» » »
POWERING HOME THEATERS LEDs get bigger, brighter, p36 LONG-FIBER INJECTION MOLDING Cuts weight of boat hull, p38 GADGET FREAK LED PROJECT
Build this cool rotating display, p76
MARCH 2009 $15.00
ACCELERATING ENGINEERING INNOVATION www.designnews.com
2008
THE ENERGY
HARVESTERS: ULTRA-LOW-POWER COMPONENTS SPUR NEW BATTERY-LESS APPS, p52
Plus
ADVANCED MATERIALS POWER NEW SOLAR PROJECTS, p57
ACCELERATING ENGINEERING INNOVATION www.designnews.com
contents 03.09 volume 64 no. 03
Features
Departments
GADGET FREAK
MAIL COVER STORY
12 Readers Sound off The technology behind the Ford Flex, problems with engineering schools and a discussion over the P.E. exam are getting readers talking. RANT
14 Do You Know Where Your E-Waste is Going? 52 Energy Scavengers From big manufacturers to start-ups, companies are teaming to create energy harvesting systems that could enable products to run forever. BY CHARLES J. MURRAY, Senior Technical Editor, Electronics F E AT U R E
57 Plastics Power New solar projects use advanced materials, including highly secretive, patented Power Plastic, to boost efficiency. BY DOUG SMOCK, Contributing Editor, Materials and Fastening
The U.S. and Canada need strict laws governing the disposal of outdated electronic equipment. BY KEN MANCHEN, Corporate Director of Safety, Health & Environmental Affairs, Newark and Premier Farnell
The battery in David Kerry’s iPod Nano swelled to three times its original size. Was the device a dud or is operator error to blame? BY KAREN AUGUSTON FIELD, Editor-in-Chief
William Grill’s ‘blue light’ drew a crowd to his trade show booth.
10 POST OFFICE DN’s most popular blog posts
16 MECHATRONICS Fresh ideas on integrating mechanical systems, electronics, control systems and software.
20 FLASH
AT S TA K E
28 Banish the Mundane: It’s TED Time The Technology, Entertainment, Design conference allows people to exchange “ideas worth sharing.” BY GEOFFREY C. ORSAK, Dean of Engineering, Southern Methodist University
New and Noteworthy Products
26 TIPS FROM TITUS Unbelievably Useful Information from a Test Expert
33 NEWS Trend, Developments, Breakthroughs
50 TREND WATCH Stuff You Need to Know
61 EXPO
THE FIELD REPORT
9 What? You’ve Never Seen a Pregnant iPod Before?
76 AttentionGrabbing ‘Blue Light Special’
Best of the Engineering Marketplace DESIGN NEWS SUPPLEMENT
CALAMITIES
T E C H N O L O G Y- B A S E D F E AT U R E S
74 The Case of the Raving Racer
DRIVE AUTOMOTIVE SALES
What caused a race car’s brakes to fail, resulting in the driver running over and severely injuring an onlooker? BY MYRON J. BOYAJIAN, Contributing Editor
With car sales sliding, automakers say innovative technologies such as navigation, keyless ignition, rearview cameras and MP3 connectivity could bring buyers back to the showroom floor.
COVER IMAGE: CHUCK MACKEY DESIGN NEWS® (ISSN 0011-9407), (GST Reg. #123397457, C.P.C. Int’l. Pub Mail #0360120) is published monthly by Reed Business Information, 8878 S. Barrons Blvd., Highlands Ranch, CO 80129-2345, a division of Reed Elsevier Inc., 360 Park Avenue South, New York, NY 10010. Tad Smith, CEO; Mark Finkelstein, President, Boston Div.; John Poulin, CFO. Periodicals postage paid at Littleton, CO 80126 and at additional mailing offices. Circulation records are maintained at Reed Business Information, 8878 S. Barrons Blvd., Highlands Ranch, CO 80129-2345. Phone: (303) 470-4445. POSTMASTER: Send address changes to DESIGN NEWS,® P.O. Box 7500, Highlands Ranch, CO 80163-7500. DESIGN NEWS® copyright 2008 by Reed Elsevier Inc. Rates for non-qualified subscriptions including all issues: U.S., $125.90 one year, $214.90 two years, Canada, $184.90 one year, $314.90 two years (includes 7% GST, GST #123397457); Mexico, $172.90 one year, $295.90 two years; Foreign surface $227.90 one year, $387.90 two years; Foreign air expedited surcharge add $323.90 one year, $579.90 two years. Except for special issues where price changes are indicated, single copies are available for $10.00 U.S. and $15.00 foreign. Please address all subscription mail to DESIGN NEWS® 8878 S. Barrons Blvd., Highlands Ranch, CO 80129-2345. DESIGN NEWS® is a registered trademark of Reed Elsevier Properties, Inc., used under license. Reed Business Information, a unit of Reed Elsevier Inc., is the publisher of more than 85 specialized business and professional publications as well as CD-ROM and online services. RBI, headquartered in New York, NY, serves the vital information needs of over 5.6 million business managers and professionals around the world. In addition to its publications, RBI also provides publication and industry-based research, economic forecasting, reprints, direct mail services, database marketing plus custom publishing projects in all its served markets. Reprints of articles are available on a custom printing basis at reasonable prices in quantities of 500 or more. For a specific quotation, contact Reprint Management Services; phone 800-290-5460; e-mail: designnews@reprintbuyer.com. (PRINTED IN U.S.A.) Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: Deutsche Post, 4960-2 Walker Road, Windsor ON N9A 6J3. E-mail: subsmail@reedbusiness.com.
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 5
䊳 䊳 䊳
Check Out Our Blogs …
Made By Monkeys Blog
See what our editors have to say with Design News’ blogs covering several topics including electronics, materials, motion control, alternative energy and CAD/CAM. Check them out at www.designnews.com/blogs.
From fluorescent lights that crispy-crittered to bloated batteries to metal castings that crumbled, an irreverent look at products that somehow slipped by the quality control cops. http://designnews.hotims.com/23098-502
LOG IN
… and Our New Videos, Too • At Georgia Tech, engineers are using piezoelectric nanogenerators to harvest energy from the movements of a hamster wearing a jacket: http://designnews.hotims.com/23098-500. • At the 2009 Consumer Electronics Show, STMicroelectronics demonstrated a robotic vision system based on its VS6724, a 2-megapixel singlechip camera module, and the STT912FA ARM-based 32-bit microcontroller: http://designnews.hotims.com/23098-501.
Gadget Freak® Calling all backyard inventors — check out our Gadget Freak files for profiles of past and present Gadget Freaks, watch videos and give up your opinion on our Gadget Freak blog. www.designnews.com/gadgetfreak
E-mail Newsletters Go to www.designnews.com/subscribe.asp to get the latest technology news and trends delivered right to your e-mail inbox.
Designing with Sensors Confused by the terms smart sensor, intelligent sensor, smart transducer or other variations frequently used to describe different sensor technologies? Find out more in this month’s Frank Answers and the Sensor Know-How NOW webcast. www.designingwithsensors.com
SafetyBase.com Sponsored by Siemens Energy & Automation Learn how safe environments correlate to increased productivity, improved machine, process and personnel safety. Reduce risks while minimizing insurance/liability costs. Access industry standards, OSHA regulations, white papers, case studies, blogs, webcasts, videos, forums, services, advice and more. http://designnews.hotims.com/23098-503
Supplements Go to www.designnews.com/archive to view our technology-specific supplements.
WEBCASTS BLOGS PODCASTS
WEBCAST: CAN’T CONSERVE ENERGY? STAY OUT OF THE KITCHEN! Conserving energy and sustainability are the most compelling reasons for a mechatronics’ approach to design. Appliances must do more with less energy. Efficiency is the result of many components working well together. Like any design variable, there is a price associated with efficiency, but the greater costs are incurred when efficiency is overlooked. In this three-part webcast series, Dr. Kevin Craig highlights case studies and processes you can implement in your own design: Part 1: Environmental Concerns & Mechatronic System Design. Part 2: The Front-Load Washing Machine — Designing for Efficiency & Sustainability. Part 3: Resonance and Its Applications. View the webcast now at www.mechatronicszone.com.
Online Resource Center
»
Product Brief HepcoMotion® SBD Sealed Belt Drive from Bishop-Wisecarver Corp. The SBD is driven by a high-strength tooth belt and is completely enclosed in stainless steel to protect the internal mechanism from debris. It features caged linear guides with such high load capacity that system life is rarely an issue. Corrosion-resistant and clean room-certified versions also available. http://designnews.hotims.com/23098-504
Web Event Best Practices for Green, Energy and Supplier Challenges from Dell Computer In three brief, focused webcasts, you will learn how Dell is taking on an unprecedented range of challenges including the environment, energy consumption and the need to ensure quality throughout the supply chain. http://designnews.hotims.com/23098-505
Reference Guide A Quick Look at Additives from Solvay Advanced Polymers Commercial grades of engineering plastics often contain five or more additives that can represent a significant percentage of the final compound. This reference guide educates readers about the various plastic additives that could affect your polymer. http://designnews.hotims.com/23098-506
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 7
THE
F IELD
R EPORT
What? You’ve Never Seen a Pregnant
iPod Before? I FOR ONE HAD NOT, UNTIL I CAME
across the freakish photos at left of a Nano that looks as if it’s about to give birth to a bunch of baby Shuffles. I found the images on a blog by Brit David Kerry. Upon removing the Nano’s cover, he wrote: “What I was greeted with inside was rather shocking. It would appear as though my battery has swollen to around three times its original size. I’m going to attempt to bring this to Apple’s attention, as I believe this has been caused by a s***ty in-car charger, however I think Apple should be told just in-case there’s a small chance there’s a dodgy batch of two year old Nanos out there about to start popping.” Surprise! A candidate for our new Made By Monkeys Blog: The lithium-ion battery on David Kerry’s Nano swelled to about 3X its normal size, popping off the device’s cover in the process. The culprit? Possibly improper charging or a malfunction of the device’s internal charging circuits.
Check out our new blog featuring all sorts of cheesy products Made By Monkeys at http://designnews.hotims. com/23098-508.
Kerry e-mailed me that he never got a satisfactory answer out of Apple, though I’d personally finger either improper charging or a malfunction of the device’s internal charging circuits. There’s a limit on how much current can be put through a lithium-ion cell and exceeding the threshold can produce a gassy chemical reaction that causes the battery to bloat up. I came across Kerry’s write-up while researching material for a blog I started up while I was on Electronics Weekly in the UK. Called Made by Monkeys, it reports on products that snuck by the Quality Control Cops. In a lot of the cases, the makers seem to have had good intentions, but regrettably bungled the execution. So whenever possible, I try and discuss the specific failure mode, bad trade-offs made and what could have been done to avoid the defect.
While I often draw upon my research and personal experiences (lousy luck, I guess), some of the best and most entertaining blog posts have come from EW readers, like a photo taken of a solar-powered parking meter located under a leafy canopy and a Chinese-made stereo that had a spectacular meltdown. The blog has been well received by EW’s engineering readers. I think it’s because it was you who gave me the idea for the blog. In survey after survey, I’d hear the same thing from design engineers: “Don’t just tell us about what worked. Tell us about what didn’t work and what could have been done to avoid the problem.” So we listened, first with the Calamities’ column that appears in the back of every issue and now with a new, American-version of my Made by Monkeys blog. Of course we’ll link to the best of the British content, but our version will feature original content highlighting our own cheesy products. Check out our newest post, for example, on a kitchen appliance done in by the nonisotropic properties of onions. You can also read up on an American author’s examination of whether or not Napoleon had a wardrobe failure due to tin pest. You can find these MBM candidates and more at http://designnews.hotims.com/23098-508. And of course we welcome your submissions to Made by Monkeys. Photos with an amusing caption are appropriate fodder, with extra credit for a brief analysis of the suspected defect and proposed ways it could have been avoided. E-mail them to me at kfield@ reedbusiness.com and we’ll feature the best of them in print, as well as online. Karen Field, Editor-in-Chief kfield@reedbusiness.com
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 9
» designnews.com/blogs
Post Office SHOCK & VIBRATION
DN’s most popular blog posts
SOLUTIONS 1. SolidWorks Gets Sage about Environmental Impact With all the focus on green product development, SolidWorks believes engineers can play a much stronger role in dictating the environmental impact of their products and the company is planning an extension to its CAD tool to help them do just that. http://designnews.hotims.com/23098-511
— Beth Stackpole, CAD/CAM Corner
Sorbothane® is the ultimate isolation material for absorbing shock and vibration. No other material can dissipate energy as effectively. Engineers worldwide choose Sorbothane® for applications requiring shock absorption, vibration isolation and damping. s 2!0)$ 02/4/490).' s ,/7 #/34 4//,).' s &!34 452. !2/5.$
MADE IN
U.S.A.
