Design Engineering October 2013 by Annex Business Media

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Contents | Volume 59, No. 5

IN THE NEWS

8 Bouchard to lead

Lockheed Martin Canada

8 Hawk Ridge extends Canadian territory

8 ATS Automation to acquire IWK

8 Wainbee purchases

Cowichan Hydraulic

8 10

Canadian tech creates “unbreakable” hockey stick Canada launches R&D tech demo program Valve-less hydraulic system boosts fuel efficiency

Sauer-Danfoss changes name

Wireless research lab opens at University of Waterloo

Flex camera takes panoramas in one shot

Growth slowing in PT/MC industry

READER SERVICES Annual Subscription Rate In Canada: $52.95 (1 year) $71.95 (2 year) Outside Canada: $99.95 (1 year) Single Copy In Canada: $10.00 Outside Canada: $22.00 Directory Rates In Canada: $27.00 Outside Canada: $45.00 Reader Service Contact Information ecallaghan@bizinfogroup.ca Toronto: 416 442 5600 X 3538 Elsewhere: 1-866-543-7888 Mail: Business Information Group Design Engineering Circulation Dept 80 Valleybrook Drive North York, ON M3B 2S9

Columns

13 DEX 2013 Industrial table-top trade show to feature Canada’s brightest innovators 18 CAD News DesignSpark Mechanical offers no-cost push-pull solid modeling and other 3D design stories 22 CAD Beat The top four steps to ensure a successful technology implementation

30 Motion Control Modern LVDT linear position sensors gaining preference in industrial applications 32 Idea Generator The latest in industrial products including motion control, fluid power, power transmission and sensors

Features 14 Inside Solid Edge ST 6 Is the latest version of Siemens’ Synchronous Technology the best yet? 26 Wheels in Motion Flo Cycling’s Canadian engineers up-end bike racing equipment industry armed with CFD and a competitive drive

37 Canadian Innovator Spring-loaded Bladetech skates leave conventional blades behind, in more ways than one

Printed in Canada

www.design-engineering.com

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October | 2013

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6 EditorialViewpoint

3D Printing Slugfest

www.design-engineering.com

lthough 3D printing has existed for more than 30 years, uptake of the technology has been slow in coming. In the last three to five years, however, what was a curiosity important to a few niche industries has become pervasive in fields as far flung as food production and bio-medical engineering. And the advent of cheap, desktop 3D printers has allowed many aspiring inventors to become over-night crowd-funding site sensations. Even so, additive manufacturing remains a relatively small industry. In April, IT research analyst firm, Gartner, pegged the industry’s 2011 market value at $1.7 billion. Even so, financial analysts expect the industry to explode in the near future. The same Gartner report anticipated that the 3D printing market value will balloon to $6.5 billion by 2019. That projection was echoed by Citi Financial analyst, Kenneth Wong, who predicted in August that the industry will more than triple by 2018. “We feel the 3D printing and additive manufacturing market is on the cusp of seeing much broader adoption across more upstream production applications and the consumer end-market,” Wong wrote in a note to customers that subsequently sent the stock prices of Stratasys and 3D Systems to 52-week highs. Wall Street’s bullish take on additive manufacturing is based on the fact that, beginning in February 2014, core patents now protecting 3D Systems’ selective laser sintering (SLS) process, will begin to expire. Once those intellectual property restrictions are lifted, the expectation is that the cost of SLS printers will follow the same path as Fused Deposition Modeling machines. Within a few years of Stratasys’ FDM patents expiring, cheap desktop FDM printers like the RepRap, Solidoodle, MakerBot Replicator and many others brought the technology to within the budgets of hobbyists and the Maker crowd. However, the idea that we’ll see cheap SLS machines flood the market soon is doubtful, say long-time industry watchers. They point out that SLS requires much more sophisticated machinery than FDM printers, as well as tighter control on build material quality, to produce the technology’s characteristic high resolution and durable models. In addition, even though some SLS technology will be open for adoption, many of the improvements made over the last 30 years are still actively protected, making for an IP minefield potential competitors may shy away from. Whatever the case, the industry’s two heavy weights, Stratasys and 3D Systems, aren’t taking any chances. Over the last couple of years, both companies have been in a frenzied acquisition mode, buying anything vaguely 3D printing related, to cement their positions. 3D Systems, for example, has acquired roughly 20 firms since 2011, most notably one-time contender Z Corp. Although not as voracious, Stratasys’ merger with Objet in December 2012 plus its more recent $403 million deal to acquire MakerBot, have maintained the company in its weight class. And consolidation in the industry shows no signs of slowing down. As the 3D printing market ramps up over the coming years, there will always be new up-starts to take down. Because, as Blackberry painfully discovered, when it comes to emerging disruptive technology, simply because your company created the field doesn’t mean a contender can’t land a one-punch knock out.

Mike McLeod

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

October | 2013

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Editor Michael McLeod (416) 442-5600 ext. 3231 mmcleod@design-engineering.com Publisher Alan Macpherson (416) 510-6756 AMacPherson@design-engineering.com Group Editorial Director Lisa Wichmann (416) 510-5101 LWichmann@canadianmanufacturing.com Accounts Manager Taebah Khan (416) 510-5230 tkhan@design-engineering.com Technical Field Editor Pat Jones, P. Eng. Art Director Kathy Smith (416) 442-5600 ext. 3215 KSmith@plant.ca Market Production Manager Jessica Jubb (416) 510-5194 jjubb@bizinfogroup.ca Circulation Manager Cindi Holder (416) 442-5600 ext. 3544 CHolder@bizinfogroup.ca BIG Magazines LP Executive Publisher Tim Dimopoulos Vice-President of Canadian Publishing, Alex Papanou President of Business Information Group, Bruce Creighton Publications Mail Agreement #40069240 ISSN: 0011-9342 (Print), 1929-6452 (Online) Privacy Notice: From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 E-mail: privacyofficer@businessinformationgroup.ca. Mail to: Privacy Officer, 80 Valleybrook Drive, North York, ON M3B 2S9 Subscriber Services: To subscribe, renew your subscription or to change your address or information contact us at 1-800-387-0273 ext.3552. Subscription Price: Canada: $52.95 for 1 year; $71.95 for 2 years; $10 for single copy. Outside Canada: $99.95 for 1 year; $22 for single copy. Directory/buyer’s guide: Canada $27; Outside Canada $45. Design Engineering, established in 1955, is published 6 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. Published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. Tel: 416-442-5600, Fax: 416-510-5140 80 Valleybrook Dr., Toronto, ON M3B 2S9. Contents of this publication are protected by copyright and must not be reprinted in whole or in part without permission of the publisher. DE receives unsolicited features and materials (including letters to the editor) from time to time. DE, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. DE accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. DE is indexed in the Canadian Business Index by Micromedia Ltd., Toronto, and is available on-line in the Canadian Business & Current Affairs Database. We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.

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8 DesignNews Up Front Bouchard to lead Lockheed Martin Canada Lockheed Martin appointed retired Lieutenant General Charles Bouchard to head Lockheed Martin Canada. Bouchard retired in April 2012 after more than 37 years in the Royal Charles Bouchard Canadian Air Force. His military career includes many senior leadership roles including serving as commander of the combined joint task force that led NATO operations in Libya. Lockheed Martin Canada today has more than 700 employees at facilities in Ottawa, Montreal, Dartmouth and Calgary, as well as Department of National Defence sites across the country. www.lockheedmartin.com

Hawk Ridge extends Canadian territory Solidworks reseller Hawk Ridge Systems has extended its geographic coverage in Canada to include the provinces of Manitoba and Saskatchewan. Last April, former SolidWorks Canadian reseller, Automated Design Systems (ADS) sold a large percentage of its SolidWorks customer base to Hawk Ridge Systems. Since then, Hawk Ridge Systems has been providing sales, training and technical support to SolidWorks users across Canada. www.hawkridgesys.ca.

