technology but for different reasons. In part, the company is showing off; by adapting DWG, the company November/December | 2016

doesn’t need to work out new file formats and solve the subsequent tedious translation issues. On the marketing side, it uses the sole-source DWG to lure the users of millions of DWG files, saying, “It doesn’t matter what you do, we can edit it with one program” – albeit in some cases with extra-cost add-ons. The most important concept in MCAD and BIM is assemblies, and Bricsys figured out how to do them with DWG: attach xrefs (parts) in 3D with a 3D constraint system, which the company wrote for itself. To show what’s possible, Bricsys built its own add-on app for doing sheet metal design ($300). Much of its MCAD technology is being applied to their BIM add-on module ($240). Bricsys DWG Files Not Necessarily AutoCAD-compatible Being compatible with AutoCAD is not a concern of de Keyser. He wants new customers bringing their AutoCAD drawings to BricsCAD, not the other way around – as do most other CAD vendors. All the stuff that BricsCAD adds to DWG files, however, is incompatible with AutoCAD. While both CAD systems use the ACIS solid modeling kernel (well, Autodesk uses a variant that it modified on its own), the two have incompatible constraint management systems, for instance. I found that AutoCAD has no problems opening and displaying models constructed in Bricsys. The 3D parts look accurate, (See Figure 2). I tested a BIM model of a house, a sheet metal part and an assembly of 3D parts. Editing is limited, however, as AutoCAD lacks the ability to define BIM slabs, bend sheet metal or constrain parts in 3D. For accessing files from other CAD systems, Bricsys licensed www.design-engineering.com

CADReport 17 translators to handle all the usual neutral formats (STEP, IGES, and so on) and many MCAD systems, like Creo, Inventor and CATIA. The company has also added intelligence to BricsCAD to analyze incoming 3D models using design intent and direct editing â&#x20AC;&#x201C; similar to what SpaceClaim is famous for. The Bricsys Communicator translation add-on is US$610; Autodesk translates models in the cloud and does not charge for the service. Anything can be stored in DWG, but it is not necessarily the best place for everything. On the AutoCAD side, shared data like hatch patterns, linetypes and block libraries are stored externally. The same happens in BricsCAD, where it stores shared data like bending tables for sheet metal and material definitions for BIM slabs in their own files. The ODA also is modernizing DWG by adapting it to multi-user streaming environments, along with change management and project archiving. This will let several people work on a single DWG file online. The organization credits Onshape for some of its inspiration. Bricsys executives are betting the company on a file format they do not control. Whatever Autodesk does to DWG in the years to come, however, is immaterial to the millions of CAD users not employing AutoCAD. Their security rests on the one or two billion DWG files that are already in place. Firms will always need to access them, update them and even start anew. A unified file system is becoming important to the future of the CAD industry, as we see electrical diagrams become part of MCAD models housed in BIM buildings situated on GIS/DTM terrains being viewed in VR and AR. History shows that a more convenient product often overcomes a superior one, and DWG is sufficiently a common denominator that it could become the one pervasive file format for all CAD. DE www.bricsys.com

Ralph Grabowski writes on the business of CAD in his weekly upFront.eZine newsletter. He is the author of many articles and books about AutoCAD, BricsCAD, Visio and other graphics software. He also maintains the WorldCAD Access blog at www.worldcadaccess.com. www.design-engineering.com November/December | 2016

18 SustainableDesign

END-OF-LIFE

DESIGN Diverting e-waste from local landfills and toxic “backyard” operations in developing nations begins with product designers.

espite increasing public awareness and international treaties banning the export of e-waste to developing nations, the amount of discarded computers, TVs, cell phones and other electronic garbage finding its way to other countries continues to increase annually. According to the United Nations, approximately 46 million tons of electronics were discarded globally in 2014, an amount estimated to grow to 50 million by 2018. Of that 46 million, the U.S. accounted for more than 7.7 million tons, while Canada, by comparison, generated 725,000 tons. The good news is that initiatives to divert e-waste from local landfills, at least in Canada, are pushing public behavior in right direction. According to Statistics Canada, the majority of Canadians dispose of electronics via donation, returning it to the supplier or taking it to drop-off centers or depots; a small percentage simply include it in their regular garbage. The bad news is that relatively few Canadian landfills ban e-waste outright. Only Nova Scotia, Prince Edward Island and Newfoundland have banned e-waste from landfills provincewide while the majority British Columbia and Ontario landfills have a ban in place. Conversely, no landfills in Alberta, Quebec, Manitoba and nearly all of Saskatchewan ban e-waste dumping. As a result, more than 140,000 tons of e-waste finds its way to Canadian landfills each year, according to Shift Recycling, one of the major e-waste recycling companies in Ontario. In addition, only 20 percent of e-waste generated annually in Canada is collected by e-waste recyclers as many household simply hold onto old computers, monitors, cell phones etc. than get rid of it. Worse still, even if people properly dispose of their e-waste, it still finds its way to developing nations, where rudimentary salvaging operations expose workers and communities to high levels of toxicity. According to the Basel Alliance Network (BAN)–a non-profit watchdog organization named for the United Nations Basel Convention that restricts the trade of hazardous waste – approximately 50 percent of e-waste generated in the U.S. and Canada ends up in unregulated “backyard” operations in countries like Kenya, India and China. During a “sting” operation conducted by BAN between July November/December | 2016

2014 and February 2016, the organization followed the journey of 205 electronic items from initial drop-off at recycling centres to their final destinations. GPS tracking devices hidden in these e-waste items revealed that 66 of them (32 percent) were exported illegally. In total, 27 presumably “responsible” recyclers, including one certified by BAN’s own e-Stewards program, exported e-waste to countries where importing it from the U.S. is illegal. Those in the industry say the reasons for this are purely economical. Although provinces have implemented extended producer responsibility (EPR) programs, with their associated point-of-purchase eco-fees designed to off-set the cost of recycling, disreputable brokers profit more by exporting e-waste to the U.S. According to reputable firms like Shift Recycling, it’s approximately 10 times cheaper to export e-waste than to dispose of it domestically. Part of the solution, says the Electronics Product Stewardship Canada (EPSC), is reducing the costs associated with recycling end-of-life electronics. In its 2016 Design for Environment Report, the industry-led not-for-profit organization says cost reduction begins with designers. Its members are taking steps to reduce and recycle their electronic products from the outset. For example, the report says that, between 2009 and 2016, the weight of the average 65-inch TV has decreased by 51 percent. Similarly, the material footprint of desktop computers has gone down by 37 percent, printers/copies by 45 percent and computer monitors by 60 percent. More importantly, the organization points to initiatives within member companies to implement design principles that make it easier to dismantle end-of-life electronics. For example, Cisco stipulates that all mechanical parts greater than 100 grams consist of one material and that all plastic parts more than 25 grams be material coded and therefore easily identified by recyclers. Similarly, Dell restricts their suppliers in the use of metallic or galvanic coatings and specifies that plastic parts over 100 grams can’t contain paints or coatings that aren’t recycling compatible. As part of its design guidelines, HP recommends that snap-in features and common fasteners be used in place of adhesives where possible and that plastic and metal parts be easily separable. In addition, the report says companies are opting for higher levels of recycled plastic in newly manufactured equipment. PC-maker Lenovo, for example, says it has used more than 55 million pounds of post-consumer recycled content (PCC) plastic in its new notebooks, workstations and monitors since 2005. Samsung has increased use of recycled plastic in all its products to 5 percent while Sony says that 76 percent of the plastic used in one of its latest hand-held cameras was recycled material. While encouraging, these efforts are relatively small compared to the sheer volume of e-waste being produced globally. In the near term, large e-waste producers and exporters like the U.S. will have to strengthen national and state laws that let e-waste slip through. In the meantime, designers can do their part to ensure there is more profit in responsibly dismantling end-of-life products than dumping it on poorer countries. DE