SHOCK & VIBRATION
SOLUTIONS
800.838.3906 Sorbothane Inc. 2144 State Rt 59, Kent, Ohio 44240
www.sorbothane.com
2. CFL Is One Crispy Critter PowerSource Blogger Margery Connor at sister pub EDN carps about the pathetically short life of CFLs (compact fluorescent lights) in down lights. A case of exaggerated advertising or an application failure? An EE, Margery theorizes that it’s a thermal management problem ... and to prove her point, she shot the temperature of a down light CFL in her home with an IR gun. http://designnews.hotims.com/23098-512
— Karen Auguston Field, Made By Monkeys
3. Is Engineering Education Too ‘Science-Centric?’ A recent publication from the Carnegie Foundation for the Advancement of Teaching raises questions about whether engineering curricula are sufficiently focused on professional concerns. The study’s authors hint at the idea that engineering programs have too often put professional issues on the back burner while emphasizing a very “science-centric” approach to education. http://designnews.hotims.com/23098-513
— Charles J. Murray, Electronic News and Comment
4. Improve Surface Appearance of Filled Nylons Improving surface aesthetics of glass-filled engineering thermoplastics is one of the Holy Grails of injection molding. Last year, we showed you the heat-cool process under development at the SABIC Innovative Plastics’ Polymer Processing Development Center in Pittsfield, MA. The key to “heat-cool” or “variotherm,” as it’s known in Europe, is to heat the mold surface above the material’s glasstransition temperature (Tg) prior to injection and then rapidly cooling the tool to solidify the molded part. http://designnews.hotims.com/23098-514
— Doug Smock, Engineering Materials
5. Collecting Energy from a Human-Powered Gym An entrepreneurial buddy of mine once pitched to me an idea: Put generators on exercise bikes so people can make electricity while they work out. My philosophy toward alternative energy was then as it is today. Retrofits only make sense if the economics are competitive with conventional technology. http://designnews.hotims.com/23098-515
— Matt Traum, I Have the Power
6. Weird Gadgets at CES This year’s Consumer Electronics Show offered a number of strange gadgets, including a Gumby-like toy that eats coins, a tiny turntable for hip-hop, ultra-thin HDTV screens and illuminated clothing. http://designnews.hotims.com/23098-516
— The Gadgeteer, Gadget Freak
PUBLISHER
MAKERS OF THE FORD FLEX SHOULD BE REWARDED
It was quite interesting to read your detailed coverage of the Ford Flex, “Engineering Still Shines in Detroit” (DN 02.09, http://designnews.hotims. com/23098-517). This seems to be quite an innovative product — though not well known in the marketplace. Why not reward the development of such clever products by providing tax credits specifically for them — rather than provide bailout money that primarily just supports the old way of doing things? John Fischer Palatine, IL ENGINEERING EDUCATION NEEDS MORE PRACTICALITY
I am a fairly recent college graduate and now work in the industry and maintain a blog about electrical engineering. I saw your sidebar inquiry in the latest Design News’ e-mail, “Study Calls for Improvements in Engineering Education” (DN 02.12.09, http://designnews.hotims. com/23098-518), and thought I would write to you, as I agree with much of the report you linked to. Here are some of the general problems I saw while in engineering school, now that I have a bit of perspective on my time there. 1. Since many students do not specialize into degrees until a year (or more) after entering school, classes do not have time to delve deep enough into topics to have any real bearing on real-world problems. The ones that do go deep enough into topics are so rushed that they do not have time to explain why you need to know the detailed information you are learning. Advanced degrees become “necessary” to specialize in certain subjects. 2. Practical experience over any extended period of time is not required at most schools (though some have exceptional co-op programs). Unless you find a job that is recruiting and prepared to train you, there is a lower likelihood that you will find a job out of school (with a BSE degree). Even then, you don’t know what to expect from a job as opposed to school and most career offices don’t know how to explain the differences. 3. My biggest gripe — engineering programs (and specifically the academics who teach them) today assume that you are going on for a Master’s Degree or higher. They teach skills and methods
Russell E. Pratt 781-734-8417
MAIL R EADERS SOUND OFF
ASSOCIATE PUBLISHER
Al Schmidt 972-980-8810 EDITOR-IN-CHIEF
Karen Auguston Field 781-734-8188 Elizabeth M. Taurasi Executive Editor Chuck Mackey Senior Art Director Charles J. Murray Senior Technical Editor Regina M. Lynch Web Editor Jennifer Roy Production Editor T E C H N I C A L S P E C I A LT I E S
that are suited for a researcher/scientist, as opposed to an engineer. Encouraging hands-on engineering education from a younger age (HS or earlier) would solve all these problems by helping to mold young minds into the tinkerers that focus on product development (as most engineers do) throughout their education. Some wonderful programs exist (FIRST, IEEE) and we should continue to support and expand pre-college engineering education. Chris Gammell Cleveland, OH A P.E. ISN’T A GUARANTEE OF QUALITY
I enjoy your column but was sad to see some of the comments from fellow professional engineers, “P.E.s Sound off ” (DN 11.17.08, http://designnews. hotims.com/23098-519). They seem to think a government stamp of approval is what really matters and not the competence of the individual. What guarantees that the P.E. exam tests what is relevant to the work you need done or that it will continue to do so in the future? We can all point to examples of government incompetence and it is disappointing to hear fellow P.E.s put their faith in bureaucracy. I agree with you when you say that “the license is important to the profession and I respect those who’ve passed the exam.” I acknowledge that a P.E. license is much more important in some engineering disciplines than in others, where I can see that it is a minimal standard. While I would look for someone with a P.E. license and consider it evidence of achievement, I would not presume that someone who didn’t have a P.E. license was not qualified to do the work nor would I regard a P.E. as an absolute requirement. To those of you who blindly accept that a P.E. stamp is a guarantee of quality or that this will “protect the public” (as one P.E. wrote to you), all I can say is this: “Baaaa.” Tom Blooming, P.E. Smyrna, GA
CAE Software & Hardware: Bstack@stackpolepartners.com Electronics: charles.murray@reedbusiness.com Motion Control/Power Transmission: kfield@reedbusiness.com Automation: kfield@reedbusiness.com Fasteners & Materials: doug.smock@reedbusiness.com Mechatronics: howardbaldwin@pacbell.net CONTRIBUTING EDITORS
Howard Baldwin howardbaldwin@pacbell.net Myron J. Boyajian mboyajian@sbcglobal.net Terry Costlow tcostlow@comcast.net Randy Frank r.frank@ieee.org Al Presher apresher@rochester.rr.com Ken Russell kenruss@mit.edu Doug Smock doug.smock@reedbusiness.com Robert Spiegel robspiegel@comcast.net Beth Stackpole Bstack@stackpolepartners.com Jon Titus jontitus@comcast.net GRAPHICS
Norman Graf Director of Creative Services Daniel Guidera Illustrator PRODUCTION
John Blanchard VP/Manufacturing Dorothy Buchholz Group Production Director Linda A. Lepordo Print Production Manager Adam Odoardi CMS Business Analyst Shirley Surles Graphic Production Manager BUSINESS OFFICE
Karen Norris Strategic Marketing Manager Cara Barrett Project Manager, Integrated Marketing Colleen Heckman Senior Sales Associate David Perrotti Online Client Service Manager Kaitlyn Neff Client Services Associate DESIGNNEWS.COM
Brian McAvoy Internet Sales Director 781-734-8191 Regina M. Lynch Web Editor INTERN
Daniel Mondello 781-734-8542 U . S . S A L E S R E P R E S E N TAT I V E S
IL/IN/MI/MO/ON Nicole Dalesandro 630-288-8636 FL/GA Jim Leahy 262-656-1064 NH/ME/VT Kathy McNamara 781-734-8421 IA/ND/MN/WI Doug Robertson 781-734-8182 CT/MA/NY/RI Julie Simoneau 781-734-8536 NC/NJ/OH/PA/SC/VA Dave Stanley 610-933-9186 AR/AZ/CA/CO/NV/OR/UT/WA
Todd Tidmore 512-477-3806 REGIONAL/SALES MANAGERS
CUSTOM PUBLISHING Mike Paul 781-734-8179 I N T E R N AT I O N A L R E P R E S E N TAT I V E S
UK Stephen Waddell 011 44 1322 437091 GERMANY Erhardt Eisenacher 011 49 2 28 65 0013 FRANCE Alain Faure 011 33 1 53 21 88 03 JAPAN Toshiyuki Uematsu 011 81 3 5775 6056 R E E D B U S I N E S S I N F O R M AT I O N
CHIEF EXECUTIVE OFFICER
Tad Smith PRESIDENT, BOSTON DIVISION
Mark Finkelstein CHIEF FINANCIAL OFFICER
John Poulin VP-EDITORIAL DIRECTOR
Karen Auguston Field Design News® is a member of the Reed Elsevier Group 225 Wyman Street, Waltham, MA 02451 781-734-8000 Fax: 303-470-4280 dn@reedbusiness.com www.designnews.com Design News is a registered trademark of Reed Elsevier Properties Inc. used under license SUBSCRIPTION INQUIRIES: www.getFREEmag.com/DN REPRINTS: The YGS Group
800-290-5460, ext. 110 designnews@theygsgroup.com LIST RENTAL INFORMATION:
12
Courtney Michaels 630-288-8354
RANT Really Opinionated People KEN MANCHEN, CORPORATE DIRECTOR OF SAFETY, HEALTH & ENVIRONMENTAL AFFAIRS, NEWARK AND PREMIER FARNELL
Do You Know Where Your E-Waste Is Going? THE U.S. NEEDS FEDERAL RULES REGARDING PROPER DISPOSAL OF OUTDATED ELECTRONICS, RATHER THAN SHIPPING THEM OVERSEAS IN THE U.S., WE ARE PURCHASING NEW
and improved electronic products like TVs, printers, laptops, computer monitors and MP3 players faster than ever. The problem is we are also disposing of outdated electronic products (e-waste) just as fast and often improperly. Our used electronic products contain toxic substances like lead, mercury, cadmium and toxic flame retardants. When improperly handled, workers and the environment can be harmed in ways you may never have realized. For example, it is estimated 50 percent of the e-waste generated in the U.S. and Canada is being sent to India, China and Africa. Why? Simple economics: It costs a fraction of what it would cost to dispose of it properly at home. More troubling — it is a common practice in India, China and Africa for adults and children to make money “backyard recycling” scrap electronic products. Unprotected workers heat the products over open fires to remove reusable components. They soak what remains in acid baths to extract reclaimable metals. In the process, these “backyard recyclers” are exposed to a variety of toxic substances. Toxic residuals from this process are also polluting local water, soil and the air. Backyard recycling is such a widespread practice in Bangalore, India that Dr. Thuppil Venkatesh, advisor to the National Referral Centre for Lead Poisoning in India, reports 53 percent of the children under 12 in Bangalore have elevated lead levels in their blood, which is resulting in brain damage and is restricting their ability to learn. This is too big a price to pay to avoid paying the going rate to responsibly dis-
pose of our used electronic equipment. There ought to be a law, you say? The majority of western countries, with the exceptions of the U.S. and Canada, have enacted rules to prevent the improper disposal of e-waste and support an international treaty (the Basel Convention) that bans trans-border shipments. While well-meaning, they’ve proven not be very enforceable. Too often, European e-waste is exported under the guise of being “reusable gifts.” In the absence of federal legislation, 12 U.S. states and five Canadian provinces have recognized the seriousness of this problem and have gone ahead and enacted laws requiring the proper disposal of electronic products. Responsible manufacturers like Sony, Samsung and Nokia have also introduced their own product take-back. This patchwork of policies is not an effective approach. It’s time for our federal government to produce uniform e-waste rules that can be enforced. Tough rules are the only way to ensure our e-waste stops being sent to developing countries, where it is being crudely handled in a manner we would never allow here. E-waste should be an issue for everyone in the electronics’ industry. You can read more about this problem and sign a pledge voicing your concern at www.newark.com/ewaste. We’ll then keep you informed of progress in this area and let you know how you can make a difference. Ken Manchen is Newark and Premier Farnell’s corporate director of Safety, Health & Environmental Affairs.
AU
TIVE MO
S S
IC A
CE
D L
mechatronics Electromechanics
TU
Mechanical CAD
Electronic Systems
RI NG
Software
S
M
FA U
Y
E
C
Mechanical Systems
S T
M
S
CO
A
N
S CT NSU MER PRODU
Bridging the Proverbial Gap Next-generation computer tools need to be as dynamic as the engineers using them In my last mechatronics’ article, “Is ‘Engineer Programmer’ An Oxymoron?” (DN 02.09, http://designnews.hotims. com/23098-572), I posed that question and now I want to further ponder it. I believe most people will agree most engineers, young and old, fear traditional low-level code — like C and Assembly— to such an extent they turn computer control over to a software expert, and rarely, if ever, program. Therefore, it appears the term “engineer programmer” is an oxymoron! This begs the question: What is it about computer programming that seems so out of place in engineering problem solving and implementation that an engineer would relegate it to an external computer programmer, leave it out of the process entirely or even design a complicated solution so that they do not need to do it? Rather than looking for people to blame for this situation — and that would start with me as an engineering educator — I decided to try to break some new ground and get to the essence of the problem. During one of his visits, I spoke with National Instruments’ Academic Field Engineer Andy Watchorn. He, I and a colleague of mine at Marquette, Professor Phil Voglewede, had a most stimulating discussion. Here are some thoughts that came out of it. Engineers solve problems to help society. In order to solve these problems efficiently, engineers use computer tools. Ideally, the human, the computer tool and the problem should all be in perfect harmony throughout the entire problem-solving process. The ideal computer tool maps seamlessly onto both the topography of the problem and the experiences of human beings involved. For both inexperienced and experienced engineers, the computer tool offers invaluable insight into problem solving if it maps onto the topography of the problem and Tool
People
People
Problem
Problem
People
Problem
onto the way a human being solves a problem equally well. So for a computer tool to be truly useful throughout the entire design process, it must deliver on both sides — problem and problem-solver. What seems to impede this seamless mapping is translation. In problem solving, an engineer starts in the physBY KEVIN CRAIG ical world and ends in the physical Kevin C. Craig, Ph.D., world. Any translations that take place Robert C. Greenheck along the way can take the human be- Chair in Engineering ings far from the physical/visual realm Design & Professor of where many have their best intuitions Mechanical Engineering, and insights. For example, flattening College of Engineering, a physical problem into words, just Marquette University. because the final computer program For more mechatronics will consist of them, represents just news, visit www.mechasuch a translation. This is an unneces- tronicszone.com. sary detour. Translating the world into words, or from one language to another, will always result in errors and losses. Minimizing translational and conceptual detours is certainly a goal. Why then shouldn’t computer code be represented graphically? Graphical modeling packages like LabVIEW, Simulink, PSpice and others seem more approachable for modeling and implementing real systems because they show the flow of energy and information among real components maintaining problem topography. So, revising the initial question, why doesn’t the engineer programmer exist? I believe that is due to the way these computer languages map (see diagram, left). While Assembly and C map onto the problem very well, they do not map onto the experiences of the majority of engineers, young and old. Given that, the engineer will shy away from that which is uncomfortable. If the computer tool can accurately map a problem onto a hardware solution and also allow for each abstracted layer to be peeled away right down to the bit level, then the engineer will be empowered to be both a gearhead and bithead at the same time. This is a tool both the senior and junior engineer will undoubtedly use … if we can find it. For More
Mapping of computer tool onto people and problem — the tool must map onto both the people and the problem equally well. 16
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
information
RAPHY ROG XE
M AT E R I ALS PR O
E
Control Electronics
Digital Control Systems
SE
FRESH IDEAS ON INTEGRATING MECHANICAL SYSTEMS, ELECTRONICS, CONTROL SYSTEMS AND SOFTWARE IN DESIGN
E
Control Systems
N FE DE
MECHATRONICS IN DESIGN
AERO SP AC
M
G
I
N
TO
M E C HAT RO NI CS
For more information on design tools aiding mechatronic design, visit www.mechatronicszone.com.