ATS Automation to acquire IWK ATS Automation Tooling Systems Inc. announced that it will acquire IWK Verpackungstecknik GmbH and OYSTAR IWK USA, Inc., a tube filling and cartoning machinery firm, for approximately CAD$144 million. Headquartered in Germany, IWK has 420 employees based at production facilities near Karlsruhe, Germany and Bangkok, Thailand, and at sales/services centres in the US, Europe and Southeast Asia. ATS expects IWK to contribute approximately $18 million in EBITDA. www.atsautomation.com

Wainbee purchases Cowichan Hydraulic Canadian fluid power and automation distributor, Wainbee Limited, has acquired Cowichan Hydraulic Equipment Service and Supply Ltd. As a result, Wainbee now has 15 locations coast-to-coast servicing customers from Vancouver Island to Halifax. Founded in 1957, Wainbee Limited is a 100-percent Canadian, employee-owned company. www.wainbee.com October | 2013

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Canadian tech creates “unbreakable” hockey stick

hile composite hockey sticks are favored for their light-weight and performance relative to wood, they tend to break under competitive play conditions. And at around $300+ a pop, the costs and annoyance can tally up quickly. At least it did for Daniel Lucchesi, whose start-up company, Toronto-based Colt Hockey, is creating a composite stick covered in nano-tech cladding that’s purported to make the sticks virtually unbreakable yet without making them heavier or inflexible. The high-tech cladding comes from Toronto-based Integran Technologies, which licenses a process called Nanovate CoP (PowerMetal for its sporting goods clients), originally designed for coating hydraulic components for the aerospace and defense markets. Similar in concept to chrome plating, Nanovate CoP elecroplating can coat most materials with a thin layer of nanocrystalline Cobalt that imparts steel-like durability to nearly any material. Its strength, the company says, comes from the nanoscale of the metal’s grains (10-100 nanometres as opposed to 10 microns for polycrystalline metals). At the same time, Integran says Nanovate CoP boasts a high elastic limit (1.5 percent) that allows equipment, like a hockey stick, to remain flexible. To date, Integran’s technology, through its spin-off firm PowerMetal Technologies, has been incorporated into True Temper “Epic Shaft”, Ping “IN” series putters, Anderson “NanoTek” series bats and the forks of Cervelo’s $10,000 RCA racing bike. www.colthockey.com www.integran.com

Canada launches R&D tech demo program The Canadian Ministry of Industry launched the Technology Demonstration Program to help large-scale technology demonstration projects move from the lab to real-world testing. According to the ministry, the Technology Demonstration Program will cover up to 50 percent of eligible project costs. In total, the program will provide up to $54 million in non-repayable funding annually. To qualify, projects must be led by an OEM or Tier 1 integrator with a large scale R&D project in the aerospace, defense, or security sectors and must be for-profit, incorporated and conducting business in Canada. http://ito.ic.gc.ca/eic www.design-engineering.com

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DesignNews Up Front Magellan awarded $110 million MDA contract Magellan Aerospace announced the award of a CAD$110 million contract from MacDonald, Dettwiler and Associates for the RADARSAT Constellation Mission (RCM) satellite bus manufacture. RCM is a Canadian Space Agency mission to support maritime surveillance, disaster management and ecosystem monitoring. The primary areas of coverage are Canada and its surrounding Arctic, Pacific and Atlantic maritime areas. The launch is planned in 2018. www.magellan.aero

Sauer-Danfoss changes name Sauer-Danfoss announced that it has officially changed its name to Danfoss and now operates as a new business segment called Danfoss Power Solutions within the Danfoss Group. The company says it will continue to provide mobile hydraulic solutions but will benefit from the wider global network and broader technology base that Danfoss has to offer. powersolutions.danfoss.com

SKF named among most sustainable companies For the 14th year in a row, SKF has been listed as one of the world’s most sustainable companies by both the Dow Jones Sustainability World Index (DJSI) and the Dow Jones Sustainability Index for Europe. DJSI rated SKF as best in class for the company’s approach to environmental management. SKF BeyondZero is the company’s strategy to reduce its environmental impact from operations and provide products and solutions with improved environmental performance. www.skf.com October | 2013

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Off-road valve-less hydraulic system boosts fuel efficiency Researchers at Purdue University’s School of Mechanical Engineering have developed a hydraulic steering system for heavy construction equipment they say significantly reduces fuel consumption and improves efficiency. In essence, the new approach eliminates the wasted energy introduced by the valves common in most heavy off-road equipment’s hydraulic systems. Monika Ivantysynova, Maha Fluid Power Systems Instead, a pump precisely con- Professor at Purdue’s School of Mechanical Engineering trols each actuator’s motion by adjusting the pump displacement. This, in turn, allows the diesel engine to run at optimal fuel saving speeds. According to the Perdue researchers, their “electro-hydraulic power steering system” showed a 15 percent fuel savings and 23 percent increase in machine productivity during tests performed on a front loader. In total, the test resulted in fuel efficiency increase of 43 percent during steering maneuvers. In previous projects, Maha researchers have shown that valveless systems could reduce fuel consumption by 40 percent in an excavator and a 70 percent productivity improvement in terms of tons of soil removed per kilogram of fuel consumed. The Maha Fluid Power Research Center is part of the Engineering Research Center for Compact and Efficient Fluid Power, funded by the National Science Foundation. www.purdue.edu

Wireless research lab opens at University of Waterloo The University of Waterloo opened its 5,000 square-foot, $15-million Centre for Intelligent Antenna and Radio Systems (CIARS), considered one of the best in the world for testing electromagnetic devices. According to the university, the facility and its instruments can measure electromagnetic fields radiated by anything from a human hair to a two-ton truck, with the highest precision over the widest range of frequency possible in any academic facility in the world. CIARS features a unique multi-configuration electromagnetic radiation lab, including an anechoic chamber and terahertz measurement facilities. The centre is expected to help academic and industry researchers who specialize in everything from nextgeneration wireless communications, to mobile health, car radar, satellite communication, futuristic nano-sensors and smart devices. Researchers hope the facility will help them learn more about terahertz, a part of the electromagnetic spectrum between radar and fibre optics that is not yet fully understood. The University of Waterloo CIARS lab houses a world class anechoic chamber to measures electromagnetic fields.

www.uwaterloo.ca www.design-engineering.com

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DMR_

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12 DesignNews of flex in the display, which is then used by the camera’s software to adjust the viewfinder virtual FOV display. In addition, the flex input dynamically stitches images captured by an array of camera lenses on the back of the handheld device. At present the FlexCam is a prototype and the panoramic pictures aren’t always seamless but Queen’s researchers envision the device becoming one aggregate flexible, thin-film device. www.hml.queensu.ca

Growth slowing in PT/MC industry

Flex camera takes panoramas in one shot Researchers at Queen’s University’s Human Media Lab have developed the FlexCam, a bendable camera that can capture panoramic photos in one shot. Typically, such pictures require a special lens or stitching together a series of standard photos. Using a Flexible Organic Light Emitting Diode (FOLED) as the viewfinder display, the FlexCam goes one better by allowing photographers to broaden or narrow the camera’s field of view (FOV) on the fly. The FlexCam’s integrated bend sensors measure the amount

October | 2013

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According to the Power Transmission Distributors Association’s (PTDA) 2Q13 Business Index, the power transmission / motion control (PT/MC) industry expanded for the 13th consecutive quarter but at a slower pace compared with 1Q13. The report’s index showed a reading of 54.7, which represents a decrease over last quarter’s reading of 61.1. When comparing this reading to 2Q12, this is a slight increase to the reading of 54.2. To put the numbers in perspective, the index reading indicates the rate of change compared with the previous period. For example, a reading of 50 indicates no change from the prior period while readings above 50 indicate growth and below 50 indicate contraction. The further the index is above or below 50 suggests a faster or slower rate of change. www.ptda.org/Index

www.design-engineering.com

13-10-10 1:25 PM

DesignNews 13

2013 showcases Canadian innovators

Dr. Todd Reichert (left) and Cameron Robertson, the engineering team behind the Sikorsky Prize winning human-powered helicopter, will keynote the 2013 Design Engineering Expo on October 30.