www.epsc.ca

www.design-engineering.com

www.design-engineering.com November/December | 2016

CADBeat

THROUGH THE KEYHOLE Laser welding simulation shortens design cycle and optimizes component design. By John Kirkley

hen Byron Bemis, senior research associate with insula- weld metal. As the heat source progresses, the molten metal fills tion and roofing manufacturer Owens Corning, was in behind the hold to form the weldbead. asked to design a new laser wielding technique for manufacturAll of these considerations – in particular, the blind keyhole ing components that couldn’t be made using existing processes, welding – meant a lot of trial and error. Running hundreds of it wasn’t an everyday assignment. In fact, with this particular repeated physical experiments using expensive alloys and highR&D project, Bemis and his team were breaking new ground value component parts was prohibitively expensive and time at the company’s Science and Technology Center in Granville, consuming. It was obvious that simulation was the answer. But Ohio. To design and fabricate the requested parts, their initial high fidelity simulation of the complete keyhole physics was designs called for blind keyhole welding through one sheet-metal very complex, expensive and slow. The simulation had to adepart and into another. quately predict quantities “Developing the weldof interest – such as weld ing parameters to make pool diameter, zone shape those welds work reliably and penetration depth – to and robustly took a lot of specify the optimal laser trial and error,” Bemis process parameters. says. “To accomplish this using physical prototypes Seeking A Solution meant fabricating the Contemplating the task individual component at hand, Bemis recalls, parts and then laser weld“We needed an economiing them up using a set of cal solution – one that pre-determined paramewas fast, robust and easy ters to see what happens. to use.” In search of this You continue doing simusolution, he spoke with lation of laser welding his support engineer at In this STAR-CCM+ screen shot of the Owen Corning’s design applicaton, Case 1 shows until you find the right CD-adapco, who had how the weld pool melts in through the corner at constant power and speed. Case 2 combination. This shortexperience with welding pictures an optimized setting allowing for a uniform melt pool throughout the weld cycle. ens design cycle and optisimulation. Based on CDmizes component design.” adapco guidance, he Bemis adds that one of the most challenging aspects of this decided to use STAR-CCM+ to conduct the simulations. project was the necessity to weld close to small features or near Among the points in its favor, the simulation software corners or edges. If the laser ran too hot or moved too slowly, features a suite of geometry creation and preparation tools the feature or edge could melt, ruining the part. that reduce the number of man-hours required to prepare a In addition, these were small welds, he says, varying in size model for meshing. In addition, its single integrated environfrom millimeter to submillimeter scale, made on very small ment provides an automatic route from complex CAD models parts that demanded high precision fabrication. They were also to engineering solution. These met two of Bemis’ criteria – speed running very narrow weld beams – in many cases 50-micron and robustness. weld spots using up to a kilowatt of laser power on an indiAs to ease of use, he says the software’s meshing tools cut vidual spot. The materials used were alloys with very high melt- down geometry preparation and meshing time from weeks ing points, high molten metal viscosity and surface tension. This and months to hours. Bemis used STAR-CCM+ to simulate made for some interesting, non-standard welding physics. the welding heat transfer process. In practice, he says the Complex geometries were also involved, including small solution predicted both the weld width and the behavior of features, edges and circular sections. Because deep penetration features affected by the blind welding. was necessary to make the part, a keyhole mode was required. “STAR-CCM+ has the unique ability to simulate the weldKeyhole mode is a welding technique in which a concentrated ing process and provide insight into the thermal transient heat source, such as a laser, penetrates completely through a experienced during welding in a manner that is both practical work-piece, forming a hole at the leading edge of the molten and fast enough for industrial use,” he says. November/December | 2016

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Overset Meshing For the past 30 years, engineers trying to perform Computational Fluid Dynamics (CFD) simulations struggled with the interaction between multiple moving objects. Traditionally, this required the generation of an interconnected mesh between the objects, an intensive and time consuming manual process. In fact, it was almost impossible if extreme ranges of motion or close interaction between objects were involved. To address this problem, Bemis employed STAR-CCM+’s Overset Mesh feature. This strategy – sometimes called “overlapping” or “chimera” mesh – gives users a more effective way to model and simulate the complex physics associated with moving objects. It also allows the user to generate an individual mesh around each moving object, which can then be moved at will, over a background mesh. “In the welding process, you can either move the heat source or the material,” Bemis says. “Overset meshing allows you to simulate the relative motion between the heat source and the parts that are being welded together. That motion, along with the laser’s power, really dictates how wide the weld gets, the size of the molten zone and the depth of penetration.” “With the use of overset meshes, we were able to run a fairly coarse background mesh as well as a fine, detailed mesh of the weld zone,” Bemis continues. “We moved rather arbitrarily through the background mesh and generated any weld pattern we wanted. Some of the welds were 100mm long and ½ mm thick, resulting in big aspect ratios and a really large mesh count to refine the simulation in the weld zone areas.” In addition to working with a moving target, Bemis had to contend with heat building up in the weld zones resulting in changing parameters as the laser moved from weld to weld. Overset meshing allowed him to simulate individual welds on the component, taking into consideration the changing nature of the material being worked on due to heat transfer. An implicit unsteady simulation with a moving overset mesh permits the prediction of the extent of the molten zone as it progresses along the joint, temperatures in the workpiece and heat transfer to the fixture. Parameters such as laser power, travel speed, acceleration and pulse frequency can be tuned to provide the desired optimal weld.

November/December | 2016 DES_Nov_Dec_2016_LEMO_CSA.indd 1

www.design-engineering.com 2016-08-25 2:08 PM

CADBeat 23 A New Methodology The research team also worked with a methodology recently introduced by CD-adapco known as Multidisciplinary Design eXploration (MDX). MDX allows the automatic testing of designs from early in the concept stage against all of the physics that might impact performance. This is possible due to the increasing capabilities of simulation software that allow engineers to determine how a product will perform under the actual conditions it will face during its life cycle. “We used Optimate to explore the parameter space up front and alter the process and components to get the final results we wanted,” Bemis explains. “We were able to set up weld speed, power and field functions to mimic laser control. We could ramp the laser up and down, simulate voltage feeds and all the other parameters that Optimate could access. We then used the software to run cases to determine such things as how far back from a corner we needed to slow down, and how much to drop laser power in order to make a weld around a sharp corner while maintaining the same heat effective zone in the base material components. The simulation allowed us to prescribe all the welding parameters for experimental validation early in the design process.” “Accurate Enough” He points out that using CD-adapco’s simulation solutions meant that the results were “accurate enough.” The results they obtained provided sufficient information to accurately predict real world weld characteristics, evaluate parameters and decide which directions to take. This process, Bemis says, was very fast considering it was a fully transient simulation with motion and overset meshing. He was able to run enough cases on a high-end workstation loaded with STAR-CCM+ / Optimate to allow design space experimentation and optimization. The software is flexible enough to simulate complex motion in time-dependent parameters for heat input field function interface. “It’s incredible to have that kind of power at your fingertips without having to write your own C code or FORTRAN,” Bemis says. “I figure we saved at least six months of trial and error development – six months of experimental lab time – which is huge. In fact, by freeing up more time for design, we managed to figure out how to avoid using blind welds, a definite plus.