S
P E C I A L
A
D V E R T I S I N G
S
E C T I O N
R A Q ’ s
Rarely Asked Questions Strange stories from the call logs of Analog Devices
Impedance Measuring Chip Offers Little Resistance to Applications Q: I came across your Impedance measuring chip (IMC) in a recent article. It sounds interesting, but how does it work and what can it be used for?
Application Engineer at Analog Devices in the High Speed Linear group. John has been with Analog
A:
The impedance measuring chip you mention is an extremely versatile device with countless practical applications. Able to measure complex impedances from 100 to 10M with 0.5% accuracy, the IMC is a marvelous example of integration, elegance and practicality. The IMC comprises a direct digital synthesis (DDS) frequency generator, a 12-bit analog-todigital converter (ADC), and a digital-signal-processing (DSP) engine. The frequency generator provides a voltage stimulus to the device under test (DUT) at frequencies between 1 kHz and 100 kHz, and the ADC samples the resultant current. The DSP performs a discrete Fourier transform (DFT) on the digitized signal, and produces real (R) and imaginary (I) data words at each frequency. Using this information, the magnitude and phase can be calculated along any point in the frequency sweep. Limited only by the imagination, some applications for an IMC include virus detection, blood coagulation monitoring, electro-impedance spectroscopy, and loudspeaker optimization. Different virus strains cause different chemical reactions in blood. Characterizing these reactions by measuring their impedance over frequency enables researchers to identify different virus strains by their impedance signature.
Contributing Writer John Ardizzoni is an
Devices since 2002, he received his BSEE from Merrimack College in N. Andover, MA
Blood clotting time can be determined by measuring the impedance as it coagulates. Crucial to recovery of heart bypass patients, monitoring coagulation enables doctors to maintain a balance between bleeding and clotting. Electro-impedance spectroscopy uses impedance to measure corrosion of aluminum and steel in infrastructure, cars, planes, and ships, preventing early failures and unneeded repairs. Impedance measurement chips can be placed in remote, hard to reach spots. This constant “structural supervision” signals maintenance crews to the first sign of corrosion or premature wear. Measuring speaker impedance across the audio frequency range enables designers to actively match the speaker impedance to the audio driver for optimal performance and power transfer.
and has over 29 years experience in the electronics industry.
Have a question involving a perplexing or unusual analog problem? Submit your question to: raq@reedbusiness.com
For Analog Devices’ Technical Support, Call 800-AnalogD
It’s almost maple sugar season here in New England. I wonder if an IMC could measure the sugar content of the sap… hmm, I’ll have to look into that. SPONSORED BY
To Learn More About Impedance Measurement Applications http://designnews.hotims.com/23098-100
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w . d e s i g n n e w s . c o m ] 19
FLASH
NEW AND NOTABLE PRODUCT DESIGN
As digital controls get more sophisticated, they’re transforming more aspects of our lives. Design engineers are pushing the envelope in health, education, espionage and even entertainment. By Terry Costlow, contributing editor
SPY PLANE EMPLOYS GREEN TECHNOLOGY Reducing fuel consumption and emissions is a goal even in the world of espionage. AeroVironment Inc. is designing an unmanned aircraft that runs on liquid hydrogen-power. Its Global Observer will fly at an altitude of 65,000 ft for up to seven days. The high altitude, long endurance aircraft is being built for the U.S. Special Operations Command, which teamed up with other military to provide $57 million for three aircraft. AeroVironment recently picked Rockwell Collins to design the drone’s navigation system. Rockwell’s Athena 411 incorporates solid-state gyros and accelerometers, magnetometer, a GPS receiver and air data sensors into a single small unit.
http://designnews.hotims.com/23098-521
PORTABLE SYSTEM FINDS ENTERTAINMENT EVERYWHERE Increasingly, TV is being augmented by entertainment pulled from the Internet and other media sources. Internet Media Tablets from Archos let consumers explore and navigate the Internet, then switch to TV or other media, displaying all video on a highresolution 5-inch screen. The tablets have 60 to 250 Gbytes of memory and both Wi-Fi and 3.5G-ready cellular links. The Archos 5 and its larger Archos 7 both employ Texas Instruments’ OMAP 3 processor. This chip includes a 600 MHz superscalar ARM Cortex-A8 processor and TI’s video digital signal processor. Battery life ranges up to seven hours for video and 22 hours for audio playback.
http://designnews.hotims.com/23098-522
20
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
FLASH
PRODUCTS
TINY PROJECTORS, BIG PICTURES
Pico-projectors are getting smaller, but they’re projecting sharp high resolution images as large as 60 inches. 3M™ recently unveiled the MM200 Mobile Projection Engine, which uses less than 1W of LED power to project a 15-inch image in a normally lighted room or up to 60 inch in a darkened room. The battery-operated module, which is only 10-mm thick, is based on an imager from Displaytech® that generates 360 color fields per second over a temperature range of -10 to 70C. 3M™ also makes a line of MPro Professional Projectors, which are shrinking the size of projection systems.
http://designnews.hotims.com/23098-523
SPEECH GENERATORS ENHANCE COMMUNICATION Digital technologies continue to help improve the lives of stroke victims and others. O’Brien Technologies is finalizing design of a speech-generating device that will assist those who can’t speak. The handheld devices are designed to assist speech language pathologists and other health care professionals who treat individuals with severe communication disabilities. The devices can be customized to supplement communication for many users. O’Brien is working closely with the Kessler Foundation, a public charity dedicated to improving the lives of people with physical disabilities caused by stroke and brain or spinal cord injuries. The Advance Micro Power Research Technology Incubator (AMP-RTI) helped design the system it produces in conjunction with 1-Source Electronics.
http://designnews.hotims.com/23098-524
ROBOTS INVADE MORE HIGH SCHOOLS The FIRST competition, designed to get high school students interested in science and technology, continues to expand. Founded in 1992, For Inspiration and Recognition of Science and Technology gives students six weeks to design, build, program and test robots that match up in regional contests and culminate with an international championship meet in Atlanta, GA, April 16-18. More than 42,000 students from 10 countries received parts’ kits with 604 items. This year, that includes MPC5200 Power microprocessors from Freescale Semiconductor. The contest rewards both good designs and collaboration. The latter includes working with competing teams, as well as with team members.
http://designnews.hotims.com/23098-525
22
Green politics and white light are destined to be intimately linked for many years to come. The Obama administration’s economic stimulus package allocates approximately $50 billion dollars towards efficient and renewable energy, another $4 billion to improve energy efficiency of public housing, and provides $20 billion in tax incentives for further development and deployment of efficient renewable energy technologies. The largest single “consumer” of electrical power in most buildings is lighting—about 24%. Similarly, municipal streetlights account for more than 20% of the power consumed in the average US city, and up to 38% of European cities! Clearly, if we need to use energy more efficiently, optimizing the conversion of electricity into light comes to the forefront. For indoor applications, there is no match for the efficiency of high-brightness LEDs (HBLEDs), especially when one takes into account the fact that compact fluorescents contain hazardous materials such as mercury and are relatively short-lived. For outdoor locations which require a large quantity of light, sodium vapor lamps are very efficient. Unfortunately, because these lamps produce nearly monochromatic yellow light, they have notoriously poor color rendering ability- a traffic safety concern. Is designing an HBLED-based streetlight difficult? Yes, it can be. The biggest challenges are heat and optics. Driving HBLEDs from the AC mains or solar power is easy; however having the proper amount of light falling with prescribed “zones” is not so easy. Most US cities follow the recommendations of the Illumination Engineering Society of North America (IESNA), which prescribes several standard distribution patterns for roadway lighting. A common pattern is Type II, shown in Figure 1.
which contributes to light pollution, and “light trespass”— the excess light cast in unwanted areas, such as your bedroom window. Lastly, there is glare. It has a direct impact on roadway safety. There are several key advantages of HBLEDs in streetlights and other outdoor area lighting. The most obvious are the visual qualities of the light and high color rendering. The biggest cost impact though, is realized when the HBLEDs are dynamically controlled. This isn’t an option for sodium vapor lamps because they are either full-on or completely off, and most require a minimum delay between successive “strikes”. These technologies rely on dusk-to-dawn timers or distributed light sensors.
Cary Eskow is director of LightSpeed, the solid state lighting and LED business unit of Avnet
Now imagine the benefits of an “intelligent” HBLED streetlight. The HBLED drive electronics would include a microcontroller, temperature and humidity sensors, input from a pavement-embedded inductive loop or other vehicle sensor and an RF or power-line network interface. Here’s how it would operate: 1) As the day slowly fades to darkness, ambient light sensors would gradually increase the HBLED’s intensity. 2) If there are periods, perhaps early in the morning, when no traffic is passing under the lights, they would dim—until a vehicle is sensed by the roadway sensor of an uplinked streetlight. 3) If there is an emergency, police activity or road hazard, streetlights in the immediate vicinity can be brought to full power via network control. 4) During inclement weather such as fog or rain, the streetlights would automatically adjust their output as required for maximum safety.
Electronics Marketing. An ardent advocate of energy efficient LED-based illumination, he has worked closely with LED manufacturers, advanced analog IC and secondary optics vendors since his first patent using LEDs was issued two decades ago. LightSpeed works with customers through their national team of illumination-
A system like this was tested in Oslo, Norway, and it yielded an additional 50% energy savings. Last month the city of San Jose, California issued a public RFI (Request for Information) to upgrade their streetlights in a similar fashion1, most likely a precursor to a formal bid solicitation. Today there are literally billions of dollars available to capitalize on energy efficiency, so you can be sure many proposals are being written to bring these benefits to other cities.
focused engineers called “Illumineers,” experienced in thermal, drive stage and optics design. Prior to LightSpeed, Cary was Avnet’s technical director and managed Avnet’s North American
Figure 1 – An IESNA Type II Distribution Pattern
We generally use an array of HBLEDs with special lenses attached to achieve broad elliptical patterns like a Type II. Other factors come into play as well, namely “sky glow”
If you’re considering developing HBLED lighting systems, intelligent or not, let us know how we can help. As always, comments and questions are welcomed and can be sent to me at LightSpeed@Avnet.com 1
FAE team. To submit questions or ideas, e-mail Cary at LightSpeed@Avnet.com
Download San_Jose_RFI.pdf from www.em.avnet.com/LightSpeed
To learn more about designing an LED-based illumination system, go to:
www.em.avnet.com/LightSpeed
T I Pfrom S
TITUS
Unbelievably useful info on data measurement, collection and analysis from the test expert
JON TITUS CONTRIBUTING WRITER
Let’s Learn More about Statistics SOME ENGINEERS MIGHT NEVER HAVE HAD AN
opportunity to take a statistics class so they struggle through standard distributions, variances, correlations and other aspects of data Jon Titus, a former designer and chief analysis. Even people who took a formal class editor of EDN and in statistics need a “statistical” hand from time Test & Measurement to time. Two new books from O’Reilly Media World magazines, can help (see references, below). remembers when “Head First Statistics” covers material you’d “fast” signals operencounter in a first-year statistics’ course. So ated at 10 MHz and if you haven’t taken such a course, start here. programs came on Instead of giving readers just another dry acapaper tape. demic tome, author Dawn Griffiths takes a refreshing approach to statistics that includes many helpful illustrations and annotations that look like notes students write in book margins. I liked the many diagrams, problems and the questionanswer sections that help readers better understand a concept. I’d dare say the author makes it fun to learn about statistics because she introduces many practical examples and problems. This book can’t cover every statistics’ topic, but it lays down a solid foundation. Even if you routinely use statistics’ software to analyze data, after you read this book you will better understand how to interpret the results. Today’s engineers must understand statistics to ensure their Two new books from O’Reilly Media data-collection and -analysis help students and professionals bettechniques make sense. ter understand statistics. 26
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
The second book, “Statistics in a Nutshell: A Desktop Quick Reference,” doesn’t shy away from math, but you can go for many pages without seeing an equation. The authors wrote this book as both an introductory text for students and to help professionals better understand how statistics presents information and how to use that information. But the word “text” loosely describes this book’s approach to statistics. To me, the writers aim to stress the use of statistical information much more than how to apply mathematics to calculate statistical results. I liked the emphasis on interpreting statistical information and the many graphs and tables that clearly illustrate concepts for people like me who would rather see a diagram than an equation. Chapters cover basic statistics and probability, interpreting statistical information presented by others, research design, inferential statistics, correlation and similar topics. The last three chapters describe the use and interpretation of statistics in business and in medical and educational studies. With a bit of fundamental statistical knowledge, readers can tackle chapters and sections individually and out of order. Each book addresses statistics in its own way. If you want to brush up on creating, using or interpreting statistical information, one or both books will meet your needs. For More
REFERENCES
information
1. Broslaugh, Sarah and Paul Andrew Watters, “Statistics in a Nutshell,” O’Reilly Media, 2008, (ISBN: 978-0-596-51049-7. $34.95): http://designnews.hotims.com/23098-526 2. Griffiths, Dawn, “Head First Statistics,” O’Reilly Media, 2009, (ISBN: 978-0-596-52758-7. $34.95): http://designnews.hotims.com/23098-527
AT STAKE Visions for the Engineering Century
Banish the Mundane:
Geoffrey C. Orsak
It’s TED Time
The annual Technology, Entertainment, Design conference is a must-attend event for any engineer
I
must be crazy. Having completed a detailed application that would make the HR folks at Intel proud, then paying a small fortune for registration, I flew halfway across the country to watch a conference on TV. But, hey, this was the TED (Technology, Entertainment, Design) conference and I couldn’t get into the main room. You do what you must. Until about a year ago I never heard of the conference — but now I am knee-deep in the cult of TED. You should be, too. Once a year since 1984, this gathering of leading innovators, artists, scientists, engineers and socially concerned thinkers and doers meet to exchange “ideas worth sharing.” The format is simple: If you are making noise in this world, then you have 18 minutes to give what they call “the talk of your life.” No marketing, just pure ideas. What a lost concept. Trying to put TED into words is like trying to tell your parents what Woodstock was like. There’s no story line here, just random thoughts and experiences I think are worth sharing: The fascinating engineer/artist Golan Levin is creating a new kind of art that answers the question, “If art was aware you were looking at it, what would it do?” (Check out his SNOUT on YouTube — a piece of sculpture that is actually surprised to see you http://designnews.hotims. com/23098-528)! Tim Berners-Lee, designated inventor of the World Wide Web, shared the funny story of the memo he wrote to his boss requesting time to work on his Web idea. The memo resurfaced years after his boss’s death with a note he’d scribbled in the corner: “Vague, but exciting.” Former Oracle powerhouse Shai Agassi laid out his vision for an all-electric auto transportation system he estimates can run at a cost of two cents per mile. Juan Enriquez, head of a life science research and 28
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
investment firm, introduced his concept for a new life form, — the hominid Homo Evolutis — that for the first time in history takes control of its own evolution. Brilliant. Denmark-born Icelander Olafur Eliasson is using creative engineering and technology to blur the line between author and consumer in art and ideas. His immensely popular work, “The Weather Project,” attracted two million visitors to the Tate Modern in London. Check out “Naturally 7” — a New York vocal group that creates great music from absolutely unbelievable sounds from their mouths.