esign Engineering magazine, Canada’s leading B2B publication for Canadian mechanical engineers and OEMs, announced that it will showcase some of Canada’s most creative, young engineering minds at the Design Engineering Expo (DEX) 2013, in Mississauga, ON. Scheduled for October 30, 2013 at the Mississauga Convention Centre, the one-day show provides a forum for face-to-face interactions where engineers, product developers, machine builders and systems integrators can discuss, network, solicit advice and ‘kick the tires’ on the latest technologies. Those on hand to present and talk about their engineering innovations include: AeroVelo Human-Powered Helicopter Dr. Todd Reichert and Cameron Robertson— aerospace engineers and design leaders of the Canadian human-powered helicopter, Atlas, that recently claimed the 33-year-old AHS Sikorsky Prize—will keynote DEX 2013. At the keynote, Reichert and Robertson will talk about innovation, the design of the prize-winning helicopter and AeroVelo’s next “impossible” project. www.design-engineering.com

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Bladetech Hockey Skates Canadian engineer and hockey player, Jeffrey Azzolin, will display his springloaded Bladetech hockey skates. Azzolin’s innovative approach to the classic ice skate not only reduces stress-related injuries but helps skaters speed down the ice faster. University of Waterloo EcoCar 2 Entry Engineering students from the University of Waterloo will showcase their entry in General Motors’ EcoCar 2 competition. The team’s modified Chevy Malibu features a plug-in hybrid electric architecture that delivers 260 HP and an all-electric range of 60 km plus a 2.4L engine to provide power and extend vehicle range. U of T FSAE Racing Team A Formula-style race car—designed, built and raced by the University of Toronto’s FSAE Racing Team—will show off the engineering skills of the university’s undergrad-run club. www.dexexpo.com October | 2013

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14 CADReport

Inside Solid Edge

ST6

Is the latest version of Siemens’ Synchronous Technology the best yet?

By Ralph Grabowski

very software vendor likes to think the newest release of its software is the best ever, and so Siemens PLM Software was no different last May introducing Solid Edge ST6 to users at Solid Edge University 2013. We heard phrases like “greatest version ever,” “sixfold performance increase” (on some tasks), and “1,300 new features” — although that list never was distributed. ST 6 is not the sixth release of Solid Edge, as the software was first released nearly 20 years ago. When in 2008 it added Synchronous Technology to Solid Edge, Siemens PLM reset the numbering system, and so this is the sixth release since then. (ST is short for “Synchronous Technology,” the name given to the hybrid of direct editing and parametric modeling

used by Solid Edge, as well as in bigger brother NX.) It’s a nice change to see a software company show new software first to its users, rather than the usual industry practice of previewing it to the media under an embargo. Here are some of the highlights of the new release, which shipped in July. Surfacing with SynchTech Solid Edge had a surfacing component that it called “BlueSurf,” but it was in serious need of upgrading, because it did not employ Synchronous Technology. So in Solid Edge ST 6, surfacing becomes part of the history-free SychTech environment. This feature is aimed at industrial designers, who like to make consumer products with swoopy curves (See figure 1). Surfacing differs from solid modeling

Figure 1: An example of surface modeling in Solid Edge ST6. October | 2013

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www.design-engineering.com

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CADReport 15

Figure 2: Dimensions laid out automatically by Solid Edge ST6.

in that we manipulate points on the surfaces of 3D objects, rather than the objects themselves; the CAD program fills in the rest visually to make the objects look solid. To ensure swoopiness, Siemens added C2 curvature in all areas. (C0 positions, C1 ensures tangency, C2 ensures continuous curvature; these are visually similar to the more general G0-G2 curvature used by other CAD systems and differ only mathematically.) C2 means that any two adjacent surfaces will meet smoothly, with no kinks. Siemens also added a whole wack of new functions to create and edit surfaces. These include in-place curvature edits, bounded surfaces, 3D control handles (instead of just 2D), ruled surfaces, userdefi ned UV curve densities, curvature combs, symmetrical reflection, trimming and extending multiple faces at once, and defi ning replacement faces. This last one is useful for imported surfaces. It replaces many “dumb” surfaces with intelligent ones (i.e., ones that use SynchTech). The replaced faces can then be interactively edited once key point curves are added, and transitions between faces made smooth through C2. Integrated CAM For the fi rst time with ST6, a CAM (computer-aided manufacturing) system runs inside Solid Edge. While this capability is not new to other MCAD systems, www.design-engineering.com

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it serves to illustrate how Siemens PLM does not have a strong third-party developer community, as do competitors Inventor and SolidWorks. To make this happen, Siemens PLM worked specifically with Geometric Software Solutions and its CAMWorks software. The advantage to integration is that when the CAD model is updated, the CAM tool paths are updated automatically. (The reverse does not occur.) It becomes a single click to switch between CAM and CAD modes. CAMWorks provides 2.5- and 3-axis milling, and 2- and 4-axis turning. As an added bonus, CAMworks has automated feature recognition that lets it treat imported CAD models from Inventor, SolidWorks, CATIA, Pro/E, NX, CADKEY, Rhino and standard formats as native Solid Edge fi les. All CAM data is stored in the Solid Edge drawing fi le, but can be exported if necessary. There are, however, some drawbacks: You need to upgrade to ST6, and you have to like CAMWorks. Some users I spoke with at SE University were not keen on how CAMWorks handles certain operations. In that case, you’ll have to continue to use your preferred CAM software external to Solid Edge. Drafting Enhancements The biggest cheer from users was reserved for one feature in particular: After numOctober | 2013

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16 CADReport bered balloons were placed along an aligned shape, the demo jock dragged the shape to smoothly repositioned all connected balloons. The same happens with dimensions: select a drawing view, and dimensions are arranged automatically. (See figure 2.) These automatic alignment functions serve to emphasize how important Siemens PLM considers 2D drafting to be: More important than 3D modeling and surfacing. “[2D] drawings are still king of the product development world,” the company insists. Here are some more enhancements ST 6 upgraders can expect to see: Center marks and callouts are placed automatically for slots. It’s easier to draw circles that defi ne bolt holes. Parts lists (BOMs) are generated automatically by selecting objects and linked balloons are created automatically as well. BOM tables can be edited directly, and the formatting of individual cells can be overridden. The drawing view wizard previews proposed views and view settings can then be saved for later reuse in new drawings. Any two views can be aligned by relating a point in each view, or by using the center of each view. Broken (detail) views are associative, so they update when the source view changes. Schematic blocks can be edited inplace, kind of like the RefEdit command in AutoCAD. Similarly, embedded objects like spreadsheets and images can be edited inside Solid Edge through the OLE mechanism, which displays the source program’s user interface and editing tools. Finally, the display speed of drawings is improved, with zooms, pans and hatches redrawing more quickly. Other New Functions When there are 1,300 new features, it’s hard to fit them into a single article. Let me run quickly through a few more significant improvements: ST6 now deforms sheet metal parts with dimples, louvers, drawn cutouts, and beads. Contour flanges can be added along edges. Sheet metal features can be placed on ordered parts. A body can stamp a target body. Flatten operations preserve chamfers, October | 2013

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Figure 3: Options for importing SolidWorks assembly and part files.

bends, and holes across bends. The online video service YouTube runs in a dockable pane for viewing instructional videos; a new dialog box lets ST6 record design sessions for upload to YouTube, creating instant tutorials for other users. Goal-seeking is available for 3D, instead of just in 2D. Physical properties in a table are used for iterative solving; significantly, this analysis now works in synchronous and ordered (a.k.a. history) modes. The Simplify Assembly Environment makes use of all ordered (history) part modeling commands. The new Enclose Components command replaces selected items with simplified representations. The Duplicate Body command copies and patterns (arrays) solid bodies— single or multiple. Targeting the uncertainty over the future of SolidWorks, Siemens PLM makes it possible to bulk-import parts and assemblies. The user interface of Solid Edge can be adjusted to better suit exSolidWorks users. (See figure 3.) Solid Edge Insight XT is renamed Solid Edge SP, where SP is short for Microsoft’s SharePoint online file management system. And, as for the cloud, company executives emphasized that there would be no cloud version of Solid Edge itself, although drawings can be accessed through TeamCenter servers and portable apps running on Android and iOS.