“The high quality simulation using STAR-CCM+ and Optimate allowed us to explore the research, design and analysis of the component as well as the manufacturing process all at the same time. We were able to deliver the final component design complete with all the fab steps and processes in place. This is a very powerful way to work.” DE

www.CD-adapco.com

For more than 25 years, Portland-based John Kirkley has been writing about the high tech, HPC and advanced manufacturing.

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11/10/2016 9:49:48 AM 2016-11-14 10:50 AM

CanadianInnovator

ROBOTIC REHABILITATION Toronto-based startup develops exoskeleton fit for children with physical impairments. By Lindsay Luminoso

erebral Palsy affects over 50,000 Canadians and upwards of 17 million people worldwide. The disease presents in early childhood and affects muscle tone, movement and motor skills. There are rehabilitation treatments to help manage symptoms, but as University of Waterloo engineering alum, Manmeet Maggu, realized after finding out his nephew, Praneit, was diagnosed with the disease, there are limitations to traditional treatment methods. “That’s when we decided to build something for my nephew,” Maggu explains. “We also saw that there are so many children out there with similar disabilities who could benefit from some sort of device to help their walking and rehabilitation.” While at the University of Waterloo, Maggu partnered on the endeavor with fellow engineering undergrad Rahul Udasi as a fourth year Mechatronic Engineering project. In the process, the duo discovered promising research in the area of robotic rehabilitation but early investigations revealed few options on the market – primarily exoskeletons designed to assist adults with mobility issues. These devices were bulky and expensive, making them inaccessible for most children. It was at this point that they decided to launch their own company, Trexo Robotics, to design a pediatric exoskeleton for robotic rehabilitation. “Over the years, the project has been evolving with many different prototypes to improve the design,” Maggu explains. When it comes to designing an exoskeleton, two major concerns came into play – safety and weight-bearing ability. Maggu explains that although there are adult exoskeletons available, they require a certain upper body strength and cognitive ability to operate, rendering them ineffective for their purposes. “Because we were designing this for children, we decided to design around an outer frame and an exoskeleton device inside that frame,” Maggu explains. “That way, with this device, the child can never fall and there is maximum support provided.” The outer frame is similar to a walker with wheels that stabilizes the child while the exoskeleton is affixed to the body to help with mobility and rehabilitation techniques. The team’s focus has shifted from developing a device that works at the most basic level to designing a sophisticated product that can improve the lives of those requiring it. In the early stages of development, Maggu and Udasi traveled to India to allow Maggu’s nephew to test out the device. They were able to get positive real-time feedback from Praneit as well as his parents and physiotherapists about the benefits of using such a device. This particular exoskeleton, dubbed Trexo, was designed November/December | 2016

Manmeet Maggu’s nephew Praneit tests out the Trexo pediatric exoskeleton.

with robotic rehabilitation in mind and can help a child’s gait, posture and overall balance. Along the way, the team encountered some design challenges though, including deciding on the best actuator technology. “In our case, space was a big constraint, we weren’t only designing an exoskeleton that needed to be small and mobile but also it was an exoskeleton for children, so making sure that everything is compact was a big design challenging,” says Maggu. “Not only keeping the actuators small and compact but at the same time keeping them big enough so that they could handle the different range of weights that we can expect a child to have.” The device includes its own control system with a proprietary control algorithm that can detect the forces a child is applying and takes these into account to generate a gait pattern for the child to operate within. “We have our own micro controller and computer board on the device,” Maggu adds. “We also have additional smaller computer units doing smaller things like getting encoder www.design-engineering.com

CanadianInnovator 25 data and preparing the data for the main computer to do the computing. We have internal PID loops/internal control loops for each joint and a master algorithm providing the higher level gait patterns.” The device itself was designed with a combination of material. Stainless steel is used throughout the exoskeleton at maximum stress points. Maggu explains that they also used a lot of 3D printed parts as plastic is light and inexpensive and in many cases ideal for mobile devices. “3D printing has made production much easier for us, otherwise we would have to pay thousands of dollars to have molds made,” explains Maggu. “Now, we can get 3D printed parts instead. As we ramp up production, we will obviously move into injection-molded parts. However, 3D printing has really enabled startups to make it possible to develop part for their products.” Getting everything to work together seamlessly has been a challenge, but one that both Maggu and Udasi have overcome. Trexo Robotics is pushing the limits of robotic rehabilitation to improve the lives of children living with disabilities. “This is a natural evolution for us,” Maggu explains. “Needing up to three physiotherapists to do the same motion that a robotic device can do, developing a robotic exoskeleton seems like the sensible path to go forward. Physiotherapists can now have these robotic devices at their disposal to provide better

care to these children. By making them more accessible and more affordable, we are enabling both physiotherapists and children to enable better care overall.” The duo is currently working on their fifth iteration of the device, ensuring that the device is highly adjustable, while also focusing on the commercial applications of the exoskeleton. Every point requires a level of adjustability to enable children of all sizes and skill level to be able to operate within it. They are also working on the mobility aspects, making sure the device can fit through regular doors and that it is light and easy to transport. Maggu believes Trexo is at the cutting edge of robotic rehabilitation technology. The company has had some commercial success, having spoken with several clinics in Ontario. For example, London, ON-based Able Bionics, a distributor of exoskeleton devices, has agreed to purchase the first Trexo device. Going forward, the two hope to broaden their range of support devices with different sizes and versions. With this expanded product range, Maggu expects the company to grow with it, and the duo are always on the lookout for like-minded people to join them in the cause. “Our philosophy is to explore the leading research regarding different topics and incorporate that to build something that is as advanced as it can be,” Maggu says. DE www.uwaterloo.ca

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26 CoverStory

PIONEERING ADDITIVE DESIGN Renishaw empowers medical device designers with specialized metal additive manufacturing and design software By Lindsay Luminoso

The additively manufactured guides used for facial reconstruction.

ne of the biggest trends in medical device manufacturing is bespoke design. Gone are the days of one-size-fits-all devices, traded in for patient-specific implants. Advancements in new manufacturing processes and CAD software has enable the medical sector to move towards comprehensive care packages for patients. One-offs are easily produced through additive manufacturing, designed in the latest software developed with the best of both clinical and mechanical tools and next-gen technology. Renishaw, a global engineering and scientific technology company with expertise in precision measurement and healthcare, has worked to bring design engineering to the medical sector for the best possible patient care. The company has a longstanding history with medical device manufacturing and has focused on dental restorations, neurological drug delivery systems and more recently maxillofacial implants. The company has also focused its attention on developing additive manufacturing systems. On November 1, 2016, Renishaw opened its first North American Additive Manufacturing Solution Centre in Kitchener, ON, demonstrating its latest product, the RenAM 500M laser powder bed fusion additive manufacturing system. The Canadian team believes that medical device design and patient care will benefit greatly from the processing capability. For Renishaw, additive manufacturing opens up many possibilities including partnering with industry professionals to design patient specific implants (PSI) with unique features that November/December | 2016

leverage the skills and specialities of both medical professionals and design engineers. Skull Reconstruction Because additive manufacturing is a recent phenomenon in the medical sector, Renishaw recognized the importance of partnering with leading experts in both the clinical and design engineering field to bridge the gap that previously existed with traditional processes. In a recent collaboration, the company worked with Professor Adrian Sugar, a consultant in Cleft and Maxillofacial Surgery at Morriston Hospital in Swansea, UK, to design and develop surgical guides for a patient, Stephen Power, who suffered from multiple skull fractures. Power underwent emergency surgery to reconstruct his face, but required additional surgeries to restore its symmetry. Renishaw was responsible for producing custom guides made from cobalt chrome alloy on its AM250 metal 3D printing machine. Using CT scans, the design team was able create patient specific guides to help surgeons place the implant with a near perfect fit and reconstruct Stephen Powerâ&#x20AC;&#x2122;s face. This first-of-its-kind partnership opened up new opportunities for collaboration between the medical and design engineering field. Traditional surgical boundaries were extremely limiting; additive manufacturing enabled Stephen Power to get the best possible care and ushered in a new era of medical device manufacturing, one that is centered on the patient. www.design-engineering.com