“If you are making noise in this world, then you have 18 minutes to give what they call ‘the talk of your life.’” Yes, Bill Gates and Al Gore updated us on their “projects” — the eradication of disease, the overhaul of education and the severity of global warming. Chilling stuff. You probably heard about Gates opening a jar of mosquitoes over the audience, explaining there is no reason only poor people should be infected with malaria. And, indulge me — I was given three minutes to give the talk of my life. I introduced a new project called the Global Open Source Home, or GOSH! I am committed to addressing the housing needs of the billion or so people around the world who live in grossly substandard conditions. All of these great talks are online at TED.org. So join the conversation, banish the mundane and jump with me into this funky exchange of ideas worth sharing. Geoffrey C. Orsak is dean of the Southern Methodist University Lyle School of Engineering in Dallas, TX. He can be reached at dean@lyle.smu.edu.
S P E C I A L A DV E RT I S I N G S E C T I O N
Design Challenge: Modernize
Equipment for Soldiers By partnering with the right design and manufacturing partner, defense-market engineers can create fresh designs to ease the burden on ground troops hink your job is tough? Try lugging around 80 lbs of gear all day in 100-degree heat while under threat from enemy fire. That’s what our soldiers face in Iraq, and the Defense Department is looking for ways to reduce the sheer weight of equipment that can wear down these troops and hurt their performance. Specifically, the Pentagon has told the EDGE Network, a consortium of leading defense industry
T
For communications equipment, magnesium injection molding produces parts that are 30% lighter than aluminum, with excellent EMI/ RFI shielding. 30
suppliers, that it wants to trim 20 lbs of weight from the ground soldier’s equipment ensemble (GSE). Finding that weight reduction will require design breakthroughs in virtually every part of a soldier’s gear: body armor, weaponry, communications equipment and more. With Defense officials calling for equipment that is rugged, yet lighter, more compact and more ergonomic, old approaches to designing and manufacturing combat equipment fall short. It will take fresh thinking to achieve a 25% reduction in GSE weight. A Strategy for Change As design engineers in the defense field take on this tough challenge, one key strategy is becoming clear: Replace conventional materials with new technologies. No matter what the design target — from equipment cases and rifles to goggles and body protection — innovative materials can shed weight, while improving performance in water proofing, impact resistance and durability. By harnessing new manufacturing methods for materials, engineers can make big strides in parts reduction, component miniaturization, and improved ergonomics. Four methods in particular are emerging as standouts —
DESIGN NEWS MARCH 2009 [www.designnews.com]
DoD wants engineers to design a whole range of new equipment with a combined 25% weight savings.
Magnesium Injection Molding (MAG). Magnesium demonstrates excellent performance, especially in communications gear. As durable as aluminum, magnesium offers superior EMI/RFI shielding, even in thin-wall designs. Bottom line: A magnesium housing performs better than one made from aluminum — at a 30% weight savings. MAG combines the best qualities of plastic injection molding with die casting to produce lightweight, high-density, net-shape parts. Components demonstrate excellent properties for stiffness and strength-to-weight. Moreover, you can design MAG parts in a wide array of sizes, ranging in weight from 4 grams to 1800 grams. You can also specify plastic overmolding on magnesium components, as well as special coatings to prevent corrosion. And MAG won’t harm the environment. The material is recyclable, and no ozone-depleting gases are used in molding operations. Metal Injection Molding (MIM). Ideal for manufacturing weapon components and other intricate assemblies, metal injection molding can produce high-volume parts with com-
S P E C I A L A DV E RT I S I N G S E C T I O N
plex geometries, superior strength and excellent surface finish. Using MIM, you can typically produce precisionshaped parts for 50% less than comparable CNC machining or investment casting. Yet finished parts offer the same mechanical properties as those produced by machining. MIM really stands out for parts weighing 30 grams or less. The process can create tiny metal parts with total volume of as little as 0.0001 to 0.003 cubic inches, with tolerances as tight as +/- 0.001 of an inch. Density and mechanical properties are approximately 98% of wrought. Among the many materials choices: stainless steels, titanium, Kovar®, nickel steels, tools steels, tungsten, super alloys, and soft-magnetic alloys. Micro Molding. This manufacturing technique answers the need for miniaturization in soldier equipment, yielding high-precision finished parts as small as a pinhead. Parts measuring just 0.020 inch per side can be molded, and you can specify details such as undercuts, threads, and thin wall sections down to 0.002 inch. Micro molding also yields a larger proportion of finished part to molding runner versus conventional molding, and the investment necessary to produce a part is generally several times lower. In addition, prototype tooling can typically be used in final production. Materials options include: engineering-grade plastics, stainless steel, iron nickel, titanium and ceramics. Multi-Shot Liquid Silicone Rubber Molding ( MS LSR ) . With this innovative process, a designer can get a molded part that combines traditional thermoplastics with liquid silicone rubber. MS LSR is ideal for parts, such as seals, that demand superior biocompatibility, chemical resistance, clarity, and the ability to withstand harsh environments. Among other design advantages, the process can accept a wide range of colorants, while offering temperature resistance up to 410 deg F (210 C). It can also provide bacteria resistance, gas
A trusted partner for Defense designs In Wisconsin-based Phillips Plastics, engineers will find a supplier with broad capabilities in the new technologies required to tackle the DoD’s ambitious weight-reduction goals. As a member of the Edge Network, a consortium of leading-edge defense suppliers, Phillips stays abreast of the new design objectives and performance specs that the military is seeking in next-generation equipment for ground soldiers and other needs. The company also offers extensive production facilities for magnesium injection molding, metal injection molding, micro molding, and multi-shot liquid silicon rubber. In addition, you can harness Phillips’ engineering expertise for design, prototyping, testing, tooling and final manufacturing and assembly. For the special needs of defense designs, Phillips offers secure facilities, class 100,000 clean room production, ITAR registration (International Traffic in Arms Regulation), and ISO 9000:2000
permeability, and excellent light illumination. Plus, you get excellent enduser ergonomics, including parts with a soft feel to the skin. That’s particularly useful for goggles, head phones and ear pieces for communications. Targets of Opportunity With these ground-breaking technologies, opportunities for developing lightweight, high-performance soldier gear are limited only by the designer’s imagination. Among the many immediate applications: mobile battery chargers, compact targeting devices for air support, and joysticks, keyboards and other input devices for communications. The military also wants a long menu of new lightweight devices that soldiers can wear, such as antennas, computers, displays and video receivers. In designing such products, engineers will need to pay more attention than ever to factors such as ergonomics and ease of use. Offering a traditional rectangular metal box with buttons on the top won’t
With the multi-shot liquid silicon rubber process, engineers can design products with a soft-touch feel for ear pieces and other wearable gear. and ISO 13485:2003 quality certification. “The new design mandates for defense require a willingness to look at what can be done with new materials and processes,” says Tom Rothgery, Defense Market director for Phillips. “Engineers should lean on their suppliers to meet that challenge.”
hold much appeal to young soldiers who grew up with clever video game controllers in all sorts of shapes and styles. In short, making the transition from machined or stamped metal parts to new molding technologies requires a paradigm shift in the way engineers design and build military products. That’s why it’s essential to find a supplier who can offer assistance with engineering design, styling and prototyping, with an eye to making the most of such innovative production methods as MAG, MIM, micro molding, and multi-shot LSR. Engineers can download a detailed White Paper on new technologies for improving ground soldier equipment by visiting the Phillips Plastics Web Site: http://designnews.hotims. com/23098-130
DESIGN NEWS MARCH 2009 [www.designnews.com] 31
INSIDE NEWS
» ELECTRONICS LEDS ON THE MOVE New technology that uses bigger, brighter LEDs in home projectors eliminates warm-up time. Page 36
TRENDS BREAKTHROUGHS DEVELOPMENTS
NEWS
» MATERIALS FIBER CUTS WEIGHT A boat made with a new longfiber injection molding technology is coming to a lake near you. Page 38
» MOTION CONTROL CONTROL IN MOTION Industrial Ethernet and various fieldbuses now mix, thanks to a new motor control platform called MotionFire. Page 40
» DESIGN TOOLS ENHANCED SEARCH Aras’ new advanced search services help make engineers’ everyday workflows easier. Page 42
» AUTOMOTIVE HYBRID TESTING Sakor Technologies’ Hybrid Vehicle Battery Test System combines high-voltage capability with a programmable control system. Page 44
» MECHATRONICS MIT’S FORKLIFT IS READY FOR BATTLE A remote-controlled robotic forklift developed by MIT is making war zones a little safer. Page 46
» SENSORS PLANT SENSOR AIDS GROWTH PlantSense’s new EasyBloom Plant Sensor uses four sensors to detect temperature, humidity, soil and light. Page 48
Source: 3M™
The integration of technologies, such as tapes and adhesives, will simplify specifications for applications such as blade protection for wind turbines. A S S E M B LY
3M™ Targets Renewable Energy New division will tap existing products, develop new technologies By Doug Smock, contributing editor, materials and fastening
3M™ will leverage its wide technology portfolio in a new Renewable Energy Div. that will include existing and brand-new technologies. Two business units have been established within the new division: Energy Generation and Energy Management. “3M™’s new operation will serve the renewable energy market globally and bring the best products and technologies from a single source to customers worldwide,” says Michael Roman, who was named vice president and general manager of the new division. “3M™’s leadership will spread the company’s next-generation products to the global marketplace where customers will reap the benefits of having one face that can provide D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 3 3
N EWS ASSEMB LY, C o ntinued
DRIVE PRODUCTS FROM PROTOTYPES TO PRODUCTION PARTS FASTER WITH REDEYE.
SAVE TIME. CUT COSTS. GET MORE MATERIALS AND OPTIONS. RedEye delivers the entire digital manufacturing experience on demand: functional prototypes, fixtures and assembly tools, lowvolume parts production. Online, on your schedule. Just upload your CAD file and go. Start with a free quote at: RedEyeOnDemand.com
proven solutions, when the and adhesives to enhance need is of the utmost imporwind turbine reliability and tance.” efficiency. 3M™’s technologies, for example, may be Energy Generation will leveraged to mitigate erofocus on solar energy, wind sion, fouling and icing of energy, geothermal and blades, as well as enhanced biofuel, with product solublade aerodynamics. tions such as films, tapes, In Energy Management, coatings, encapsulants, seal3M™ received the very first ants and adhesives that help reduce the cost of renewable window film patent in 1966 and continues to be a world energy. These products proleader in window film techvide functionality for light nology. 3M™’s window film management, environmenportfolio has tal durability, grown to thermal manENERGY include solar agement and GENERATION management, productivity and improvement. WILL FOCUS ON safety security and The resources inSOLAR ENERGY, decorative technology clude 3M™’s core technolo- WIND ENERGY, platforms that gies in materi- GEOTHERMAL are sold in the als’ science automotive, AND BIOFUEL. commercial that have already paved building and the way for breakthroughs residential markets. in concentrating light. The Prestige Series, one of For example, 3M™ panels 3M™’s lines of window film concentrate light and are products, is the first clear and manufactured to match cusnon-metal-based window tomer specifications. Other film to significantly reduce next-generation films proheat and ultraviolet rays envide durability and reliability tering a building. These films required in solar panels, with block up to 66 percent of added properties for ultravio- heat penetrating the window, let stability, low flammability resulting in less stress on air and self cleaning. conditioning and lower en3M™ has been providergy costs. 3M™ continues to ing technology in the wind break new ground with innoindustry for more than a vative products and services decade. Polyurethane tapes in the ever-changing and have been used extensively rapidly expanding energy for protecting the leading management market to meet edge of wind turbine blades, customer needs. and 3M™’s abrasives and For More safety products have been information used to enhance manufactur3M™ Renewable Energy Div.: ing efficiency and safety. http://designnews.hotims. The formation of the Recom/23098-529 3M’s™ Prestige Series: newable Energy Div. will alhttp://designnews.hotims. ™ low 3M to focus its expercom/23098-530 tise in films, tapes, coatings
» ELECTRONICS
Home Theaters Employ Bigger, Brighter LEDS New chipsets are the key to bringing LEDs to DLP projectors
By Charles J. Murray, senior technical editor, electronics Home theater projector makers at the recent Consumer Electronics Show (CES) in Las Vegas demonstrated a new technological twist: using light-emitting diodes (LEDs) to power their optical engines. At least two manufacturers at CES showed off LEDbased home projectors. Chi Lin Technology Co. Ltd. and Delta Electronics Inc. are said to be the first in a wave of manufacturers making digital light processing (DLP) projectors and using high-powered LEDs as a source of illumination. Both companies employed DLP technology from Texas Instruments and PhlatLight PT-120 LED chipsets from Luminus Devices in their home theater projectors. “The next logical step after rear projection televisions is home theater systems,” says Matt Mazzuchi, general manager of the Projection Display Business Group at Luminus Devices. The LEDs serve as a replacement for conventional mercury vapor arc lamps, commonly employed in DLP-based projectors. LEDs are said to offer several advantages over the mercury lamps, including instant start-up and no warm-up time. They also last the lifetime of the projector and maintain their color stability over time. Luminus engineers say their LEDs can serve in home theater applications because they are significantly larger and can operate at higher current levels. Delta Electronics is employing the PhlatLight technology in its HT-8000 projector,
Vivitek’s H6080FD employs PhlatLight technology from Luminus Devices and DLP technology from Texas Instruments.
which serves in Vivitek USA’s H6080FD home theater system. Similarly, Chi Lin is combining the PT-120 chipset with TI’s DLP technology in its new home theater system. Both projector manufacturers worked closely with Luminus and Texas Instruments on the construction of the optical engines, which process the light from the LEDs through separate channels for red, green and blue light devices. Projectors from both companies are due out this year. “Up to now, the LEDs simply weren’t big enough and didn’t offer enough brightness to make it happen,” Mazzuchi says. “But the big LEDs work because they deliver a lot of brightness into the optical aperture of the system.” For More
ELECTRONICS
information
LED sales headed for 20 billion units per year: http://designnews.hotims. com/23098-531 Texas Instruments’ DLP technology: http://designnews.hotims. com/23098-532 Luminus Devices’ PhlatLight PT-120 LED chipsets: http://designnews.hotims. com/23098-533
» MATERIALS
Novel Long-Fiber Injection Technology Cuts Weight Bayer and Krauss-Maffei help Camoplast develop a polyurethane-based system for large molded parts
By Doug Smock, contributing editor, materials and fastening The first application of a new long-fiber injection molding technology is used to make the hull of a personal watercraft that will hit the market this summer. The new technology produces a lighter, more efficient hull, according to Yves Carbonneau, engineering director at Camoplast, a privately owned company based in Sherbrooke, Quebec. In the new process developed jointly among Camoplast, Bayer MaterialScience and Krauss-Maffei, long glass fibers are injected, along with polyurethane resin, in a one-step process. A fiberglass chopper is attached to the polyurethane dispensing mixhead, which connects to a robot. The robot is programmed to move over the open mold cavity, while simultaneously dispensing both the long glass fibers and the polyurethane resin in an open-pour method. At the end of the pour, the mold is closed to form the part in a low-pressure process.