Greatest Ever? This is a rare occasion when a software release actually can be described as “the greatest ever.” While CAD vendors typically improve one area in a new release significantly, Solid Edge ST 6 makes strong advances in four important areas: C2 surfacing and editing, CAM integration, SolidWorks compatibility, and greater automation in 2D drawings. But just how well is Solid Edge doing? Siemens PLM is secretive about sales figures, unfortunately. We know only that Solid Edge grew 25 percent in USA licenses in the second quarter of this year—a cherry-picked statistic, clearly. The question is, 25 percent on what? We don’t know, other that before it was purchased in 2007 by Siemens, UGS reported revenues that made it the third largest CAD vendor, ahead of PTC but behind Autodesk and Dassault Systemes. Being a small part of the $100 billion-ayear Siemens AG, Solid Edge didn’t get sufficient attention marketing-wise for the first few years. This, however, is changing for the better, as we see with the new, annual Solid Edge University. Solid Edge is in a good position to become the strongest MCAD package to provide hybrid history and direct editing. DE www.solidedge.com

Ralph Grabowski is a CAD journalist and blogger at worldcadaccess.typepad.com www.design-engineering.com

13-10-10 1:26 PM

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CADNews

DesignSpark Mechanical offers no-cost push-pull solid modeling

ypically, learning to use 3D CAD software efficiently requires a sizeable investment in time and money— two factors that keep many drafters rooted to their familiar 2D packages and many would-be designers at arms length from complex 3D applications. To help spread the use of 3D CAD design, electronics distributors, Allied Electronics and RS Components, in partnership with SpaceClaim, released DesignSpark Mechanical, a no-cost direct modeling 3D solid geometry creation tool. Based on SpaceClaim Engineer code, DesignSpark Mechanical isn’t so much a “dumbed-down” version of the comprehensive modeling package but a rearrangement of the interface to simplify it for new and/or casual users, say No-cost Designspark Mechanical offers many of the modeling functions of SpaceClaim reps. For example, using Mechanical is similar SpaceClaim Engineer but lacks its extensive import and export capabilities. to Sketchup’s sketch and extrude technique, but focuses on scale geometry, while Move can be used to reposition, rotate, four basic modeling commands: Pull, Move, Fill and Combine. Within each of those commands, however, reside many of pattern or mirror 3D features or 2D sketch components. the functions experienced CAD users would be familiar with. Similarly, Fill is used to create surface patches and Combine For example, Pull is used to extrude, fillet, sweep, shell, and contains all the common boolean functions. While Mechanical isn’t “Toy CAD” and features many of its big brother’s modeling capabilities, it doesn’t include the extras of commercial applications such as industry specific tools or rendering. The biggest distinction between Mechanical and SpaceClaim Engineer is the former’s lack of import and export capabilities. While SpaceClaim is a veritable “universal translator” of CAD data, DesignSpark Mechanical is limited to only a few options. For example, it imports only open formats such as OBJ, SketchUp, STEP, STL and notably, ECAD files (IDF) like those created by the company’s free electrical CAD application, DesignSpark PCB. This, the company says, allows electrical and mechanical engineers to collaborate easily on the creation of circuit boards and the larger enclosures and/or assemblies to house them. Similarly, Mechanical exports AutoCAD (DXF), OBJ, STL, XAML, JPEG, and PNG file formats, along with 3DPDFs. This fact somewhat limits its use beyond 3D printing, CNC preparation and early-on design conceptualization. However, solids can be - Over 100 strong in exported individually or combined (internalized) into assemblies Engineered Sales & Technical or “components” which can be packaged as a single file. Support Representatives Even so, Mechanical users do have access to approximately 38,000 3D models in DesignSpark’s online component library as well as TraceParts’ extensive CAD portal in DesignSpark Mechanical format. In addition, the modeling application also acts as a sort of e-commerce portal, in that a tab within the interface allows users to order components, in the automatically populated BOM, directly from Allied Electronics/RS Components. DesignSpark Mechanical is compatible with Windows XP Call 1-888-458-0554 or chat live @ through 8 in either 32- or 64-bit versions. The application is www.ellsworthadhesives.ca available for download on the DesignSpark website.

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20 CADNews Autodesk integrates CAM into Inventor After two months in beta development, Autodesk announced the release of its free CAM add-on, Autodesk Inventor HSM Express. The software is the result of the company’s acquisition a year ago of HSMWorks. Although the CAM developer was closely associated with Solidworks, Autodesk has repeatedly assured Dassault Systemes customers that it will continue to

Autodesk’s Inventor HSM Express offers 2.5-axis machining, toolpath strategies, adaptive roughing and backplot simulation at no cost.

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refine the package in parallel for both platforms. While free, HSM Express includes many of the functions of its approximately $10,000 stand-alone product, Inventor HSM, which won’t ship until 2014. Besides its integration into the Inventor interface—allowing for full associativity between model and generated toolpaths—HSM Express supports 2 and 2.5-axis CAM operations, representing a sizeable portion of CAM work being done. In addition, Express fully exploits the advantages of modern 64-bit processors, allowing it to address more system memory and harness multiple cores simultaneously. HSM Express also includes toolpath strategies for generating milling, drilling, counterboring and tapping operations as well as adaptive clearing or roughing that generates roughing/clearing toolpaths inside closed curves both with and without islands. It also includes a backplot simulation tool and a CNC program editor for NC functions, fi le-compare, CNC templates, backplotting, and serial communications for RS232 DNC transfers. The CAM add-on also includes generic post processors for CNC machines from Fanuc, Heidenhain, Haas, Hurco, Mazak, MillPlus, Okuma, Siemens and Yasnak, among others. Although free to download from Autodesk’s CAM website, Inventor HSM Express does requires an active license of Autodesk Inventor or Inventor LT 2014. http://cam.autodesk.com

13-10-10 1:43 PM

CADNews 21 3DConnexion releases wireless 3D mouse 3Dconnexion announced a wireless version of its popular 3D mouse, appropriately dubbed the SpaceMouse Wireless. Similar to its other products, the SpaceMouse features 6-degrees-of-freedom to manipulate the view of 3D models quickly without having to look at a keyboard. For this version, however, the 3D mouse cuts the cord and includes a 2.4GHz bluetooth 3Dconnexion’s SpaceMouse dongle that operates at a range Wireless boasts a 10-meter range up to 10 meters. The mouse and one month battery life. also has an lithium-ion battery, charged through a micro-USB port, that lasts up to one month, the company says. The 3Dconnexion SpaceMouse Wireless is compatible with Windows, OS X and Linux and is available for order from the company’s web site for US$129. www.3Dconnexion.com

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22 CADBeat

Top Steps to Ensure a Successful Technology Implementation Design software is great but it isn’t auto-magical and can even be counter-productive if not implemented intelligently. By Scott Hale

uch has been said about the Canadian manufacturing industry’s productivity. There are highly educated professionals in both technical and business fields. Capital markets are healthy and capable of funding infrastructure requirements. Why then is productivity notably lower than capacity? One area that holds promise for big productivity improvements—and that is regularly exploited—is buying into manufacturing software. But, as many have discovered, software isn’t a magic bullet. A poor implementation can lead to large work October | 2013