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28 CoverStory are micro-movements that are conducive to implant loosening; these are a good indicator of implant success/failure.” Additive manufacturing enables the ability to adjust and adapt the device to meet patient needs. This process also allows for unique features to be incorporated into the design that are unheard of in traditional manufacturing. The hip implants produced through the partnership were modified to including an open-porous lattice structure, comprised of 1.5mm unit cells and 0.5mm struts. Parkes explains that this type of structure enhances bone ingrowth and device fixation. “In healthcare, there’s lots of potential for novel ideas and concepts,” says Parkes. “3D printing has really opened up a whole host of new possibilities that weren’t there with subtractive techniques, whether that is lattice structures or a patient-specific result or the ability to quickly iterate a design and test a concept.” What is more, designing patient specific implants is much easier with additive manufacturing. The cost of producing oneoffs is significantly reduced without the added expense of tooling. Multiple iterations can be produced quickly and effectively to fit patient requirements.

Additive manufacturing enables designers to include unique structures in medical device implants like lattice for bone adhesion.

A Canadian Perspective Over the years, Renishaw has partnered with many UK-based companies to develop next-gen technologies for medical device manufacturing. However, with the opening of its new North American Additive Manufacturing Solution Centre, the company is exploring opportunities within the Canadian medical device market. One way is through collaboration with Dr. David Holdsworth, the Dr. Sandy Kirkley Chair of Musculoskeletal Research and scientist in the Imaging group of the Robarts Research Institute at Western University. This collaboration has proven that additive manufacturing opens design possibilities to develop structures that couldn’t be achieved with traditional manufacturing processes. One example of this is through the development of next-generation “smart” hip implants. In conjunction with Western University, the team recently designed and 3D printed a device instrumented with electronic sensors and wireless telemetry in a porous implant. This hip joint prototype allows for sensors to monitor health-related data including strain, temperature, movement and the like. “You can imagine in the IoT environment, the ability to use this data in healthcare opens up a lot of options, especially the type of data that wouldn’t be available to clinicians currently,” explains Matt Parkes, senior medical development engineer at Renishaw. “Whether that’s patient compliance, how quickly they get back on their feet when they are told to rest, or if there November/December | 2016

This new ADEPT software brings together both a clinical and engineering perspective to design the best possible medical devices.

A New Design Tool One of the challenges with additively manufactured medical devices is in the design process. When it comes to traditional manufacturing, designers generally know about all of the manufacturing techniques of machining; however, in this case, the design engineer needs to also know about the clinical requirements. “Those two sets of experiences aren’t typically naturally occurring,” explains Parkes. “There aren’t many 3D printing experts who happen to also be surgeons.” He says that either design tools need to inform an engineer or manufacturer of clinical requirements or they need to enable a clinician to design implants that conform to manufacturing needs. Unfortunately, he says, there weren’t any suitable tools for this task. Of those that were capable of the organic shapes needed for implants, Parkes says they were extremely complex and had a steep learning curve. “For example, a cranial plate could take upwards of a day to design with some of these tools,” he says. “Quite often, they aren’t built around an engineering or clinical approach. Some solely utilise freeform design tools, a design-whatever-you-want www.design-engineering.com

CoverStory method; this lack of structured process isn’t particularly helpful for either approach.” Renishaw is working to solve this problem with its ADEPT software, which was developed in-house by the Medical and Dental Products software team in conjunction with user experience experts PDR (Cardiff, UK) and clinical partner Abertawe Bro Morgannwg University Health Board (Swansea, UK). “Our collaboration with end users has enabled us to develop a tool uniquely tailored to the clinical situation,” Parkes adds. The software is able to simplify the craniomaxillofacial (CMF) patient specific implant (PSI) design workflow through tools that easily achieve complex anatomical design. Another challenge the team addressed was file format conversion. For the most part, when it comes to patient specific medical devices, designers start with CT scans and voxel-based data. Parkes explains that converting this data to an engineering surface can cause lots of issues. Working with surface features that are hard to identify on a CT scan and then accurately recreating them in a form that can then be designed or worked with is typically time consuming and difficult. However, the ADEPT software is able to dramatically streamline this process, allowing the user to quickly go from CT data through to design. “Existing tools for PSI design are convoluted – requiring months of expertise to fully utilize, hours to complete simple cases and poor focus on the clinician’s requirements,” says Parkes. “By simplifying this process and offering intuitive tools, ADEPT will improve patient outcomes through reduction and removal of barriers to additive manufactured craniomaxillofacial patient specific treatment.” The ADEPT software is currently in closed beta testing, but Renishaw says they have had positive feedback from clinicians and technicians in the UK and Europe. The software will be publicly released in early 2017. “Ultimately we’d like to see PSIs used in the majority, not minority, of CMF cases, allowing patients and surgeons to exploit the benefits of custom fitting devices,” says Parkes. “ADEPT is a tool to help turn this into a reality.” With the use of this software, the design of medical devices is becoming easier and with additive manufacturing, the devices are becoming highly customizable to meet patient needs. More medical professionals are recommending and opting for PSIs and Renishaw is helping advance this trend.

Because the company also manufactures the additive manufacturing systems, they are in a position to assist from both the machine side and the design process. “It’s a pretty unique situation,” Parkes says, “There are lots of opportunities when clinicians and engineers with manufacturing experience work together in close collaboration, developing designs that both suit the medical purpose and can also be made effectively.” DE

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30 DesignR&D

DUST RUST THE

Battelle and Xerox Research Centre of Canada harness advanced material science to bring rust-fighting technology to market. By Dr. Paul Smith

t sounds almost too good to be true – harnessing the destructive power of rust to eliminate itself and promising to protect billions of dollars worth of critical infrastructure around the world in the process. But that is precisely the technology being developed at a state-of-the-art lab in Mississauga, ON by two of North America’s leading research and development organizations – the Xerox Research Centre of Canada and Columbus, Ohiobased Battelle Memorial Institute, the world’s largest nonprofit research and development organization. However, there’s more to the partnership than just an interesting invention. The alliance of Xerox and Battelle can also serve as an example for Canadian firms on how to navigate the so-called “Valley of Death” and scale an innovative idea from the lab to commercialization successfully. Smart Corrosion Detector beads are the brainchild of Battelle, which began developing the tiny rust fighters several years ago. The self-healing beads detect corrosion before it can be seen by the naked eye. Corrosion causes a chemical reaction that breaks the shell of the miniscule beads, releasing a proprietary chemical agent that fills the microscopic cracks that rust creates. November/December | 2016