The goals of the project are to achieve a superior Class A finish, reduce part weight without sacrificing strength and keep costs down. “Because this particular customer had used glass-reinforced polyester resin for years, initially there was skepticism that making such a big leap to a new material, polyurethane, and a new technology would result in high-performance and great aesthetics,” says Carbonneau. Bayer MaterialScience developed a proprietary grade of its Baydur STR 814 polyurethane system, which features a 60-sec open time compared with a traditional open time of roughly 10 sec. This facilitates the flow of the material and reinforcing glass into tight spaces, making it possible to design-in strengthening ribs and other features that can boost the effectiveness of the hull. Krauss-Maffei enhanced its long-fiber
Source: Camoplast
New technology used in a boat hull doubles glass output capability from 180 to 300 gm/sec.
processing technology by nearly doubling the glass output capability from 180 to 300 gm/sec. For More
MATERIALS
information
Camoplast Inc.: http://designnews.hotims.com/23098-534 Bayer MaterialScience: http://designnews.hotims.com/23098-535 Krauss-Maffei Technologies GmbH: http://designnews.hotims.com/23098-536 Watch a video of the LFI process at http://designnews.hotims.com/23098-537.
Our innovative electric systems are being used to upgrade gas spring and manual operations, and due to their simplicity and state of the art designs, are rapidly replacing hydraulic and pneumatic systems. LINAK has a selection of reliable actuators to provide your application the movement you desire.
Visit our website for our complete product range: www.linak.com
LINAK U.S. IInc. n • North and Sou nc. South outh American Headqu Headquarters • 2200 Stanley Gault Parkway Louisville, KY 40223 • P. 502 253 5595 • F. 502 253 5596 • info@linak-us.com
3 8 ad_designnews_fall08.indd 1
8/28/2008 2:36:09 PM
Âť MOTION CONTROL
Motor Control Platform Simplifies Communications FPGAs simplify process of linking fieldbuses and Ethernet
By Charles J. Murray, senior technical editor, electronics National Semiconductor, Altera Corp. and Arrow Electronics have teamed up to deliver an FPGA-based motor control development platform that simplifies the process of supporting several different communication protocols. Known as MotionFire, the new motor control platform could be a boon for developers who want to control motors from inside and outside the factory, mixing Industrial Ethernet with various fieldbuses. The three companies say they are targeting the platform at a variety of industrial, automotive, medical, instrumentation and consumer electronics’ applications. “With FPGA technology, users can reprogram everything on a single platform to support multiple protocols,� says Jason Chiang, senior technical marketing man-
ager for Altera Corp., which supplies the field programmable gate array (FPGA) technology for the platform. “That way, they don’t need to re-spin a custom board for each solution they deploy.� The three companies say the key to the new platform is Altera’s Cyclone III FPGA technology, which is programmed to support and bridge multiple industrial networking protocols. The platform can be used to control various motor types, including stepper, servo, ac and dc motors. The platform connects up to 12 motors, providing such network communication options as Ethernet/IP, EtherCAT, Profinet, SERCOS III, CAN, USB and RS485. Engineers from the three companies say they hope the new technology will simplify the process of connecting various fac-
Source: National Semiconductor
The FireFighter FPGA-based communication baseboard enables Industrial Ethernet and fieldbus communications.
tory floor fieldbuses to outside networks. “More and more, our customers are telling us that they not only need to upgrade and maintain multiple motion control platforms, but also that they need to integrate those into a network environment, so that they can manage systems remotely,� Chiang says. “With FPGAs, they can put everything on a single board. And they can support both the industrial connectivity and the motor interfaces that they need.� For More
MOTION
CONTROL
information
MotionFire: http://designnews.hotims.com/23098-538 Altera Corp.’s Cyclone III FPGA technology: http://designnews.hotims.com/23098-539. Read more about Industrial Ethernet at http://designnews.hotims.com/23098-540.
.BLF B RVBMJUZ DPOOFDUJPO 6/4631"44&% 26"-*5: */ 13&$*4*0/ $6450. &-"450.&3 .0-%*/( '03 36##&3 1-"45*$4 "/% 51& 8F IBWF TVQFSJPS DBQBCJMJUJFT BOE VONBUDIFE TFSWJDF XJUI PWFS ZFBST FYQFSJFODF TP ZPV DBO DPVOU PO DPOOFDUPST PG UIF IJHIFTU RVBMJUZ $BMM VT UP NBLF UIF DPOOFDUJPO 0S WJTJU VT POMJOF BU XXX EBQSPSVCCFS DPN Electronics s Aerospace s Medical Components s General Applications s Precision Tolerance Virtually Flash-free Parts s Rubber to Metal s Rubber to Plastic s Diaphragms With +/– .0015� Tolerance Custom Compounding s Prototype Tooling Designed to be Incorporated Into Multi-cavity Production Tooling
Compression - Transfer - LIM - Injection s ISO 9001:2000 s Class 10,000 Cleanroom USA 918.258.9386 s Europe 49.251.32266.0 s Singapore 65.6264.1880 s EMail - Sales@DaProRubber.com
Š2008 DaPro Rubber, Inc. All rights reserved.
» DESIGN TOOLS
Aras Innovator Outfitted with Cloud-Based Search Functionality Integration with Microsoft Live Search and GlobalSpec lets engineers perform advanced part searches within the context of PLM
By Beth Stackpole, contributing editor, design tools Aras, which staked its claim in the PLM market as the enterprise open source provider, recently announced new advanced search services for its Innovator platform designed to help engineers more easily find parts as a function of their everyday workflows. Seamlessly embedded in the Aras onpremise enterprise PLM software suite are new capabilities that allow engineers to access and query cloud-based search services in Microsoft Live Search and GlobalSpec, a Web-based engineering part, product and specification database. As part of the integration, Innovator users can conduct parametric searches on GlobalSpec’s databases, which cover more than 24,000 OEM and distributor product catalogs spanning more than 177 mil-
lion parts in 2.3 million product families. The GlobalSpec integration also facilitates full-text searching within Innovator on GlobalSpec’s Engineering vertical search engine index, which covers millions of pages of content, including engineering articles, technical research papers, materials properties and patents. The enhancements blend the power of cloud-based search capabilities with the traditional enterprise PLM environment, enabling engineers to locate product information more quickly without having to rekey data or leave their primary development environment, according to Peter Schroer (Aras’ Chairman and President). In other news, Aras announced a partnership with Actify Inc., a maker of a 3-D
With Innovator’s cloud-based search capabilities, users can search millions of parts, BOMs, drawings, data sheets and quality information to find the right part at the lowest cost.
viewing solution for visualizing CAD files. Every user who downloads Aras Innovator will receive a bundled Actify 3-D viewer as part of the package, he says. For More
DESIGN
TOOLS
information
Aras’ Open Source PLM strategy: http://designnews.hotims.com/23098-541 Microsoft Live Search: http://designnews.hotims.com/23098-542 GlobalSpec: http://designnews.hotims.com/23098-543 Aras Corp.: http://designnews.hotims.com/23098-544 Actify Inc.: http://designnews.hotims.com/23098-545
CNC. ASAP. “…excellent finish, good tolerances, and the quick turnaround time was great.” J.R., VIR Innovations, Inc.
CNC Machined Parts. Down to a Science. CNC is now as quick, easy, and automated as SLA and FDM. With our proprietary computer cluster technology and automated manufacturing process, you can now get real CNC machined parts in your choice of over 25 engineering resins in as little as one business day. Upload your 3D CAD model and experience an interactive, web-based 3D automated FirstQuote® today.
A Proto Labs Service
Free Prototyping White Paper: Whether you are new to the field or an expert, we’ve created a prototyping primer you shouldn’t miss. Download today at www.firstcut.com/asap and enter source code DN109.
www.firstcut.com 763.479.8600
©2009 Proto Labs, Inc.
Enter xx at www.edn.com/info
» AUTOMOTIVE
Sakor Rolls Out Tester for Hybrid Vehicle Batteries Designed for the high voltages and variable loads of hybrid cars
By Charles J. Murray, senior technical editor, electronics Manufacturers of hybrid vehicles now have a dedicated battery tester designed for the high voltages, currents and variable drive cycles of their vehicles.
Sakor Technologies Inc., a maker of dynamometers for hybrids, recently rolled out the Hybrid Vehicle Battery Test System, a product specifically designed for voltages as
GET CONNECTED WITH QUALITY PT COMPONENTS
RINGFEDER® power transmission components have long been regarded as the best in the business. Our wide range of quality products, combined with unparalleled expertise and product support will help you get the job done.
Whatever the application, Ringfeder Corporation has the power transmission solution that will get you connected. Please call us during the planning phase of your next project at 800-245-2580 or log onto www.ringfeder.com.
MEMS sensors will serve in energy harvesting applications. With current draw as low as 120 µA, they leave room in the power budget for operation of microcontrollers and converters.
high as 1,000V and for the real road loads and unsymmetrical driving cycles common to everyday driving. The system could be significant for automakers, which must assess hybrid battery packs that weigh hundreds of pounds and operate at voltages ranging from 200-600V. The new system’s key advantage, however, is it combines its high voltage capability with a control system that can be programmed for various types of driving cycles, much like the dynamometers used in torque testing of engines and electric motors. “A battery may have one level of performance if you just do simple, long-cycle, long-wave types of testing,” says Randal Beattie, president of Sakor Technologies. “But that doesn’t necessarily translate well to the mileage you get out of a battery when you put it in a real vehicle and subject it to real-world loads.” Sakor’s system is driven by the company’s DynoLab EM controller and works with its HybriDriveline Dynamometer, both of which had already been in use for testing of hybrid motors and inverters. Because the company already had experience with hybrid power train technology, it extended its product line to include a hybrid battery tester, Beattie says. “Hybrid vehicle manufacturers need to simulate the second-by-second changes in load that occur when a car runs up and down a hill, or comes to a stop light,” he says. “The most important thing is for them to know what kind of performance they can really expect out of their battery.” For More
AUTOMOTIVE
information
Sakor Technologies Inc.: http://designnews.hotims.com/23098-546 Learn more about hybrid vehicle batteries: http://designnews.hotims.com/23098-547 44
Âť MECHATRONICS
MIT Develops Robotic Forklift for Battle Zones By Howard Baldwin, contributing editor A new unmanned remote-controlled forklift under development by MIT’s Computer Science and Artificial Intelligence Lab.
aims to make war zones safer for noncombatants by keeping them off the battlefield while the machine does all the work. The drive-by-wire forklift uses a combination of electrical, hydraulic and
Little Sensors. Big Ideas.™ 3DM-GX2Ž Attitude Heading Reference Sensor Inertia-LinkŽ Inertial Measurement Unit Both units have six delta-sigma A/Ds sampling all sensors simultaneously, providing superior performance. Features and Benefits: s -AGNETIC &IELD #ALIBRATION s &ULL 4EMPERATURE #OMPENSATION s 6' AND )-5 -ODES s 3MALL s ,IGHT 7EIGHT ,OW 0OWER ,OW #OST
GOLD
Agile-Link Wireless Data Acquisition System ™
(IGH SPEED DATA ACQUISITION FOR CONDITION BASED MONITORING OF MACHINES HEALTH monitoring of structures and industrial test and measurement applications. Features and Benefits: s )%%% $333 NODES s ,ICENSE FREE WORLDWIDE s 3TREAMING RATES UP TO +(Z s $ATALOGGING RATES UP TO (Z s 3TORES MEASUREMENTS s %XCITES AND CONDITIONS DIFFERENTIAL and 3 single ended inputs s M RANGE STANDARD M OPTIONAL s )NTERNAL RECHARGEABLE BATTERY
NEW
Streamin ! g up to 4 Krates Hz GOLD
DVRT Microminiature Gauging Sensors ÂŽ
Amongst the world’s smallest linear displacement sensors, ideally suited for tightly spaced sensing arrays.
Spherical Sapphire Tip Compression Spring World’s Smallest LVDT Patent Pending
Features and Benefits: s (IGH RESOLUTION AND ACCURACY s /PERATING TEMPERATURE TO ²# s &REQUENCY RESPONSE UP TO +(Z s 2OBUST AND WATERPROOF s 3UITABLE FOR SUBMERSION in corrosive media s 3UITABLE FOR EXTREME duty-cycle applications GOLD
Call 800.449.3878 or visit us online at www.microstrain.com 46
Source: Jason Dorfman of MIT CS & AI Lab.