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backlogs, missed deadlines, budget overruns, and outright rejection. Technology may lie at the heart of productivity and innovation, but it must be coupled to great process design. Manufacturers looking to realize productivity improvements by implementing technology that optimizes various facets of the manufacturing process need to take the time to examine and re-design workflows. Here’s some advice and best practices for those looking to realize the true benefits of technology while avoiding some common pitfalls. Designed to help you mitigate project failure, the four steps outlined below seem obvious, but are too often neglected. www.design-engineering.com

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CADBeat

Define what you want to achieve and assign champions You can’t get anywhere if you don’t know where you are going. Establish a solid foundation for the implementation project by identifying what you would like to achieve. For example, do you want to reduce staffing requirements? Slash time to project delivery by 50 percent? Optimize workflow processes? Establish product specifications once and have those retained downstream? Integrate sales orders with the shop floor’s production schedule? The possibilities are endless, but your organization will have a top three list specific to your business and based on how you currently work. A great way to narrow down the list of business objectives is to survey staff. Compile their feedback to identify the top areas for improvement. This stage results in a business case for the project, a plan that outlines the specific milestones required to complete the project and builds consensus amongst the various stakeholders. To ensure success, identify a core team of people in your organization who will be champions for the project. Look for the people who will be most impacted by change, but least resistant, and assign a clear project leader to ensure proper oversight.

Develop data and workflow standards and train staff During the development phase, identify design and workflow standards, styles, settings, preferences and any software con-

October | 2013

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figuration requirements. By creating and maintaining design standards, you ensure consistency and relieve people of redundant tasks that need not be repeated every time a new project hits their desktop. At this stage, you can start training your people on the newly defined standards, so they understand the basics and how they apply it to their workflows and environment. Where applicable, get them involved in the creation of any standards to gain the benefit of their expertise and to ensure buy-in.

Deploy a pilot project Piloting a new workflow or design process allows for testing and validation before rollout to the rest of the team. In addition, a pilot reveals unforeseen components of your plan that may need revision. Pilot project selection is key to success and should take into consideration three things. One: Pick a project that your team is used to working on. So, for example, if your shop works mostly on custom products, then select a custom project. If you manufacture product lines that have variable specifications, choose a product line that has a few variations, but not a million. Really, this is about rightsizing your choice to allow for initial success and can act as a model for other products. Two: Consider a project with liberal timelines, not one with looming deadlines. Rushing to make a deadline while imple-

www.design-engineering.com 3/20/07 12:32:48 PM

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CADBeat

menting new technology, workflows and processes is a recipe for disaster – especially when staff needs to learn the new processes and software skills. Three, pick a project that’s reasonable in size. If it is too small, you can’t fully understand the value of the new process. If the project is too large or complex, the learning curve may be too steep. The idea behind pilot project selection is that you are trying to minimize the number of curveballs thrown at your team all at once. Often at this stage you will need to provide additional training because people will identify gaps in their knowledge. This is very useful for the next stage when everyone will adopt the new system, because you can tune the training to address the most common gaps.

Deliver across your entire organization Once you have optimized your workflow, standards and configuration based on the pilot, you can start rolling out the new processes and technology to the entire company. Make sure you provide both technical and workflow training for all users. Assigning mentors for different roles gives people the support they need to work at their own speed and receive guidance when they run into difficulties – whether technical or interpersonal. Provide feedback to everyone regarding their progress and encourage them to make improvements as they learn. Getting your whole team up and running with more efficient and optimized processes is exciting to watch and the results should be evident in massive productivity improvements. Keep your antennae up and be ready to adopt new technologies and approaches that will improve productivity and your ability to innovate. Recognize though, that every manufacturing operation is unique and will require a unique solution. Make sure your software implementation goes beyond installation and delves deep into the heart of how you work. DE www.imaginit.com

Scott Hale is the Director of Consulting Services for the Manufacturing Solutions Group of IMAGINiT Technologies. The team provides a wide range of customized services to meet the needs of manufacturing focused organizations. Scott can be reached at shale@rand.com www.design-engineering.com

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October | 2013

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26 CoverStory

Canadian engineer and FLO Cycling co-founder, Jon Thornham inspects one of his company’s high-end, CFD-designed bike racing wheels.

Wheels in Motion FLO Cycling’s Canadian engineers up-end bike racing equipment industry armed with CFD and a competitive drive. By Mike McLeod

t’s somewhat rare that a small entrepreneurial player not only breaks into an established industry but also beats its long-time incumbents at their own game. However, for Jon and Chris Thornham—FLO Cycling’s twin mechanical engineering duo from Dartmouth, Nova Scotia—the transition from “audacious” idea to entrepreneurial success has been nearly as quick as the high-end, aerodynamic, yet affordable, bike racing wheels their young company is known for. “There is no single component you can change on a bike that will give you better aerodynamic performance than a set of wheels,” says Jon Thornham, who founded FLO Cycling in Las Vegas with his twin brother Chris in 2010. In contests where speed is the deciding factor, competitors will search for any advantage, no matter how seemingly small. For example, in bike racing, hundreds of a second can add up to a commanding lead or relegate less streamlined racers to footnote status. Consequently, competitors will bear nearly any price to assure their aerodynamic superiority. At least that was the case for Chris Thornham, a competitive triathlete himself, when he told his twin brother Jon in 2010 how much he’d just paid for a set of high-end racing wheels for his road bike. “He told me what he’d paid for them and I said, ‘You’ve got to be kidding me!’” relates Jon Thornham, adding that such wheels commonly cost anywhere from $1,800 to $3,500. “He October | 2013

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asked me if I thought we could make them cheaper and I said, um, yeah. So, I asked him if he thought we could make them with the same performance and he said yes. So we just started.” Although both Jon and Chris had worked as mechanical engineers for several years after graduating from University of New Brunswick, neither had experience in manufacturing or sports-related product development. Added to that, they were facing an industry dominated by big name companies that had spent years—and untold amounts of R&D money—in expensive wind tunnel testing to refine and prove the aerodynamic efficacy of their products. Against this headwind, the self-funded start-up leveraged a few key advantages. The first was an appreciation of the real world conditions racers face. According to Thornham, the aerodynamics of an aero wheel primarily comes down to the depth and shape of its fairings, the strip of material that spans from the tire rim inward toward the hub. During straight-on headwinds, fairings have little influence on aerodynamics, but such conditions rarely happen during competition. However, when hit by off-center winds, the leading edges of both the front and back of the wheel split the air and the fairings help maintain attachment of the airflow, thereby reducing turbulence and drag. The challenge, then, became designing a wheel that performed consistently over the most common range of side-wind angles, or degrees of yaw, that riders encounter, Thornham says. “What we did was create what we call a net reduction drag www.design-engineering.com

13-10-10 2:01 PM

CoverStory 27 value,” Thornham explains. “We know that 80 percent of a rider’s time is spent between 10 and 20 degrees of yaw so we looked for specific shapes that were aerodynamically efficient over that whole range and not just at one very specific yaw angle.” To optimize for that broad range, Jon and Chris devised a distinctive wide fairing design that deviates significantly from the industry standard. Most fairings have either a V-notch or teardrop toroid cross-section that taper to a point. While aerodynamic, they can introduce instability when hit by a gusting crosswind. The asymmetry between the leading edge of the wheel’s front half (rounded tire) and the leading edge of the wheel’s back half (the sharp edge of the V or toroid) creates uneven wind resistance that can cause the front tire twist suddenly. By contrast, FLO’s wide and rounded fairing mirrors the shape of the tire, providing even aerodynamics at the first and back half of the wheel. At the same time, the rounded shape enhances boundary layer attachment while the fairing’s depth takes advantage of the off-angle airflow to propel the bike forward, similar to a sailboat tacking into the wind. “We designed our wheel to create a smooth transition from the tire to the rim to the wide toroidal fairing, which allows the boundary layer of airflow to stay attached longer,” Thornham says. “At the same time, we were looking to balance forces in a way that reduced drag by pushing the bike forward to some extent while not creating a wheel that is rough to ride”

V-NOTCH WHEEL

EARLY TOROIDAL WHEEL

FLO WIDE TOROIDAL WHEEL

The rounded profile of FLO Cycling’s Wide Ride fairings provide greater stability and aerodynamic airfl ow than designs common in other racing wheels.