Because the beads fluoresce in the presence of corrosion, the reaction can be detected with a special light. This provides an early warning sign that rust is settling in – even if it’s hidden beneath paint – creating an opportunity to address the problem before it becomes too tough to fix and too costly. Roughly the size of a grain of salt, the 20- to 50-micron beads look like a fine, whitish powder than can be mixed with paints or other coatings and applied to bridges, pipelines or other pieces of vital infrastructure that can be damaged by rust. But while Battelle scientists and researchers came up with the corrosion-killing beads, they didn’t have the facilities or equipment to produce large quantities of the product to be field tested by potential customers. Battelle was not planning to expand its mandate from R&D into manufacturing and invest in the facilities and human resources necessary to begin making large batches of the beads. That’s where Xerox and its Canadian research and development lab came in. Battelle looked across the border and found a partner with complementary material sciences capabilities, as well as the facilities and expertise needed to commercialize innovative technologies and manufacture large www.design-engineering.com

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DesignR&D qualities of product. The XRCC’s Scale-Up Engineering Pilot Plant is outfitted with chemical reactors capable of producing anywhere from two to 2,000 litres of material at a time. For more than 40 years, Xerox has engineered new materials like inks, toners and photoreceptors for the company’s own purposes at the research lab. As the primary advanced materials research and development centre for Xerox’s operations around the globe, virtually every Xerox product in market today has been inf luenced in some way by the research team in Mississauga. But over the past four years, the centre has opened its lab doors to put its experience and expertise to work for other companies, collaborating with them to research and develop high-tech products and bring them to market. Members of the XRCC team have been able to draw on the problem-solving skills they developed in the lab to help companies – whether small start-ups or large companies – identify risks, demonstrate the value-proposition of their technologies and guide them through the steps to commercialization. Canada has a long track record of innovation, is one of the heaviest funders of discovery research in the world and fortunate to have a highly trained and educated workforce. Not to mention, a wealth of budding entrepreneurs with no

shortage of bright ideas for new technologies. But where innovation and productivity often falter is in the critical stages of moving from research to scale-up and commercialization. That’s where many start-ups fall into the gap and fail to get their ideas off the ground. And that’s where the XRCC can lend its expertise, guiding start-ups past the risks threatening to take them down before they really begin. As Canada embarks on an innovation agenda under the Trudeau government, the XRCC aims to play a crucial role helping start-ups and corporate leaders navigate the valley of death that often crushes promising ideas before they’re commercialized. Canada’s innovation prospects hold great promise for the future of this country, as do Battelle’s rust-fighting beads, which will be going to market in the next year or so – a true breakthrough that will help change the way the world around us is built and protected. DE

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Dr. Paul Smith is the Vice President and Centre Manager of the Mississauga-based Xerox Research Centre of Canada (XRCC), Canada’s leading materials research centre.

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ACCEPTED CFPA’s Fluid Power Challenge goes national to seek the next generation of future fluid power professionals. By Frank Pirri

have been steadily employed in the fluid power industry all my adult life. I owe this career choice, in part, to one of my high school teachers, Mr. Bunting. I have always been a bit of a gear head so, throughout high school, I took a good mixture of technical and academic courses. In grade 12, I was discussing postsecondary career choices with him and he suggested I look at the Fluid Power and Robotics Program at Centennial College, saying that he thought I would find it challenging and interesting. I had never heard the term “fluid power” before. I was familiar with many forms of mechanical devices that use hydraulics and pneumatics, like landing gear and heavy machinery, but I never really thought of the technology that made that equipment work. I attended an open house at Centennial College and still remember the tour and watching the promotional movie in the auditorium on the Ashtonbee campus. Still undecided, I completed grade 13. After reviewing a handful of acceptance letters, ranging from aerospace engineering to theatre set design, I chose fluid power, still not 100% sure why. I am happy I did; maybe it was the movie I had watched the year before. I mention this only because, if it were not for Mr. Bunting, I would never have heard of the fluid power program. For whatever reason, fluid power just isn’t recognized like other high-tech disciplines. If you think I’m joking, just look into the eyes of someone who asks you what you do for a living and watch them glaze over when you respond “I work in the fluid power industry.” Few people realize they owe their current standard of living, in part, to fluid power. It’s used to harvest, process and manufacture almost everything that we touch, but few of us even give it a second thought. It’s almost like looking at a human body. We see the outside but rarely think of the blood, bones and muscles that make everything work. In fact, fluid power technology is the blood, muscles and sometimes bones within many a modern, high-tech machine. And, with today’s heavy integration of electronics controls, fluid power technology is becoming smarter, able to perform movements faster, more accurately and much more efficiently. We in the fluid power industry already know this, but how do we get the message out to the masses, in particular to younger students? This has been and continues to be one of the main issues that the CFPA Education Committee strives to address. Over the years, we have focused on attracting middle school students to STEM (Science, Technology, Engineering and Math) programs. Our annual Fluid Power Challenge continues to be well received November/December | 2016

with 21 schools participating in this year’s event. However, it currently only includes schools from west Toronto. To reach the rest of Canada, our committee is working on making our Challenge national. This November, we will launch the first ever national challenge in six geographic locations across Canada. Along with middle schools, we’re looking to attract high school students by becoming more active at college career days. Last spring, six member companies took part at Centennial College’s event. For 2017, we would like to expand that by also participating in Niagara Colleges Career Day and possibly a lunch and learn at Mohawk College. The committee is in the process of developing presentation materials to be used during those events. Our intent is to capture the interest of potential students in choosing a career in fluid power and encourage CFPA members in other parts of Canada to make presentations at local colleges. To make it easier for students who are interested in fluid power and want to locate a post-secondary institution that offers a fluid power content, the CFPA Education Committee has put together a listing of all the colleges across Canada that do so, as well as any job fairs that are available. We’re also working with the International Fluid Power Society to upgrade the technical knowledge of the current employees of our members. To aid in closing the loop from education to employment, the CFPA has created an online listing of links to all member companies’ career sites, so they can be easily found by persons seeking employment. We will also be asking local colleges to provide our CFPA link for jobs and to link our site to their specific job postings. This service will be available to CFPA members only. If you aren’t a member, we encourage you to join to take advantage of this and many other benefits that membership provides. Like Mr. Bunting, the CFPA Education Committee will continue to reach out to young people and those between careers to consider our industry. We aim to make them aware that fluid power is a crucial, vibrant, cutting-edge technology in which they can enjoy a long and exciting career. Get more involved in helping promote careers in fluid power and developing a qualified future work force by joining CFPA. DE www.cfpa.ca

Frank Pirri serves as the CFPA Education Chair and is the Sales & Product Manager for FD FLODRAULIC. www.design-engineering.com

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36 MotionControl

Choosing a

SENSOR Selecting the optimal linear position sensor comes down to purchase cost and a few key specification parameters. By Harold Schaevitz

inear position measurement is a frequent requirement for many industrial automation or process control systems, QA functions and R&D testing. The actual position measurement function is normally performed by some type of position sensor, the selection of which quite often is based on just a few key specification parameters and its purchase cost. This article identifies the most commonly utilized industrial position sensing technologies and poses a set of questions to ask yourself about various position sensor application issues to assist you to make an optimum choice of sensor from both a technical and an economic perspective. The most commonly utilized industrial position sensing technologies incorporate a moving element which is attached to the object or workpiece whose position is being measured, while the body of the sensor is fixed in position. Typical of these are Linear Variable Differential Transformers (LVDTs), Linear Variable Inductance Transducers (LVITs), Magnetostrictive Linear Displacement Transducers (MLDTs, also known as LDTs) and linear

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resistance potentiometers (Pots). Of the four common sensor technologies, the first three are “contactless,” that is, they don’t require any physical or electrical contact between their moving element and their fixed part. Pots, however, do have a wiper that contacts their internal resistance element that is fundamental to their operation, so they are not contactless. The foregoing explanation should illustrate the difference in the meaning of “contactless” and “non-contacting” as applied to position sensors. To assist in choosing the optimum sensor for an application, here are a number of questions that should be answered first: Can you define explicitly what you are attempting to accomplish with the position measurement? While this may seem to be an obvious step, it is often overlooked during a sensor selection process and is critical to developing an overall perspective. Once you answer this question, other questions pertaining to the details of the measurement can be posed.

www.design-engineering.com

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What is the nature of your sensing application? Typical answers include automation or control systems, industrial process monitoring without automatic control, product quality assurance and R&D lab testing. Your response will help prioritize the specification parameters of the sensors under consideration. For example, an automatic control system would likely require better dynamic response than a typical quality assurance test, but quality assurance measurements usually require better measurement precision and especially calibration traceability.