Unmanned device incorporates voice commands, LIDAR for safer operation in war zones
mechanical components to unload supplies, even under fire, and fit into the smallest spaces. “We started with a 3-ton Toyota forklift with a 3,000pound load In this drive-by-wire capability,� says forklift, the MIT team Seth Teller, MIT installed electric motors to take the place of the professor of com- human operator’s hands puter science and and feet. They can turn engineering, and the wheel or depress project lead. “We the brake pedal. turned it into a drive-by-wire forklift with a combination of electrical, hydraulic and mechanical components so that it’s under computer control. We installed electric motors to take the place of the human operator’s hands and feet. The motors can turn the wheel or depress the brake pedal.� To understand its surroundings, the forklift is equipped with multiple LIDAR (light detection and ranging) sensors for measuring distance and bearings in relation to obstacles. It uses the sensors to understand its terrain and the location of pallets or people nearby. A supervisor commands the forklift remotely using a handheld PDA equipped with wireless Ethernet and voice controls. Teller says he and his team are most excited by the ability to make noncombatants safer in a military zone. But he also believes the robotic forklift has commercial applications. “One person could supervise five to 10 forklifts at a time,� Teller estimates, which would save on personnel costs. For More
M E C HAT RO NI CS
information
MIT’s Computer Science and Artificial Intelligence Lab.: http://designnews.hotims.com/23098-548 View video of the robotic forklift: http://designnews.hotims.com/23098-549 View an animated video of how the forklift works and how it was designed and tested: http://designnews.hotims.com/23098-550 For more mechatronics’ news, visit www.mechatronicszone.com.
» SENSORS
Sensors Help in Plant Selection, Diagnosis Data furnished to website-based algorithm provides a total solution for plant health care
By Randy Frank, contributing editor
The system employs four sensors to sense temperature, humidity, soil and light. “The temperature and the humidity sensor are pretty common technology,
PlantSense’s EasyBloom Plant Sensor uses a combination of sensor technologies to provide diagnostic and plant selection data.
Advanced sensors for shock, pressure and vibration The most trusted solutions for the world’s most challenging measurement applications. When you need to get it right, every time, look to Endevco. For accuracy, reliability and versatility. › Automotive crash and crush testing › Aircraft flight testing › Nuclear power plant systems monitoring › Combustion turbine testing and monitoring › Implantable medical device patient activity monitoring › Drop, vibration and very high shock testing New product offerings
although we did go and have a custom component built in Taiwan to do the humidity sensing as a cost reduction effort,” says David Wilkins, PlantSense’s chief technologist and engineering manager. That was the easy part. “The biggest hurdle we had as far as putting the technology together was finding soil sensor technology that was consumer friendly, PlantSense’s cheap, easy to build EasyBloom uses four sensors and and not patented alconnects to the ready,” says Wilkins. Internet to proUsing patented soil vide diagnostic measurement techand plant selecnology licensed from tion data. Decagon Devices, PlantSense designed a capacitance-based soil sensor to meet the consumer product’s requirements. This wasn’t the only sensing innovation in the product. Limited Spectrum Light Sensor
The next sensor hurdle in the development was an effective light sensor. Standard light sensitive resistors (LSRs) are made with cadmium, so they were quickly eliminated. Silicon-based technology was evaluated next, but also eliminated for cost reasons.Wilkins chose an LED as the light sensor because of its ability to detect light in the visible spectrum. “As an average rule of thumb, you will receive light in a fairly narrow band, 50 nanometers below the emitted spectrum,” says Wilkins. “So, the cool thing about that was we could choose an LED with its specific LED chemistry that we could target exactly the spectral content of the light that we wanted to analyze.” For More
Model 7264D
Model 65HT
Model 7286/87
1-888-ENDEVCO www.endevco.com
48
www.meggitt.com
SENSORS
information
PlantSense’s EasyBloom Plant Sensor: http://designnews.hotims.com/23098-551 Decagon Devices: http://designnews.hotims.com/23098-552 Visit Design News’ sensors microsite at www.designingwithsensors.com.
A U T O M AT I O N
TREND WATCH//MOTION CONTROL
Wireless Automation Solutions
50
Reliability, security improve as wireless applications rapidly expand BY AL PRESHER, CONTRIBUTING EDITOR
PHOENIX
CONTACT’S RADIO TRANSCEIVER
Wireless continues to be one of the fastest growing segments in the automation market for two reasons. One is that it’s a lot less costly to have devices communicate on a wireless network rather than going through the process of installing conduit. The other is the available access to very difficult locations and hazardous areas in the plant. For these applications, maintenance and diagnostic tasks can be accomplished more quickly, effectively and safely using a wireless connection. The two main issues with wireless technology, reliability and security, are being addressed in new products. For applications where there aren’t concerns about serious injury or damage to equipment, many engineers are now looking toward wireless solutions. In the future, wireless will be used in more critical applications, as well.
Phoenix Contact’s RAD-ISM-900-EN-BD industrial radio transceiver brings Ethernet or serial data onto IP-based networks from remote locations, even in high-interference environments. Using the MOTR-9T radio platform and a 1W, frequency-hopping spread spectrum (FHSS) transceiver, the unit operates in the license-free 902-928 MHz ISM band. Users can configure over-the-air data rates up to 500 kilobits/sec, while adjustable packet sizes maximize data speed and minimize latency. Selectable 128/192/256-bit AES encryption prevents unwanted intrusion and keeps data secure. Multiple wireless communication streams allow simultaneous Ethernet, I/O control and serial ASCII device communications from a single radio without external gateways or additional serial wireless converters. Using embedded software, any network PC with a Web browser can configure the devices. The unit is approved for Class I, Division 2 hazardous locations. http://designnews.hotims.com/23098-553
CONTROL MICROSYSTEMS’ ETHERNET DATA RADIO
Using “IP over Ethernet,” the JR50 from Control Microsystems utilizes portable network access to extend corporate offices onto the plant floor and beyond to remote assets such as field-installed controllers and intelligent sensors. The JR50 includes a powerful 1W transmitter (900MHz model) and ultra-sensitive receiver for high speed, over-the-air data throughput up to 256 kilobits/sec. A frequency-hopping algorithm increases security by restricting communication to permitted devices only and 256-bit AES encryption provides protection from hackers. The product is designed to operate as a remote data radio, access point, repeater or network bridge. It offers dual Ethernet ports, a built-in Ethernet switch, an extended operational temperature range and metal enclosure. The product is configured using an embedded HTML Web server that provides network management and remote diagnostics’ capabilities. http://designnews.hotims.com/23098-554
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
BANNER’S DX99 BATTERYPOWERED WIRELESS NODE Banner Engineering’s DX99 battery-powered node collects analog, digital and temperature information in hazardous areas. The system is a combination of wireless communication, battery technology and intrinsically safe electronics. Hazardous areas pose unique sensing challenges and the DX99 moves the intrinsically safe power supply from the control room to the wireless transceiver. Using a battery-based power supply, it produces an intrinsically safe power source for the transceiver and an external third party sensor. The unit can be operated as a stand-alone unit for up to 10 years on a single battery. The wireless technology transmits and receives information at distances up to three miles (150 mw with a 2dBi antenna), while consuming very little power. http://designnews.hotims.com/23098-555
COVER STORY STORY_CHARLES J. MURRAY, SENIOR TECHNICAL EDITOR, ELECTRONICS
ENERGY SCAVENGERS Ultra-low-power elec-
tronic components are enabling a new breed of battery-less, wireless electronic applications Source: ADI
MEMS sensors from Analog Devices draw as little as 120 µA. They could be used to measure vibrations in wind turbines or to track the sun more efficiently in solar arrays. 52
M
an’s quest to build perpetual motion machines is taking an unexpected twist these days, as electronics’ makers and start-up companies team up on a new breed of ultra-low-power products with the potential to run, well … almost forever. To be sure, these new applications don’t violate the First Law of Thermodynamics. Nor the Second, for that matter. But they’re out there and they’re harvesting enough energy from mechanical vibrations, temperature gradients, sunlight and even human body heat to do things that couldn’t have been done previously. “The technologies are maturing to the point where they are commercially viable,” says John Perzow, marketing director in Analog Devices’ Power Management Group. “When it comes to advanced energy transmission, there’s an alignment of the planets going on right now.” Indeed, the forces behind the concept of energy harvesting seem almost supernatural these days. Even in today’s tough economic times, investment houses and electronics’ manufacturers are socking money into new companies with names like AdaptivEnergy, EnOcean, Cymbet and Perpetuum, among countless others. And big electronics’ manufacturers, such as Texas Instruments (TI) and Analog Devices Inc. (ADI), are building microcontrollers, digital signal processors and sensors for the new breed of powerstingy applications. As a result of all this cooperative work, there could be a whole new class of renewable energy applications on the horizon. Bridges and buildings might monitor structural health with battery-less sensors powered by photovoltaic cells. Farmers could check soil moisture with solar-powered devices. Mechanical vibrations could serve as an energy source for monitors of everything from vehicle door lock switches to electric motors.
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
when it retrofitted its classroom temperature controllers using a system deThe question is: How will engineers veloped by EnOcean and Regulvar Inc., make such scenarios possible? a maker of HVAC products. The conToday, it appears there is no single trollers, wireless and battery-less, draw answer. To make it work electronics’ power from photovoltaic cells. Electrical suppliers have already taken the first current from the cells runs a microconstep by creating microcontrollers, troller and an RF transceiver that feeds digital signal processors, RF transceivtemperature data to the HVAC architecers and MEMS sensors that operate ture, which then parcels out the correct on electrical currents so small they’re measured in millionths of an amp. TI’s amounts of heat. Similarly, a Boston-based company MSP430 microcontroller, for example, has installed wireless occupancy senconsumes just 160 µA/MHz (microsors and light switches as a means of amps per megahertz) in an active state and 1.5 µA/MHz in standby. Similarly, reducing energy consumption. The occupancy sensors harvest energy from ADI has created an ultra-low-power ambient light, while the switches draw MEMS (microelectromechanical syspower from the mechanical energy that’s tems) sensor, the ADXL345, which generated when people press the light can pull as little as 120 µA in full dyswitch. Wireless signals are transmitted namic range and 25 µA in sleep mode. over an RF frequency of 315 MHz using Such products could be an order of an EnOcean protocol. magnitude less than everyday Such applications are groundmicrocontrollers breaking, not because they rely and sensors that on photovoltaic convertypically draw sion, but because of how current in the they use the trickle of milliamps, rather current from those phothan microamps. tovoltaic cells. Based on “The idea is to be those wee currents, senable to run applications sors can see, processors autonomously, remotely, can think, transceivers maybe without a battery Source: AdaptivEnergy … forever,” says Perzow, AdaptivEnergy uses a piezo- can communicate. electric device to convert Moreover, the list in a bit of hyperbole of capabilities is growthat’s common in energy mechanical vibrations to electrical current. ing. Texas Instruments harvesting circles. teamed with Cymbet Up until now, engiCorp. to bring “battery-on-a-chip” techneers with potentially brilliant energy nologies into the energy harvesting mix. harvesting ideas were handcuffed, Cymbet’s EnerChip is essentially a thin largely because the current from silicon film battery on a silicon substrate. Using solar cells and other scavenging devices the concept, makers of energy harvesting wasn’t enough to run a microcontroller systems will be able to store energy that’s or an accelerometer. Now, engineers been scavenged from ambient light or say, that’s changing. Harvesting devices sunlight. As a result, when applications are improving their energy conversion, go into complete darkness, they’ll still while electronic products are lowering have enough stored energy to do between their power requirements. 400 and 1,000 RF transmissions. “Low power electronics are really the Engineers say the battery-on-a-chip driver for all of this,” says Troy Tanner, idea is significant because it raises chief technical officer for AdaptivEnerthe possibility of so-called “pervasive gy, a maker of piezoelectric devices that power,” in which the capacity for power convert vibration to electrical energy. generation is built into everyday objects. “With our power increasing and their “With this, we can start to imagine a power decreasing, we can start doing day when power will be spread around something useful.” and energy will be stored in the chips,” says Steve Grady, vice president of marThe Dawning of ‘Pervasive Power’ keting for Cymbet. Useful, indeed. St. Joseph Elementary TI has packaged the EnerChip in School in Lacolle, Quebec recently reala developer’s kit that includes the TI ized the benefits of energy harvesting Low-Power Driver
Using energy harvesting, wind turbines could self-diagnose imminent mechanical problems. Source: VRB Power Systems
Source: ADI
Analog Devices’ system-on-chip device includes sensors, DSPs, converters and transceivers for utility metering applications that use energy harvesting.
Engineers say the real beauty of all those applications is they can now be done without wires or batteries, while at the same time saving power. “Energy systems like these are an essential issue of our times,” Perzow says. “They’re getting unbelievable amounts of attention and investment — dollars, pounds, Euros, drachmas — you name it. Every industrialized nation is involved in this.”
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 5 3
»
COVER STORY Texas Instruments and Cymbet teamed to create energy harvesting developer’s kits that include thin film batteries on a silicon substrate.