With a number of prototypes modeled in CAD, the brothers still had to narrow their candidate designs down to one. Even today, Thornham says industry practice is to run multiple physical prototypes though hours of wind tunnel testing to the tune of approximately $500 to $900 per hour, well beyond the means of a small start-up. To sidestep this cost, Jon and Chris leveraged their other key advantage: Computational Fluid Dynamics (CFD). They turned to friend and consulting engineer, Justin Smothers, founder of JSC Engineers, who ran each potential design through a comparatively inexpensive seat of CD-Adapco’s STAR-CCM+ simulation software. “I ran all the model variations in wind speeds from 5-30 mph in intervals of 5 and from 0-20 degrees of yaw,” says Smothers. www.design-engineering.com

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October | 2013

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28 CoverStory

CFD flow visualization showing pressure and velocity around FLO Cycling’s FLO 60 wheel.

“Since we only had a license for one processor, it took us 28 days to run through all the variation, but if we had more processors it would have taken a lot less.” Using a k-epsilon turbulence model, Smothers says the wheel designs were simulated in changing wind speeds and yaw angles to optimize the geometry across a wide range of conditions. Each prototype model was composed of a polyhedral mesh with 1.5 million cells, including a prism layer to capture boundary layer flow as well as refinement zones near the wheel to analyze wake. After a number of tweaks, the end result was a single wheel design

What’s Your Combination?

that performed as well in the wind tunnel as competitors’ products but at a fraction of the development cost. “CFD drastically saves time and money because we’re not having to manufacture a rough shape and then spend time in the wind tunnel,” Thornham says. “Other companies claim that they’ve spent half a million dollars developing one wheel. We developed four wheels for not anywhere close to that.” Those lower costs, Thornham says, allowed the company to price their four wheels (the FLO Climber, FLO 60, FLO 90 and FLO Disc) at a fraction of their competition. Sold directly from the company’s web site, a set of FLO Cycling’s high-end aluminium and carbon fibre wheels, for example, cost US$898. That compared to the $1,800 and up Chris had paid two years previous. Not surprisingly, customer enthusiasm was immediate and almost overwhelming, Thornham says. “In our first pre-order in 2012, we ended up selling 750 wheels in an hour even though the web site crashed the minute we opened up due to the traffic,” he says. “This year, we’ve had four pre-orders and all of them have sold out within 15 minutes. In 2012, we shipped 1,500 wheels and this year, we’re on track to ship 3,600 wheels to 38 countries. Even though we’ve experienced 140 percent growth, demand for our product continues to spread quickly. Luckily for us, people like it.” DE www.flocycling.com

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30 MotionControl

Positive Feedback Modern LVDT linear position sensors gaining preference in industrial applications. By Lee Hudson

oday’s industrial process control applications increasingly use automated systems to optimize operations and ensure a safer, more productive process. Linear position sensors used in these automated systems provide highly accurate feedback on product parameters, control states and outputs to machine controllers. Whether implemented as a standalone component or as part of a control or safety system, the linear position sensor—also known as an LVDT—is capable of providing linear displacement measurements from micro inches to several feet, under various operating and environmental conditions with high accuracy and reliability. Essentially, the LVDT linear position sensor plays an important role in machine control by providing feedback about product location. Mechanics of an LVDT In basic terms, an LVDT linear position sensor is an electromechanical device that converts linear position or motion to a proportional electrical output (see Figure 1). More specifically, the LVDT position sensor produces an electrical output signal directly proportional to the displacement of a separate movable core. Typically, the ferrous core within the LVDT is attached to the moving element on the piece of equipment requiring position feedback. In operation, the LVDT’s primary winding is energized by alternating current of appropriate amplitude and frequency, known as the primary excitation. The LVDT linear position sensors’ electrical output signal is the differential AC voltage between two secondary windings, which varies with the axial position of the core within the LVDT coil. Usually, this AC output voltage is converted by suitable electronic circuitry to high level DC voltage or current for convenient use by a computer or other digital output device. Because there is normally no contact between the LVDT’s core and coil structure, no parts can rub together or wear out. This means that an LVDT linear position sensor features unlimited mechanical life. This factor is highly desirable in many industrial process control and factory automation systems. LVDT Use in Process Control Apps Recent innovations in construction materials and manufacturing techniques, as well as low-cost microelectronics, have revolutionized the LVDT linear position sensors into a more reliable and cost-effective technology for process control applications. In the past, the electronics necessary to operate LVDT linear position sensors properly were complicated and expensive, prohibiting its wide use in process control applications for displacement measurement. October | 2013

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Modern ASIC and microprocessors give LVDT technology more complex processing functions and enable signal conditioning within the sensor housing. As a result, LVDTs generate digital outputs directly compatible with computer–based systems and standardized digital buses. In addition, today’s linear position sensors can provide more accurate and precise measurement of dimensions in a wider variety of quality control, inspection equipment and industrial metrology applications. For applications where sensors must operate in extreme environments, the sensing element can be segregated from the electronic circuitry. Connected by long cables up to 31 meters (100 feet), AC-operated LVDTs can work with remotely-located electronics that power the sensors, amplify and demodulate their output. Output is then displayed on a suitable readout and/or inputted into a computer-based data acquisition system for statistical process control. This ability to transmit data to a remote computer has made linear position sensors popular in quality assurance schemes. Tight Places with Harsh Conditions While linear position sensors were once considered too long for applications with limited space, new winding techniques and computer-based winding machines allow the linear position sensor body to be reduced while maintaining or increasing stroke length. With the improved stroke to length ratio (now up to 80 percent), the LVDT linear position sensor becomes a viable position measurement device for machine tool positioning, hydraulic cylinder positioning and valve position sensing. Smaller, contactless linear position sensors also feature a www.design-engineering.com

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MotionControl lightweight low mass core that is ideal for process control applications having high dynamic response requirements. LVDTs are also configurable in a variety of mechanical and electrical designs to meet the measurement and environmental requirements of various process control application. New corrosion-resistance/high-temperature materials such as Monel or Inconel enable the LVDT linear position sensor to operate in more hostile environments. For applications where sensors must withstand exposure to flammable or corrosive vapors and liquids, or operate in pressurized fluid, its case and coil assembly can be hermetically sealed using a variety of welding processes. For example, in power generation applications, linear position sensors designed for high temperature and mild radiation resistance can perform in power plants to provide feedback on the position of nuclear steam and gas turbine control valves for increased plant efficiency and reduced operating costs. In a typical power plant, steam turbines contain a number of control valves . Typically, plants have very precise control schemes for valve position to increase operating efficiency and save fuel. Operating within the harsh environment of a power or steam plant, linear position sensors can determine if valves are fully opened or closed to within a thousandth of an inch, providing output to remote electronics that can be monitored by operators if something is not working properly.

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Sensors also play an important role in the predictive maintenance of gas turbines as part of process control systems used to monitor shell expansion and bearing vibration. Installed on turbine shells, hermetically-sealed LVDT position sensors measure shell expansion, providing linear output that operators can utilize to determine proper thermal growth of a turbine shell during startup, operation and shutdown. LVDTs designed to withstand shocks and heavy pounding are used in the press and dye industry for the mechanical control of machine operations as improper operation can lead to broken dyes while ambiguous force of presses can lead to misshapen and out-of-spec parts. Spring-loaded LVDT position sensors are installed on presses so that the plunger of the sensor is compressed as the punch press comes in contact with the metal being shaped. The output of the LVDT is fed back into the machine’s control system, providing feedback on how far a press has moved and when to stop. For more than six decades, LVDT linear position sensors have served as part of measurement and control systems, providing essential information without which many process control systems couldn’t function. DE www.macrosensors.com

Lee Hudson is an application engineer with Macro Sensors.