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In what environment is the sensor expected to operate and how harsh is it? There are many issues involved in answering this question. One is the range of ambient temperatures in which the sensor will be expected to operate. Another is the level of vibration and/or shock the sensor will experience. A key issue is the degree the sensor will be exposed to moisture, coolant mists, solvent or chemical vapors, dust or grit. For example, in a typical factory floor environment, there can be serious shock impulses transmitted from the structures of punch presses and a large amount of grit that can accumulate from sanding or finishing operations. Is there possible electromagnetic interference (EMI) from arc welders, variable frequency motor drives or 2-way radios? Finally, is the sensor going to be operating in a hazardous location that would require a UL, FM or CSA hazlocapproved component? What reliability and quality issues apply to the position sensor? Several important factors pertain to this topic, the most important of which is whether the sensor is being used in a safety-critical application where its failure could result in serious injury to personnel. In such an application, reliability becomes the highest priority in selecting the right position sensor technology. For less critical uses, the key quality questions relate to the measurement system’s duty cycle and expected service life. Reliability comes into sharp focus when the sensor must operate on a 24/7/365 duty cycle that can cause sensor system operating cycles to accumulate very quickly and wearout to develop in a relatively short period of time. Another factor pertaining to reliability is the frequency of recalibration required for the position sensor, as well as its preventative maintenance program. Downtime of the position measuring system, whether it is scheduled or unscheduled, typically has a significant cost beyond the direct expenses of recalibration or maintenance. Replacing a worn out or failed sensor also can introduce downtime.

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MotionControl

www.design-engineering.com 2016-01-15 10:14 AM

MotionControl 39 Are there any additional items needed to make the position sensor function? Typical examples are ancillary electronics like power supplies, signal conditioners and various cables. An often overlooked extra is the need for specific mounting hardware and the labor for installing the sensor. A further requirement could be special software that must be acquired to effectively utilize the sensor. Is there any special training or a sensor-dependent learning curve for the measuring system operator? This is usually the most common unanticipated issue in applying a sensor in a measuring system. If this is a potential expense, then it is necessary to consider it in developing a budget for the real installed cost of the position sensor in the measuring system. What position measurement accuracy and resolution are actually required for your application? It’s possible for the position sensor in a measuring system to be over-specified in these regards, which can add unnecessary difficulty in making the choice of the optimum sensor from among the many technologies available. The key to this issue is a good understanding of what these parameters mean. Then you should evaluate the effect of lower accuracy and/or resolution for the position measurement application by doing the necessary calculations. In performing these calculations, pay particular attention to the exact manner in which the specification is presented. Unfortunately, it is possible for a sensor manufacturer to utilize specmanship that favors their product and can lead to misunderstanding unless the parameter is closely scrutinized. The foregoing questions assist in the selection of the correct sensor so that a prospective position sensor user or specifier will gain insight into various factors. These factors go into the choice of a position sensor for a measurement application and can establish a weighted priority list of specification parameters for the optimum sensor choice. DE www.alliancesensors.com

Harold Schaevitz is President of Alliance Sensors Group.

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www.design-engineering.com November/December | 2016

40 IdeaGenerator Automation Mobile Panel B&R Automation has added three mobile units to its HMI portfolio. The Mobile Panel 7100 series of handheld HMI units feature an ergonomic, light and shockproof design. The panels are available in a range of sizes. The 7140 and 7150 feature a 7” WSVGA and 10.1” WXGA display, respectively. The 7151 model has a 10.1” display and runs a Windows-based operating system. Mobile Panels feature an integrated touch screen as well as dedicated keys for frequently used functions. Operating elements like the key switch and stop button are recessed in the rounded, double-walled housing that is able to absorb hard impacts. The IP65-rated mobile HMI units also provide integrated interfaces including USB 2.0 and Ethernet 10/100. www.br-automation.com

Security Appliance Rockwell Automation introduced its Allen-Bradley Stratix 5950 security appliance, which incorporates the Adaptive Security Appliance (ASA) firewall and FirePOWER technology to create a security boundary between cell/area zones or to help protect a single machine, line or skid. This supports compliance with IEC 62443. The device also uses deep-packet-inspection (DPI) technology. Developed in collaboration with Cisco, the DPI technology enables inspection of the Common Industrial Protocol (CIP) and other industrial protocols. The appliance includes four 1-gigabit Ethernet ports and is available with copper-and-fiber or copper-only, small form-factor pluggable (SFP) slot options. The industrially hardened device is IP30-rated and can withstand electrical shocks, surges and noise. It can operate in temperatures ranging from minus 40° to 60°C (minus 40° to 140°F). www.rockwellautomation.com

Cable Carrier System igus has introduced the ZF14 Energy Chain cable carrier, developed specifically for use in furniture design. The cable carrier is mounted with brackets, which can either be screwed or bonded directly onto furniture. The carrier is then clipped in easily and securely, and allows for simply cable installation. Smooth inner contours offer cable-friendly guidance for years of operation. The ZF14 Energy Chain is available in a range of colors to suit all furniture designs. www.igus.com

Motion Control Servo Terminals Beckhoff released its EL72x1-9014 EtherCAT servo terminals, which implement STO (Safe Torque Off) functionality and integrate features corresponding to safety level Cat 3/PL d, according to EN ISO 138491:2015. In addition, the terminals feature 2-channel shut-off with corresponding contactors in a single motor cable that connects the TwinSAFE safety outNovember/December | 2016 DES_IndustrialEncoder_NovDec.indd 1

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IdeaGenerator

put terminal and the STO input of the servo terminal. The EL72019014 variant comes in a 12mm terminal housing and supplies an output current of up to 2.8 ARMS, while the 24mm EL7211-9014 version can supply a maximum of 4.5 ARMS. Both are designed to power servomotors from the Beckhoff AM8100 series. www.beckhoffautomation.com

Linear Actuator Portescap introduced its 20DBM series of can stack linear actuators. The 20mm linear stepper motors feature an optimized magnetic circuit. The motors provide a 7.5 deg step angle with a maximum holding force up to 50N. The customizable 20DBM actuators are powered by high energy neodymium magnets, an electromagnetic circuit and a patent pending bearing preload design. The 20DBM is available in Captive and Non-Captive versions with various leadscrew pitch options. They are manufactured in an ISO certified facility and are RoHS compliant. www.portescap.com

Piezo Scanner PI’s P-616 NanoCube XYZ piezo scanner is based on a parallel-kinematic design, with one lightweight moving platform for all 3 axes. The miniature multi-axis stage features capacitive feedback, delivering 100µm travel range. The positioner is operated with PI’s E-727 digital servo piezo controller. The scanner’s software package includes drivers for LabVIEW, dynamic libraries for Windows and Linux, MATLAB. Interfaces consist of USB, SPI, RS-232 and analog. Supported functions include Wave generator, data recorder, auto zero and trigger I/O. The XYZ stage is driven by ceramicencapsulated, preloaded PICMA piezo actuators that provide better performance and reliability than conventionally insulated piezo actuators. www.pi-usa.us