Power (mW)
MSP430 microcontroller, CC2500 RF transceiver and the eZ430-RF2500 developer tool on a credit-card-sized circuit Sou rce :C says Tanner of AdaptivEnergy. “If board. Known as the eZ430-RF2500-SEH, the ym bet Co you add up all the copper and all the kit targets developers who want to convert light to current rp. weight from cables, it ends up being a and then employ the current to run applications that need to big savings for the automakers.” communicate wirelessly. “The MSP430 works straight off the solar panel,” says Adrian Valenzuela, MSP430 marketing manager for TI. “But Eliminating Batteries if the environment becomes too dim or if it’s in complete Experts say energy harvesting may also be on the verge of darkness, the processor knows that there’s not enough energy serving as a “health monitor” for renewable energy sources. to harvest and it automatically switches over to be powered by Analog Devices’ engineers describe a scenario in which wind the EnerChip.” turbines scavenge their own energy to power microcontrollers “Every energy harvesting product needs a way to store and sensors to “listen” for problems in the wind mills. energy,” Grady adds. “We chose the solar cell because it’s nice “You could actually use a MEMS device to look for an and easy to use.” anomalous frequency of a shaft,” says Wayne Meyer, horizontal marketing manager for the Micromachined Products Div. at ADI. “It might give you an indication that a shaft is out of Beyond Solar Still, photovoltaic cells are hardly the only source of harvested alignment or a bearing is bad.” Similar scenarios could apply to solar arrays. With lowenergy. Thermodynamic theory has long held that a simple power MEMS sensors, solar panels could track the sun more temperature gradient has the potential to dissipate power. efficiently as it moves across the sky and then position themNow, engineers are starting to find ways to use that power to selves for maximum exposure. drive sensors and monitors. Automotive suppliers, for example, are said to be working on tire pressure monitoring systems Energy Comparison that can scavenge energy from the heat in the tire and use it to Energy harvesting can’t happen without ultra-low-power processors, drive RF transmitters. With that concept, engineers hope to sensors and transceivers. Here’s a look at how some ultra-low-power wirelessly provide information on tire pressures, temperatures components compare to conventional components: and even tread wear. Ultra-Low-Power Conventional (typical) The most popular and promising source of energy, howevMicrocontrollers 160 µA/MHz 500 µA/MHz – 3 mA/MHz er, may be mechanical vibration. Most start-ups in the energy Sensor 120 µA More than 1 mA harvesting arena are looking at ways to transform mechanical Transceiver (RS-232) 3 mA 15 mA energy. AdaptivEnergy, for example, is converting vibration Transceiver (RS-485) 120 µA 70 mA to electrical energy in a product called the Joule-Thief™, The reason for using such technologies is clear. Many which employs a cantilevered piezoelectric beam to carry out potential applications move from dream to reality when engithe conversion. When an inertial force deflects the tip of the neers eliminate the need for batteries. cantilever, it introduces mechanical strain in the piezo layer, “If you have something in a remote region that’s hard to which causes polarization and, ultimately, produces an electrireach, you want to use parts that won’t have to be replaced or cal current. The company’s engineers are targeting the device at such applications maintained for years,” Meyer says. Power vs. Temperature Gradient Start-ups recognize that no such applications could happen as structural health without the commitment of big electronics’ suppliers who enmonitoring, wear200 able the energy harvesting systems to sense, convert, amplify, able electronics, process and transmit signals. RFID systems and 150 “This technology will benefit existing applications, as well wireless sensing and as applications that would have been impossible to do otherswitching applicawise,” says Valenzuela of TI. “There’s a huge, huge potential tions. Automakers 100 market here.” are said to be looking at the technol50 ogy, in hopes of For More replacing some of information the bundled wiring 0 AdaptivEnergy: http://designnews.hotims.com/23098-556 15 20 in car bodies. 0 5 10 Analog Devices Inc.: http://designnews.hotims.com/23098-557 Temperature Gradient (C) “You could Cymbet Corp.: http://designnews.hotims.com/23098-558 Source: Sentilla Corp. eliminate many of EnOcean: http://designnews.hotims.com/23098-559 It’s long been known that a temperature the power cables In-Q-Tel: http://designnews.hotims.com/23098-560 gradient dissipates power. Makers of and signal cables for Perpetuum: http://designnews.hotims.com/23098-561 energy harvesting systems have begun simple applications Texas Instruments: http://designnews.hotims.com/23098-562 making use of that power. like door switches,” 54
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
STORY_ D O U G S M O C K , CONTRIBUTING EDITOR, M AT E R I A L S A N D FA S T E N I N G
Plastics
POWER New solar projects are boosting efficiencies
FLOWER POWER FUELED THE 1960S. NOW GET READY FOR PLASTICS POWER.
Conductive plastics can be printed on flexible plastic to generate solar energy.
Source: Konarka
Third-generation solar technologies use advanced materials, including conductive plastic, to achieve acceptable efficiencies and design capabilities not possible with silicon. Two of the cornerstone programs in the federal Solar America Initiative (SAI) target building-integrated organic photovoltaic technologies. One of the programs is headed by Konarka, of Lowell, MA, and the other by Dow Chemical of Midland, MI. The goal of the SAI is to deliver grid power for less than 10 cents per kilowatt-hour by 2015. Electricity from the grid costs about 8 cents per kilowatt-hour now and power generated by currently available solar technology is triple that. One novel, but pricey, application using the Konarka technology is a sun umbrella fitted with flexible solar panels that provide electricity on the spot for laptop computers, cell phones or other consumer applications. They’re already being used on outdoor patios of coffee shops in sunny locations and on patios near swimming pools. “These first units are selling for $10,000,” says Joe McKenna, executive vice president of SkyShades of Longwood, FL. “I hope to drive the price down to $7,500-$8,000 as volume increases. The first few are always a bit more expensive. Our umbrella units, on their own, sell for $5,200 as they are a structure and must be anchored to a suitable foundation.” The electricity in the flexible solar panels comes from Power Plastic, a patented and highly secretive material. A review of Konarka patents shows much of its work has focused on conjugated polymers that behave as metallic conductors and semiconductors. The polymers include at least the following: polythiophenes, polyalkylthiophene, polydihexylterthiophene (PDHTT), polythienylene vinylenes and polyfluorene derivatives. Photovoltaic cells are produced using continuous web manufacturing techniques in which a polymeric system is applied in a tree-like geometry to a substrate, and subsequently, in a roll-to-roll type manufacturing process. The substrate is any plastic that can be metallized in a web process. D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 5 7
»
SOLAR ASSEMBLIES Source: SkyShades
a 1,350-ton tandem clamp injection One preferred material is polyester. Other molding machine at its Michigan Operacandidates include polycarbonate, acrylic tions manufacturing site in Midland, MI and polystyrene. Efficiency can be imto develop technology that will integrate proved through the application of a coating flexible solar panels into plastic roofing. that will prevent the reflection of certain Current silicon-based solar cells are types of light. Some producers also further packaged within heavy glass panels on enhance performance through doping rooftops. They are expensive, hard to with conductive materials. The photovolinstall and produce electricity that is sigtaic cells can also be applied through other nificantly more expensive than electricity printing systems. sold over the grid. “Konarka’s innovations lie within its “Dow’s innovative technology is based materials, manufacturing processes and Engineers can now incorporate solar on a much more cost-effective photovolform factor for its light-activated power into structural components, taic material, called CIGS, and these cells plastic,” says Dan Williams, vice president generation such as components. are ‘packaged’ within the roofing product of business development at Konarka. creating a ‘solar shingle,’” says Bob Cleer“We’ve brought proven coating and printing eman, Dow’s senior technical director of building-integrated know-how from the chemical, photographic film and flexible photovoltaic technology. electronics’ industries to energy via a new class of CIGS, which is composed of copper, indium, gallium nanostructured materials.” and selenium, is used as light absorber material for thin-film The current demonstrated efficiency of the system is 6 solar cells. More than two dozen companies are working with percent — good but not really good enough. Typical siliconCIGS technology and some are struggling to achieve workbased solar systems have efficiencies of around 15 percent. able efficiency levels. Konarka projects its electrical output will cost less than 10 Dow’s original partner in the SAI project was Californiacents per kilowatt-hour, making its material ideal for widebased Miasloe, which at one time had been a leader in CIGS spread use as a building-integrated photovoltaic. As previously reported by Design News, another major player development. But the company missed key objectives and was replaced in the SAI project last year with Global Solar Energy, in this technology arena is Plextronics, a Pittsburgh-based which, last year, opened a CIGS factory in Arizona. The comspinoff from Carnegie Mellon University that opened its first pany expects to produce 20 MW of the film at the plant this year. manufacturing development line in January. “We are collaborating with Global Solar Energy because The small-scale throughout our search for a solar material provider, it was the manufacturing facilonly company able to supply a qualifying flexible CIGS mateity will print solar rial that meets our needs and the requirements of the SAI,” says demonstration modDow’s Cleereman. “Copper, indium, gallium and selenium ules with printable has proven to be the most efficient, cost-effective thin-film solar inks made from technology for building-integrated photovoltaic applications.” conductive polymers, Global Solar is the only company in full-scale production such as those used by of CIGS cells on flexible substrates and has achieved a recordKonarka. The moduSource: Plextronics setting average 10 percent solar cell efficiency, a requirement lar design of the line Conventional printing processes can for the SAI program. The goal of the SAI is to create solar elecwill also permit the be used to produce solar-activated tricity cost-effectiveness with grid electricity within six years. company to evaluate electrical circuits. Dow would not discuss specifics of its technology, but the new processes that will giant injection molding machine is a big clue. Dow may try to maximize the performance of those inks. “This line is focused on stimulating broad market commer- integrate the solar panels into a molded plastic structure, just cialization of our innovative ink systems,” says Andy Hannah, the way a label is molded into a dashboard inside a mold cavity. Plextronics’ president and CEO. “Sometimes, especially in an It’s an exciting idea if the solar material can be web-fed into the tool. That creates very high-volume production economics. emerging market like printed electronics, a company must be The Konarka project is very interesting as a leading-edge willing to take the initial steps to demonstrate to the markettechnology, but the Dow project has the promise to be a major place what’s possible with new technology.” Plextronics uses conductive polymer technology developed game-changer in the not-too distant future. by Dr. Richard McCullough of Carnegie Mellon University. For More
Dow Chemical’s Role
Another major player is Dow Chemical, which is receiving $20 million from the Solar America Initiative Pathways Program conducted by the U.S. Dept. of Energy. Dow is leveraging its encapsulation and roofing knowledge to develop solar roofing shingles. Late last year, Dow installed 58
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
information
Dow Chemical: http://designnews.hotims.com/23098-563 Global Solar Energy Inc.: http://designnews.hotims.com/23098-564 Konarka Technologies: http://designnews.hotims.com/23098-565 Solar America Initiative: http://designnews.hotims.com/23098-566 Read more about how power polymers are fueling solar cell advances: http://designnews.hotims.com/23098-567
Automotive
Technology-Based Features
DRIVE Automotive Sales Automakers agree the latest technology plays a key role in stimulating sales BY RANDY FRANK, CONTRIBUTING EDITOR
The current automotive sales slump is impacting nearly all automakers around the world. While outstanding pricing and financing options provide a strong incentive, according to David Cole, chairman of the Center for Automotive Research (CAR), the technology-based features from safety, comfort and convenience, infotainment and, of course, performance, frequently help the consumer decide to purchase one vehicle over another. Thanks to input from several automotive suppliers, Design News has created a technology stimulus package of goodies that could bring car buyers back to showroom floors. Some of these are still in the concept stage. WHAT DO CAR BUYERS WANT?
Answering this question requires a lot of trial and error. From a historical perspective, Automotive News identified the 10 hot features in 2008 as:
1. Electrically operated automatic and manual transmission shifters 2. Rearview camera systems 3. Turbochargers and smaller engines 4. Cylinder cutoff systems 5. Ford’s SYNC infotainment system 6. Small cars with spacious interiors 7. Gasoline-electric power trains 8. Keyless ignition systems with push-button start 9. Ford’s capless fuel system that uses internal sealing to prevent fuel from escaping 10. Navigation systems
Outside of number 6, these items fall into four areas that continue to entice car buyers: power train (performance/fuel efficiency), safety, comfort/convenience and infotainment. In the area of consumer electronics, “J.D. Power and Assoc.’s 2007
U.S. Automotive Emerging Technologies Study” of new car buyers shows 62 percent want to connect a portable music device to their vehicle’s radio. All carmakers responded in one manner or another to this customer desire. At least one automaker identified the role technology plays in moving vehicles off the lot. “SYNC-equipped vehicles are selling twice as fast as non-SYNC equipped vehicles on our dealer lots,” said Alan Mulally, CEO, Ford Motor Co., in his keynote address at the 2009 Consumer Electronics Show (CES) in Las Vegas, NV, in January. “What’s more, 31 percent of consumers who bought a SYNC-equipped vehicle said it ‘strongly influenced’ their purchase decision.” Initially announced at CES in 2007 and the 2007 North America International Auto show, Ford developed SYNC with technology partner Microsoft. Based on Microsoft Auto software, the
SOURCE: GM
Based on government restrictions, GM could not reveal the safety and infotainment options the president wanted included in his new limousine. However, we do know it uses LED lighting for the flags. [ w w w . d es i g n n e w s.c o m]
MA RC H 2009 AUTO MO T IV E / A S UP P LE ME NT TO DE S I GN NE WS A1
Automotive A D V E R T O R I A L
PRODUCTS, APPLICATIONS AND SERVICE Ticona products are typically used in challenging environments that demand strong, stiff and dimensionally stable polymers having excellent mechanical, chemical and thermal performance. They are often chosen to replace other materials such as steel, aluminum, ceramic and glass. These products include: • Celanex® thermoplastic polyester (PBT) • Hostaform®/Celcon® acetal copolymers (or polyoxymethylene) • Celstran® long-fiber-reinforced thermoplastics (LFRT) • Fortron® polyphenylene sulfide (PPS) • GUR® ultra-high molecular weight polyethylene (UHMW-PE) • Impet® thermoplastic polyester (PET) • Riteflex® thermoplastic polyester elastomer (TPC-ET) • Vandar® thermoplastic polyester alloy (PBT) • Vectra® liquid crystalline polymer (LCP) Ticona polymers are used by designers and engineers across major markets including automotive, aerospace, electrical, electronic, medical, appliance, information technology, communications, chemical processing and consumer products. Specific automotive uses range from sensors, complex connectors and gears to interiors, fuel systems, power train and other underhood and lightweight structural applications. Ticona often provides material scientists, design engineers and processing experts to help its global customers make optimum use of the Ticona polymers they select at all stages of product development from concept and design through prototyping and production.
Ticona Engineering Polymers http://designnews.hotims.com/ 23097-508
Delphi’s High-Speed Digital Data (HSDD) connectivity systems simplify connections in vehicles that use multiple data protocols including: USB 2.0, 1394, LVDS, FlexRay, eMOST and Ethernet.
software platform is easily modified and allows Ford to offer new features by simply upgrading the software. An upgrade was announced the following year at CES 2008. Ford included 911 Assist and Vehicle Health Reports to SYNC’s existing capabilities of voice commands Bluetooth and MP3 connectivity. “Because the 911 Assist and Vehicle Health Reports required modifications to software other than the SYNC module, you had to take it into a dealer,” says Velle Kolde, product manager, Automotive Business Unit, Microsoft. Normally, this is not the case. “Whenever you have to just upgrade the SYNC module, you can just download it to a USB key and plug it in there,” he adds. At CES 2009, Ford added even more features to SYNC, in spite of the automotive industry’s usual reputation for taking two or more years to implement new technology. “Yes, we are a car company, but we are learning to think like an electronics’ company when it comes to bringing fresh, new and innovative technologies and products to market,” said Mulally. Launching this summer, SYNC with Traffic, Directions and Information provides customers emergency, diagnostic and information services, as well as traffic reports and directions. The system brings together an onboard text-to-speech engine, the customer’s mobile phone and network, data-over-voice technology,
A2 AUTOM OT I VE / A S U P P L E M E N T T O D E S I G N N E WS MA R C H 2009
an off-board routing engine and voice portal, text messaging, an existing mobile application and the power of the Internet in an unconventional time frame for automotive. The reduction in time-tomarket is attributed in part to working with technology partners. By including the SYNC service in the vehicle’s purchase price, Ford provides the new capabilities with no initial monthly subscription fees for the first three years, making it even more attractive to customers. The new services will be available on nearly all 2010 Ford, Lincoln and Mercury models. This is all occurring within the first generation of the SYNC and is by no means the end of the line. “We are having releases on the current generation and will continue to have releases with new features,” says Jim Buczkowski, director Global Electrical/ Electronic Systems Engineering, Ford Motor Co. (See Q&A, page A7). “Once we launch into the next generation, it doesn’t mean that everything stops on the first generation. We’re still looking at how we can continue to have new things to offer on the current generation,” he adds. MORE CONNECTIVITY
Dealing with the hardware-specific side of connectivity, Delphi’s High-Speed Digital Data (HSDD) connector systems address the broad range of high-speed protocols in vehicles, including USB 2.0, 1394, LVDS, FlexRay, eMOST and Ethernet. In addition to high-speed data in multimedia systems that require
SOURCE: FORD MOTOR CO.