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www.masterbond.com October | 2013

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IdeaGenerator Motion Control Safe Motion Modules Kollmorgen launched its KSM Safety Module line, which combines Safety PLC functionality with safe motion functions when paired with the company’s AKD drives and automation controllers. KSM can also connect to EtherCAT, Profinet, and CANopen devices. KSM is capable of fifteen different Safe Motion functions, including Safe Torque Off (STO), Safe Stops (SSX), Safe Limited Speed (SLS), Safe Limited Position (SLP), and Safe Brake Control (SBC), among other functions. The safety system can simultaneously monitor up to twelve axes in a single system. KSM Safety Controllers are TUV certified for machines that require ISO 13849 PLe and IEC 61508 SIL3 level functionality. www.Kollmorgen.com/KSM

Stepper Motor Controller Haydon Kerk Motion Solutions added the PCM4806E to its IDEA Drive line of stepper motor controllers. The RoHS-compliant drive allows an encoder input to the controller for closed-loop position correction capability. The encoder interface is designed to accept single-

ended, 2-channel quadrature encoder input and an index signal. The 90 degree offset of Channel A and B allows the system to determine motor direction. A 1000 line encoder will be translated by the firmware as a 2000 pulse signal for use in position correction. Other features include programmable current control; a single supply voltage of 12 to 48VDC; 0.6Arms (0.84Apeak) max rated current per phase; and 8 opto-isolated general purpose I/O. Each input is rated for 5 to 24VDC, 8mA maximum per input. www.idea-drive.com

Motors and Drives ECPM Motor NovaTorque Inc. announced that its Gen2.0 PremiumPlus+ Electronically Commutated Permanent Magnet (ECPM) motors are now available in 3hp and 5hp 2400 rpm (maximum speed 3600 rpm) models. Driven by variable frequency drives (VFD), the line possesses motor-only rated point efficiencies of 93 and 92 percent for 3hp and 5hp versions respectively. Additionally, the motors maintain high efficiency and torque over a broad speed and load range, the company says. NovaTorque PremiumPlus+ motors are packaged in standard NEMA frame sizes and mounting dimensions and compatible with VFDs from most leading manufacturers. www.novatorque.com

DesignSolutions The domestic source for perfect meshing timing belts and pulleys BRECOflex CO., L.L.C. is announcing their new pulley catalog “B216” for made-to-order and stock pulleys. The new domestic “CNC” state of the art pulley manufacture allows for very precise machining standards, leading to superior product quality and quick product availability. BRECOflex CO., L.L.C., is providing finished precision pulleys made-to-specification and stock pulleys with pilot bores, for immediate delivery. Made-to-order pulleys are available with normal backlash, reduced backlash “SE” or zero backlash “0” tooth gap design. Contact: info@brecoflex.com Visit us at: www.brecoflex.com

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

To advertise your solution in this section call Alan Macpherson at 416.510.6756 October | 2013

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IdeaGenerator 33 Spindle Drive Maxon Motor released a ceramic spindle with the launch of its GP8S and GP16S spindle drives. The GP 16 S metric M6 ceramic spindle transmits up to 315 N in short-term operation. It also features axial ball bearings and an integrated planetary gearhead. Similarly, the company’s 8mm GP 8 S spindle drives come standard equipped with metric steel spindles or ceramic spindles. The M3 x 0.5mm spindle is designed for feed forces of up to 32 N in short-term operation. Two preloaded ball bearings serve as the axial bearing. Due to the extremely compact design, the GP 8 S spindle drives achieve a very high force/volume ratio, a characteristic highly desirable for collimators, dosing pumps, and many other applications. www.maxonmotorusa.com

Insulated Motor Cable HELUKABEL introduced its TOPFLEX 620 VFD, a flexible-PVC, XLPE-insulated power cable built for on/off or slow down/speed up VFD motor applications. The special PVC jacket is resistant to oils (Oil Res I & II), coolants and solvents and is also double-shielded to resist electrical noise. The power cable is available in a four conductor configuration ranging in sizes from 16 – 2 AWG. It has been rated for both 600V and 1000V applications, and can operate in varying temperature environments from -25°C to 105°C, having passed both the -25°C cold impact and -40°C cold bend tests. In addition to UL (1277 and 2277 Flexible Motor Supply Cable) and CSA (AWM I/II A/B), the TOPFLEX 620 VFD is CE approved for machine builders exporting to Europe. www.helukabel.ca

Fluid Power Pneumatic Cylinders AutomationDirect’s NITRA pneumatic product line now includes D-Series double-acting heavy-duty air cylinders with a 250 psi operating pressure and adjustable cushions to provide end-of-stroke deceleration at both ends. All D-Series cylinders are constructed with aluminum components and a magnetic piston fitted with a PTFE wear band; all cylinders can be used along with solid state or reed switches for rod position sensing. The series includes bore sizes from 1 ½-inch to four inches and stroke lengths from one inch to 24 inches to meet a broad range of applications. Models feature flange, rear clevis and rear pivot, side and rod clevis mounting options. www.automationdirect.com

Slurry Pump KSB introduced its heavy-duty KWPK series pumps, designed to handle slurries and aggressive fluids. The KWPK family is based on a modular design so that individual pumps can be customized to meet specific application requirements. Five standard material combinations are available, each with different characteristics with respect to corrosion resistance and wear resistance and cost. Seals and www.design-engineering.com

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IdeaGenerator bearings have been designed to withstand the effects of corrosive or abrasive media. This series of pumps feature KSB’s K-type nonclogging impeller design and are available in a range of sizes, with inlet diameters from 40mm to 900mm. Maximum flow rate is 15,000 m3/hour, while the discharge head is up to 100m. www.ksb.com

Ball Valve AALBORG Instruments released its Three-Way PTFE Ball Valve. The manually operated valve is constructed of PTFE wetted parts and Polypropylene structural components. Four separate handle positions facilitate ¼ turn selectable flow patterns. The valve targets corrosive and ultra-pure fluid applications in laboratories and industrial processing applications. The valve features ½-inch Female NPT Inlet and Outlet Ports; a Flow Coefficient (CV value) of 6 and maximum operating pressure of 4.1 bar (60 psig). www.Aalborg.com

Power Transmission Hinged Shaft Collars Stafford Manufacturing Corp. introduced a line of hinged shaft collars that feature a triple-link hinge and a captive clamping screw but provide the same holding power as standard two-piece collars. Available with square, hex, round and threaded bores, the shaft collars are available in 25 sizes from 3/8-inch to 4-inch I.D. and 16 metric sizes from 6 mm to 50 mm. Offered in steel and two grades of stainless steel, the collars can be modified with tapped holes for attaching sensors. www.staffordmfg.com

Endless Timing Belts BRECOflex Co. announced a line of seamless timing belts available with Nylon facing (PAZ, PAR) and a large variety of backing materials. Tension members are available in steel, stainless steel and Kevlar. Polyurethane materials are offered in 92 Shore A,

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Also available: Precision Mini-Joint Couplings for angular, parallel & axial misalgnment, with operating speeds to 30,000 RPM Our Experienced engineering staff invite all U-Joint and Shaft Coupling inquiries, as we design our product to YOUR application. Tel: (508) 746-0200, 888-309-0646 Fax: (508) 746-6494 E-mail: sales@gtcfalcon.com URL: www.gtcfalcon.com

October | 2013

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IdeaGenerator 35 85 Shore A, in FDA food grade, as well as with a high ambient temperature PU-material. All BRECOflex endless timing belts incorporate the company’s bifilar tension member technology as well as Standard Plus manufacturing technology. According to the company, the belts feature length tolerances down to 0.05 mm per meter as well as tensile strength twice that of welded “V” timing belts. www.brecoflex.com