Piezo Nanopositioning Stage Aerotech introduced its QNP2 series of parallel-kinematic, piezo positioning XY stages that combine sub-nanometer resolution and high dynamics. The stage has a 50mm x 50mm clear aperture with closed-loop travels up to 100µm x 100µm (open-loop travels to 120 µm x 120 µm). The design is ideal for optical microscopy, scanning probe microscopy, x-ray transmission microscopy and other applications where twosided part access is required. All QNP2 piezo stages are available with closed-loop feedback or open-loop (no feedback). The capacitive sensor parallel-metrology design directly measures the output of the positioning carriage enabling 0.15nm resolution, 0.01% linearity and 1nm bidirectional repeatability. www.aerotech.com www.design-engineering.com November/December | 2016 DES_RotorClip_MayJune.indd 1

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42 IdeaGenerator Fluid Power Pressure Regulator Clippard announced that its DR-2 Series provides greater accuracy and repeatability (±0.15 psi) while maintaining the same flow and performance characteristics as the

MAR regulators. Regulators are offered in either relieving or nonrelieving versions. The relieving design maintains a constant pressure output even when downstream conditions change, while nonrelieving regulators do not automatically compensate for changes in downstream flow or pressure. There is no vent to atmosphere, as in a relieving type regulator, and the output pressure can increase due to a downstream event. The DR-2 series was designed for applications where zero air consumption is required (non-bleed) and comes with a manifold mount option. www.clippard.com

Variable Frequency Drive

High-Performance Energy and Data Transmission Systems Conductix-Wampfler’s mission: To keep your operations running 24/7/365 with rugged, reliable energy and data transmission systems. Our conductor bar, cable reels, festoon systems and crane controls are time-tested in the most demanding environments and backed by a worldwide sales and service network unmatched in our industry. We have over 60 years of experience applying our complete line of mobile electrification and ergonomic products to real-world industrial applications.

Eaton’s PowerXL Series DG1 variable frequency drives now include a Frame 6 option. The drive increases available power from 150 to 250hp. The design also utilizes thermal management techniques to provide superior power density while also providing fully competitive performance, the company says. The general-purpose drive also incorporates a patented energy control algorithm, onboard industrial communication protocols and built-in harmonic reduction. The product retains the same keypad, interface and interaction features that made earlier versions of the drive popular, but increases the power available for customer applications. www.eaton.com

If you need solid solutions, look no further than Conductix-Wampfler. Now serving you from our new, modern distribution facility in Mirabel, Quebec

Spiral Hose Fitting

CANADA 18450 J.A. Bombardier Mirabel, QC J7J 0H5 Phone +1-800-667-2487 Fax +1-800-442-9817

Eaton introduced its 4S/6S series of spiral hose fittings that feature Dura-Kote plating technology for corrosion resistance, a non-brazed nipple design to decrease the risk of product failure, and class 0 cool-down leakage, following impulse testing as outlined under SAE J1176 when coupled with Eaton hoses. Built with

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www.design-engineering.com 12/30/2014 10:31:14 2015-01-21 9:39 AM AM 2016-01-25 11:21 AM

IdeaGenerator 43 captive nuts instead of crimp nuts, the 4S/6S series prevent cracking, even if over-torqued. The 4S/6S fittings have also been simplified to a common design and can be used on a wide variety of Eaton rubber hydraulic hose products. The fittings are available in sizes -12 through -32. www.eaton.com

Sensors Contrast Sensors AutomationDirect launched its Datalogic print mark contrast sensors. With 6-12mm sensing distances, the line is designed to detect the difference in the wavelength of the reflected light between a target mark and background. The S8 Series feature horizontal spot orientation, a 25kHz switching frequency, NPN or PNP logic output, 12-30VDC operating voltage and are available with IP67-rated plastic or IP69K-rated 316L stainless steel housings. The series are fitted with a 4-pin M8 quickdisconnect or have an attached 150mm cable with M12 quick-disconnect. New TL Series contrast sensors feature vertical or horizontal spot orientation, 10-30VDC operating voltages, aluminum housings and NPN/PNP or PNP logic outputs. TL series sensors are fitted with a 5-pin M12 quick-disconnect with adjust-

move-series

able exit angle; models are available with 0-5VDC analog outputs and 15, 20, or 50kHz switching frequencies. www.automationdirect.com

1D vision sensors Teledyne DALSA released its BOA Spot ID vision sensors, which combines 1D/2D code reading with OCR and verification tools. The BOA Spot ID is available in two models. A standard IDS model includes the core 1D/2D decoders, while the expanded IDE model adds advanced Direct Part Marking (DPM) decoding, OCR and verification tools. These new vision sensors can decode 1D barcodes with bar widths and spacing down to 1.5 pixels; and 2D matrix codes with cell or dot sizes down to 2 pixels. The series integrates LED lighting, lens cover and software, plus an IP67 rating. Inspections using the series can be triggered by parts in motion or from a PLC after being moved into a stationary position. Ethernet/IP and PROFINET are directly supported for communicating with 3rd party equipment. www.teledynedalsa.com

F R E E C ATA L O G & B R O C H U R E

STAMPINGS & WASHERS

The New Generation of Timing Belts

80% HIGHER CORD STRENGTH OPTIMIZED TOOTH GEOMETRY LOW FRICTION TOOTH FACING move-series is a timing belt designed for high-performance drives move-series provides a durable solution, with a friction-optimizing laminate coating to minimize wear and increase service life move-series affords space and cost savings. With a higher transmittable force, belt drives can be more compact and powerful

FOR CUSTOMER SERVICE AND FREE TECHNICAL SUPPORT CALL (732) 460-9500, EMAIL: INFO@BRECOFLEX.COM OR VISIT WWW.BRECOFLEX.COM

bokers.com

Call (888)-WASHERS 612-729-9365 sales@bokers.com

3D-PRINTED PROTOTYPES NOW AVAILABLE

www.design-engineering.com November/December | 2016 DES_Brecoflex_NovDec.indd 1

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2016-11-11 1:53 PM

IdeaGenerator

Absolute Encoder Dynapar announced the expansion of its Hengstler AI25 absolute encoder product line with the addition of the EtherCAT interface. The AI25 EtherCAT Encoder integrates into virtually any system that uses the EtherCAT communication protocol. The encoder offers cycle times of 62.5µs and a single turn resolution of 22 bit with absolute accuracy of ±35”. With 400G shock and 30G vibration ratings, the encoder is also suitable for rugged environments. Additionally, optional shaft seals and stainless steel housing are available. The encoder is also available in several configurable options including hub bore or shafted mounting and resolution options up to a combined 32-bit resolution. www.dynapar.com

Multi-Turn Angle Sensors Novotechnik launched its RMB 3600 Series of absolute multi-turn angle sensors that offer a galvanized steel housing and stainless steel shaft with up to 100N working shaft load for the HD version. Sealed to IP 69K, depending on version, the sensors are EGMR (enhanced giant magnetic resistance) devices that count turns even when power is removed. With an operating speed up to 12,000 RPM, the series also features a 36.5mm profile, count to 16 turns, angular position 0 to 5,760°, resolution to 18-bit (SSI)/16-bit for other outputs, repeatability of 0.5° or better, and typical independent linearity of ±0.03% F.S. at 16 turns. Output options are 0.1 to 10V, 4 to 20mA and 10 to 90% of power supply and SSI. All models have operating temperature range of -30 to +85°C and 0 to 98% RH, non-condensing. RMB 3600 Series sensors withstand shock to 50g and vibration to 20g. www.novotechnik.com

Electrical M12 Connectors HARTING introduced its M12 Power connectors, designed for high power applications, which established the IEC 61067-2-111 standard. The connector’s universal mating face with L-coding has also emerged from this adopted standard. At 63V/16A, the 5-pin L-coding achieves 0.75kW of power, making it suited for small servo motors, field distribution boxes, field-bus-controlled I/O boxes, power supply devices and valve applications. The M12 L-coded is viewed as the future standard equipment connector and is expected to completely replace the application area of the existing M12 A-coded and 7/8” solutions. www.harting-usa.com www.design-engineering.com November/December | 2016

CLIPPARD SOLENOID-OPERATED PTFE MEDIA MINIATURE NEW DR-2 PRECISION ISOLATION VALVES DIAPHRAGM REGULATORS EXCELLENT ACCURACYThese & REPEATABILITY miniature 2-way and 3-way valves utilize a flexible

The DR-2 series regulators are robust, costdiaphragm to isolate the actuation mechanism from the effective devices that provide precise repeatability fluid path making them ideal for sensitive or corrosive (±0.15 psi), sensitivity and stability in a small, materials. Media isolation valves are commonly used for sleek package. Designed for applications where a wide variety of applications including those that require zero air consumption is required (non-bleed), precise, repeatable dispensing of media. Many features they are ideal for medical devices, analytical include low power consumption, superior design and equipment, lab automation, printing, process construction, zero dead volume, high cycle life, fast control and more. Relieving and non-relieving designs are available. response and more. Proudly made in the USA.

Clippard Instrument Laboratory, Inc. Clippard Instrument Laboratory, Inc. www.clippard.com www.clippard.com 877-245-6247 513-521-4261

ADHESIVE LOWTHERMAL THERMAL RESISTANCE ADHESIVEHAS HAS ULTRA ULTRA LOW RESISTANCE

Master MasterBond Bond Supreme Supreme 18TC 18TC is is aa single single component epoxy that contains of component epoxy that contains aa blend blend of special thermally conductive fillers. This special thermally conductive fillers. This

smooth smooth paste paste system system can can be be applied applied in in bond lines as thin as 10-15 microns. bond lines as thin as 10-15 microns. ItIt offers offers an anexceptionally exceptionally low low thermal resistance of 5-7 x 10-6 K•m2/W 5-7 x 10-6 K•m2/W and a thermal conductivity of 22-25 BTU•in/ft2•hr•°F. Supreme conductivity of 22-25 BTU•in/ft2•hr•°F. Supreme 18TC 18TC features features outstanding heat transfercapabilities capabilitiesand andpasses passesNASA NASAlow lowoutgassing outgassing tests. transfer www.masterbond.com www.masterbond.com info@masterbond.com info@masterbond.com 1.201.343.8983 1.201.343.8983

DUSTCOLLECTORS COLLECTORS NEW LITERATURE GUIDE DUST NEW- -FULL FULLLINE LINE LITERATURE GUIDE This impressive impressive NEW outlines dozens of N.R. This NEWguide guide outlines dozens of Murphy dust collectors, installations, capacities, N.R. Murphy dust collectors, installations, styles and models. must for any reference library. capacities, styles Aand models. A must for any N.R. Murphy Limited been inLimited businesshas over 70 reference library. N.R.has Murphy been and has satisfied customers. inyears business overthousands 70 years ofand has thousands of “Dust Collectors are all we do; so get it done right satisfied customers. “Dust Collectors are all we the first time. Just Ask the Experts.” do; so get it done right the first time. Just Ask the Experts.”

N.R. Murphy Limited N.R. Murphy Limited www.nrmurphy.com www.nrmurphy.com Tel: 1.519.621.6210 • Email: 4nodust@nrmurphyltd.com Tel: 1.519.621.6210 • Email: 4nodust@nrmurphyltd.com

To advertise your solution in this section To advertise your solution in this section call Alan Macpherson at 416.510.6756 call Alan Macpherson at 416.510.6756

46 IdeaGenerator grounding studs for use with non-metallic conduit. Transformers are available in 480VAC and 600VAC models and in 3 to 15kVA sizes. Acme encapsulated 3-phase transformers are UL and CSA approved and are RoHS compliant. www.automationdirect.com

M12 Connectors

3-Phase Transformers AutomationDirect has expanded its line of power products with Acme Electric’s drytype encapsulated 3-phase transformers. The NEMA 3R transformers are designed for dust or lint-laden atmospheres and are suitable for indoor and outdoor use. The transformers feature fully encapsulated core and coil, copper lead wire terminations, electrostatic shield and are fitted with

Chogori introduced its series of field installable M12 connectors that allow the customization of cable type and length. Available in straight and right angle versions, the connectors are designed to meet the IEC 61076-2-101 standard. To ensure connectivity in rugged and high-vibration environments, the IP67/IP68-rated male and female connectors are offered with coupling nuts in brass or stainless steel. Pin configuration and termination varies from 3, 4, 5 and 8 pins with screw-in termination, and 12 pins with solder termination. The series includes metal and plastic unshielded

See Us at MD&M West Booth #2383

connectors for cables with OD ranging from 4mm to 7.5mm. The connectors are also available with A, B and D code options. The M12 Series connectors have a rated voltage up to 250V, a current rating up to 4 Amps and an operating temperature of -25°C to 85°C. www.chogori-tech.com

Advertisers Index Advertiser Website Page Aerotech, Inc

www.aerotech.com

Allied Electronics

www.alliedelec.com

32 11

Amacoil Inc.

www.amacoil.com

Automation Direct

www.automationdirect.com

Baldor Electric Company

www.baldor.com

Beckhoff Automation

www.beckhoff.ca

Bimba Manufacturing Co.

www.bimba.com

Boker’s Inc.

www.bokers.com

Bosch Rexroth Canada

www.boschrexroth.com/en/ca

BRECOflex Co. LLC

www.brecoflex.com

Clippard Instruments Laboratory Inc. www.clippard.com

Conductix-Wampfler Canada

www.conductix.ca/en

CREAFORM

www.creaform3d.com 25

Designfusion

www.designfusion.ca 14-15

ELESA

www.elesa.com 38

EPSON Canada

www.epson.ca

Fluid Metering, Inc.

www.fluidmetering.com

Great West Life Assurance Co. www.engineerscanadafsp.grsaccess.com/ engineers-canada/home.aspx 33

November/December | 2016 DES_FluidMetering_NovDec.indd 1

igus Corporation

www.igus.com

Industrial Encoder Corp.

www.globalencoder.ca

International Fluid Power Expo

www.ifpe.com

KHK-USA Inc.

www.khkgears.us/

LEMO Canada Inc.

www.lemo.com

Motion Industries / Eaton

www.motionindustries.com

ProtoLabs, Inc.

www.protolabs.com

Roto Precision Inc.

www.rotoprecision.ca

Rotor Clip Company, Inc.

www.rotorclip.com

Schaeffler Canada Inc.

www.ina.com

Schneider Electric Corp.

www.schneider-electric.ca

SCHUNK Intec Corp.

www.ca.schunk.com/

SPIROL Industries, Ltd.

www.spirolcanada.com

Tsubaki Canada

www.tsubaki.ca

www.design-engineering.com 2016-10-26 1:58 PM

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