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Spring-Engaged Brake Nexen released its dual faced brakes (DFB) and quad faced brakes (QFB) with torque capacities that range from 9,000 to 164,800 inch-pounds. The brakes feature a piston and cylinder actuator sealed with O-rings, as well as non-asbestos friction facings and low-inertia friction discs. The dual-faced brakes are engineered with a single-disc assembly, and the quad-faced brakes have a double-disc assembly. The brake housing is flange mounted to machinery, and the hub is keyed to the shaft. Cylinder inlet ports provide direct air supply. www.nexengroup.com

FREE Technical Support

Transformer Disconnect Terminal Blocks WAGO Corporation introduced its 2007 Series TOPJOB current transformer disconnect terminal blocks that feature an orange three-position (Operating, Shorting and Measuring) disconnect lever. Engaging the lever fully automatically short-circuits the transformer when using the required adjacent push-in jumper. Measuring 99mm long and 8mm wide, the series’ touch-proof design does not require a separate cover to be installed which eases access to test plugs and meter connections. Available in through- or ground-connection versions, the 2007 series employ CAGE CLAMP Spring Pressure Technology for conductor sizes 20-8 AWG. This eliminates lugs, crimps and torquing. www.wago.us

Vision1210™ PLC + HMI Starting at: $1,676

Washdown shaft collars Ruland unveiled a line of washdown shaft collars that feature a patent pending assembly containing a type 303 stainless steel shaft collar, a two-piece housing made from FDA compliant materials and three O-rings with NSF H1 registered lubricant. The collars offer holding power comparable to clamp style shaft collars and allow for simple adjustments without marring the shaft. Ruland’s exclusive design is pending an IP69K rating against the ingress of dust and water up to 80°C and 8 to 10 MPa of pressure. Washdown shaft collars are supplied with a zinc-plated forged alloy screw and are available for shaft sizes ranging from 1/4 to 1 inch or 6 mm to 25 mm. www.ruland.com www.design-engineering.com

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36 IdeaGenerator Sensors

used in low to moderate light conditions. With a footprint of 45mm x 45mm, the camera also features GigE interface and can be connected with maximum cable lengths of up to 100 meters. The uEye also integrates two general purpose I/Os, an I2C-Bus and 60 MB of internal image memory. www.ids-imaging.com

Ethernet Camera Imaging Development Systems (IDS) released its Gigabit-Ethernet board-level GigE uEye LE camera series, which feature a 5 Megapixel CMOS sensor. With a 2560 x1920 pixel resolution, the sensor’s A-Pix technology provides enhanced sensitivity and can be

Rotary Sensor

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Novotechnik U.S. introduced its Vert-X 31E Series of programmable rotary angle sensors with a permanent magnet that can be secured to a rotating shaft to prevent wear. Key specifications for sensor include 31mm profile; 0 to 360° measurement range; resolution to 14-bit; repeatability of 0.1° or better; and maximum hysteresis of 0.1°. Eight output options are available: 0.1 to 10V, 0.5 to 4.5V, 4 to 20mA, 10 to 90 percent of power supply, SSI, PWM, Incremental and SPI. The series includes 5 and 24 V supply models. VertX 31E 5V versions have a MTBF of 668 years and 24V versions are 240 years MTBF. All models feature an ingress protection rating of IP 68 and operating range of -40 to +85°C. www.novotechnik.com

Photoelectric Sensor

www.rittal.ca

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Baumer has expanded its range of NextGen sensors with a O300 Series designed for 1-inch mounting sizes. The sensor’s touchless qTeach method allows the O300 series to be programed by any ferromagnetic tool, such as a screwdriver. A blue LED light provides clear visual feedback, which thanks to its exposed position atop the sensor is clearly visible from all sides. The company says this class of optical sensor employs three sensor principles: The light sensor has background suppression while the retro-reflective sensor works reliably with reflective surfaces but without any separate reflector. www.baumer.com www.design-engineering.com

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CanadianInnovator

University of Waterloo Engineering graduate, Jeffrey Azzolin, who developed Bladetech hockey skates. photo credit: cNW Group /u Niversity of Waterloo

of a skating stride. They then make that energy available moments later, again and again, throughout the game. When a Bladetech skate hits the ice, Azzolin’s patent-pending spring mechanism compresses, absorbing some of the energy of the player’s movement. When the player pushes forward off the ice afterwards, the energy in the spring is released as it returns to its original position, providing a boost of power. Azzolin, who has played recreational hockey for many years, says that even a slight increase in speed and agility gives a player a significant advantage. Spring Loaded But these skates aren’t only about better performance on the ice. Their design also has the potential to prevent injuries to their users’ hips, knees and ankles. “As the springs compress, they capture impact loads which otherwise would have traveled through the bones and into joints, into cartilage, meniscus and synovial fluids,” Azzolin explains. “So, not only does the spring mechanism capture and harness energy which otherwise would have been wasted, it also provides a cushioning effect Bladetech skates leave conventional blades behind, on the body, decreasing joint damage and in more ways than one. reducing the probability of injury.” In addition, the design provides playBy Treena Hein ers with the ability to move smoothly from a flat-footed to a forward-angled thletes, just like the rest of us, are always looking for a stance, which reduces the chances of getting shin-splints. competitive edge. A good advantage to have in hockey is “Pro players skate many hours a day, most days of the year, extra speed, and in this case, it’s delivered by the players’ literal for years at a time,” Azzolin notes, “so it’s important to protect edge on the ice – their skates. the body as much as possible. Having technology which can It’s part of a revolutionary trend in engineering all over the reduce the likelihood of developing injuries provides is an enorworld: different sources of wasted energy are being noticed, cap- mous benefit over a professional career.” tured and made available for use afterwards. Whether it’s a flywheel The main challenges of the design process all related directly in a bus braking system or solar energy being captured and stored to a modern skate’s plastic blade holders. Their thin and tapered in a jacket as a person walks down the street, the idea makes shape limits the options for housing an internal spring-loaded enormous sense. Last year, it was the energy wasted throughout mechanism, making it tough to figure out which components hockey games that came to the attention of University of Water- and geometries would work. Azzolin and his team found some loo Mechanical Engineering grad Jeffrey Azzolin. help, however, in the fact that as player weight increases, so does During his undergrad degree and now at his start-up called foot size and blade holder size. Bladetech Hockey, he developed a skate that captures some of the “We were able to create a spring-loaded mechanism that can wasted energy produced by a player through the normal motion provide customized stiffness, depending on player weight, foot

Game Changer A

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CanadianInnovator size and preference,” he says. “After several iterations, we came up with a working solution, which we later redesigned to minimize the number of components. This made the design not only simpler to assemble, but more reliable as well.” The biggest hurdle of the whole process, he says, was ensuring the assembly fit in the allotted package size. “No measurements were available for each different size of blade holder in terms of their cavities and unique shapes,” says Azzolin. “It meant that designing the assembly to fit into each compartment took a nightmarish amount of time.” Scoring Opportunities The Bladetech team has conducted a number of tests to determine how much the skates increase player speed, agility and turning capabilities. “We’re adding to our data to help

strengthen our analysis, but we’re sure the increased performance will be a game-changer,” Azzolin says. “Users will be able to develop more scoring opportunities or defensively stop more scoring opportunities. In the elite leagues where fractions of a second can affect the entire outcome of a game, this technology will more than prove its worth.” Tests to better quantify the reduction in impact loads that the body will experience with these skates are also underway. Azzolin and his team are hoping to have the product ready by this coming spring or summer, so that they can take part in 2014/2015 pro season action. With endorsement by one NHL player already, Bladetech’s future is looking as slick as a sheet of ice. DE www.bladetechhockey.ca Azzolin’s spring-loaded skates help prevent injuries to their users’ hips, knees and ankles and return stored energy to boost skaters’ speed from a standing start.

Treena Hein is a Pembrook, Ont.based frelance writer.

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