Ticona Engineering Polymers, a business of Celanese Corp., produces and markets a broad range of engineering polymers for use in demanding applications. It achieved net sales of $1.06 billion in fiscal 2008 and employs about 2,000 individuals at production, compounding and research and development facilities in the U.S., Germany, Brazil and China. Main Ticona offices are in Florence, KY.; Kelsterbach, Germany; and Shanghai, China. Its Americas production and R&D facilities are located in Michigan, North Carolina, Texas, Kentucky, Minnesota and Suzano, Brazil. In Europe, it runs production and R&D facilities in Kelsterbach, Oberhausen and Frankfurt, Germany. Ticona also has offices in Japan, Korea, China, Taiwan, Malaysia and India, a Customer Application Development Center in Shanghai and production facilities for advanced engineered polymers and compounds at the Celanese integrated complex in Nanjing, China.
SOURCE: DELPHI CORP.
Ticona Engineering Polymers Performance-Driven Solutions
For buyers wanting more connectivity features, the Ford SYNC with Traffic, Directions and Information offers customers a system that does not require a built-in navigation system. [www.d esignnews .com]
Automotive A D V E R T O R I A L
Pepperl+Fuchs: A Heritage of Sensing Innovation For more than 60 years, Pepperl+Fuchs has been a name users trust to provide the highest-quality sensing technologies. As the world’s largest and most diverse sensor manufacturer, we know the automotive industry uses sensing technologies in some very tough environments. We’ve designed our products to be robust and reliable — to resist abrasion, corrosion, magnetic fields, sparks and weld slag. We assure performance, supply confidence and provide the technical expertise to help make your automotive application a success. Here are just a few of our products that consistently perform in unyielding applications: • Our Pile Driver™ family of products is machined from solid stainless steel, enabling it to last up to 20 times longer than plastic-faced sensors. • Our 20/20™ series weld-immune sensors feature all-metal sensing at full distance. Iron, aluminum or steel — it’s all the same to us! • The tough Rhino™ series offers a hard-wearing sensing face, super bright, high-visibility LEDs, increased sensing range and a five-way adjustable sensing head. Pepperl+Fuchs operates in more than 80 business centers on six continents. Our products are truly global in their design, most of them having certifications from inspecting organizations such as Underwriter’s Lab. (UL) in the U.S. to the most strenuous CE Mark standards in Europe. In addition, Pepperl+Fuchs production facilities are ISO 9001 certified to guarantee exceptional quality. Pepperl+Fuchs’ customers speak directly with an engineer when calling with a question or to solve a problem. Our support staff is largely comprised of engineers, ranging from applications engineers to the people who design and build the sensors used in automotive applications. If you have a sensor question, we can answer it. With Pepperl+Fuchs, you can count on value. With unparalleled service, a lifetime warranty on our sensors and a heritage of innovation dating back three generations, Pepperl+Fuchs offers the best product at the best price with the best service and support in the world. Exactly what you need from a single global supplier.
Pepperl+Fuchs Inc. http://designnews.hotims.com/ 23097-509
In HUGHES Telematics’ concept, several onboard systems are connected to the Telematics Control Unit through the CANbus to provide added connectivity to the customer.
continuous shielding, these connectors are also deployed in camera and video applications used in safety systems. Rear seat entertainment and navigation systems are increasingly on car buyers’ list of wants. In a Harris Interactive Survey sponsored by ICO Global Communications in late 2008, 63 percent of the 2,500 respondents indicated they are likely to purchase rear seat entertainment either for their existing vehicle, next vehicle or both. Also, 80 percent of the same respondents indicated they are likely to purchase a navigation system for the existing vehicle, next vehicle or both. This is good news for ICO, a company that has developed and is deploying a next-generation multimedia service known as ICO mim (from mobile interactive media). “It is a computing platform that has a lot of capability associated with it,” says David Zufall, CTO Network and senior vice president Network Systems, ICO Global Communications. Together with its satellite communications capability, Zufall says he thinks the approach allows them to do something different in the telematics’ space providing much broader service offerings for connectivity to the car. Complementing its ICO G1 satellite, the largest commercial satellite launched to date, ICO demonstrated the world’s
A4 AUTOM OT I VE / A S U P P L E M E N T T O D E S I G N N E WS MA R C H 2009
first fully integrated satellite-terrestrial network at CES 2009. ICO’s mim delivers live television, interactive navigation and two-way communications directly to the vehicle and a wide variety of portable devices. Connected to the vehicle’s CANbus, the module can talk to all the modules in the car. “Through that connectivity, we can now host a whole range of additional services beyond what existed historically,” says Zufall. In one of its concept implementations, ICO partnered with Delphi for the antenna using the DVB-SH standard, display and other hardware. Delphi’s dualview screen plus Mobile DTV capability for receiving local broadcast content allows only the front seat passenger to view entertainment while the driver observes drive-related navigation, communication and command functions. Satellite-accessed content includes premium television, automotive assistance, connected navigation and local content such as news, weather, sports and more. HUGHES Telematics has its own ideas for connecting car customers. These range from products at the production intent status to some that are strictly at the cool concept stage. With a push-totalk button, a driver can initiate conversational voice search instead of the context established, tree-based searches in current voice command systems. Us[www.d esignnews .com]
Discover completely new cable routing options
Automotive With Delphi’s dual screen display, the driver has one view and the passenger has another, providing less visual distraction for the driver. In ICO’s mim system, the passenger could be viewing a variety of satellite-broadcasted stations. SOURCE: DELPHI CORP./ICO GLOBAL COMMUNICATIONS
Cable carrier systems for any application, space and movement The quality of KABELTRAX solutions: t cost-efficient & easy to install t long service life & fail-safe t millions of systems sold to leading OE manufacturers t systems designed and built to suit unique needs readily available t located in North America, Europe & Asia t global sales and service network CALL-TOLL-FREE (US) 1-800-443-4216
ISO/TS16949 Certified
KABELTRAX WORLDWIDE 7100A W. Marcia Road I Milwaukee, WI I 53223-3363 I USA
www.kabeltrax.com a global kabelschlepp company
ing Sirius XM satellite radio, the vehicle accesses a range of audio-video content through an architecture designed to meet the Next Generation Telematics Protocol (NGTP) standard developed by the telematics’ industry to improve the technology interface capability. According to Tom Taylor, vice president of engineering development, HUGHES Telematics, the company wants to be an aggregator of vehicle content. They can demonstrate how greater connectivity can be obtained in a vehicle environment. At CES, HUGHES Telematics demonstrated how widgets, software components designed specifically for the vehicle, could provide connectivity and enhance the driving experience. With 10-MHz bandwidth, HUGHES Telematics’ vehicle demo received four channels simultaneously showing the capability of a high bandwidth communication channel. A Virtual Accessories’ feature in HUGHES Telematics’ Telematics Control Unit (TCU) allows the on-demand activation of services already integrated into the TCU such as navigation, satellite radio and Bluetooth. OTHER UNIQUE CAPABILITIES
NXP engineers put some of the company’s technologies to work in a few concepts that may get carmakers’ and customers’ attention. One of the ideas is a key with added functionality. “The idea is you can make credit card payments with the car key itself,” says Gino Knubben, an engineer at NXP. NXP engineers modified an existing BMW key to include RFID hardware to allow the key to become a smart card-like product. The key’s added functionality can be used inside or outside the vehicle. For example, simply putting the car key and items the user wants to buy on a reader is all it takes to make a secure transaction.
Purchasing gasoline is an obvious point where this capability could be used, as well. In another concept, a driver could find the location of a misplaced car by sending the car navigation system information to the key. The GPS coordinates are automatically transferred to the key when the driver leaves the car. “All you have to do is put two devices together and then the information will be transmitted,” says Knubben. Using RFID connectivity between the car key and a modified mobile phone, the driver can even verify if the doors were locked, find out how much gas is left, the estimated driving range and whether the lights are on or off. VERY LIMITED EDITION
Of course, in extremely limited editions and for a lot more money, car companies will provide just about anything. The new presidential limousine, officially called Cadillac One, but rapidly acquiring the nickname of the Obamamobile, probably includes some very sophisticated electronics especially in the infotainment area. While government restrictions prevent Cadillac from revealing those features, one exception is the high-tech LED spotlights that illuminate the flags at night. Since the traditional incandescent lamps have been replaced with the latest, more fuelefficient lighting, we can only guess at the other goodies that are inside. For More
information
J.D. Power and Assoc.’s study: http://designnews.hotims.com/23097-510 Video of Delphi Corp.’s dual-view screen, plus Mobile DTV capability: http://designnews.hotims.com/23097-500 HUGHES Telematics used widgets to enhance the driving experience: http://designnews.hotims.com/23097-501 HUGHES Telematics’ vehicle demo: http://designnews.hotims.com/23097-502 Videos of the RFID key in action: http://designnews.hotims.com/23097-503 http://designnews.hotims.com/23097-504
[www.d esignnews .com]
Automotive
Q&A
Delivering New Technology to Showrooms Faster
Automobiles with in-vehicle connectivity stimulate buyers’ interest BY RANDY FRANK, CONTRIBUTING EDITOR
Jim Buczkowski
At the 2009 Consumer Electronics’ Show, Ford made its second announcement of improvements to its popular SYNC platform for in-vehicle connectivity. Ford SYNC-equipped vehicles are moving off dealers’ lots twice as fast as vehicles without it, making the process of getting new technology out of the lab and into production more important than ever.
What’s the driving force behind SYNC? We are just responding to the fact that customer expectations, through other commodities and other types of electronic products, is very high. In the car, we should be able to try to deliver the same thing. For us, it’s how do we build electronic systems and features in the vehicle that we can deliver faster? With SYNC, Ford is delivering timely consumer electronics to customers on a carmaker’s schedule. How is this possible? There are two aspects to it. One is we have an advanced activity team within the organization that really focuses on going through and filtering technologies. They do that jointly with our advanced marketing team because not only are we looking for technologies, we want to make sure those technologies are things customers really want. So using the market research in our marketing organization, we can filter through technolo-
gies and determine that these are the things we want to move forward on. The other, more technical aspect is to be able to deliver faster. It’s a focus and strategy around building platforms in the vehicle. In the past, it might have been optimized around a design that’s very purpose-specific. When you look at SYNC and the way we want to do other things in the future, we build a platform that can be upgraded using software — software you can upgrade a lot faster, change a lot faster, than you can change hardware. So, building a flexible platform that you can run applications on, and then you can change those applications over time and improve them or add new ones is a way to try to match the traditional vehicle cycle with the fast consumer electronics’ cycle. Is the process you used to get a new consumer electronics’ product to market applicable to other areas in the vehicle? Yes, we think that it is. This same type of strategy is applicable as our advanced group is filtering through technologies and bringing them forward. They are looking at how to leverage that same solution, same methodology and strategy on other things, besides just the multimedia and telematics type space. Jim Buczkowski is the director of Global Electrical/Electronic Systems Engineering at Ford Motor Co.
USA Tolerance Rings Presents The Faster, Easier, More Flexible Way to Mate Cylindrical Components.
Rigid Yet Flexible Coupling, for… • • • •
NVH Torque Management Fastening & Joining Bearing Mounting
85 Route 31 North • Pennington, NJ 08534 Toll Free: 877/865-7464 • www.usatolerancerings.com
[ w w w . d es i g n n e w s.c o m]
MA RC H 2009 AUTO MO T IV E / A S UP P LE ME NT TO DE S I GN NE WS A7
Automotive
IN THE MARKETPLACE
ADVERTORIAL
K ABELTRAX AUTOMOTIVE’S F.I.T. CABLE ROUTING SYSTEM For organizing, guiding cables and wires
KabelTrax Automotive’s new F.I.T. cable routing system allows flexible, cost-effective organization and routing of wires and cables in a variety of on-vehicle applications. F.I.T. can be easily installed and used in static or moving applications, and can be cost-effectively custom-designed and manufactured in a variety of colors, materials and configurations.
KabelTrax Automotive http://designnews.hotims.com/23097-505
USA TOLERANCE RING’S COLLAPSE RING FOR STEERING COLUMNS Designed to keep a driver safe in a front-end collision
Continuing Education on
Communications & Controls Attend SAE Seminars to learn about relevant technologies, engineering tools, and management techniques designed for mobility engineers. SAE Seminars are taught by engineering professionals with content and industry experience. The following communications and controls-related seminars are offered throughout the year at several U.S. locations. t "DRVJSJOH BOE "OBMZ[JOH %BUB GSPN 4FOTPST BOE *O 7FIJDMF Networks t "EWBODFE &MFDUSJD .PUPS (FOFSBUPS "DUVBUPS %FTJHO and Analysis for Automotive Applications t "VUPNPUJWF &MFDUSPOJDT o "O "QQMJDBUJPOT 1SJNFS t $POUSPM 4ZTUFNT 4JNQMJm FE t $POUSPMMFS "SFB /FUXPSL $"/ GPS 7FIJDMF "QQMJDBUJPOT t %FTJHOJOH 0O #PBSE %JBHOPTUJDT GPS -JHIU BOE .FEJVN %VUZ &NJTTJPOT $POUSPM 4ZTUFNT t %JTUSJCVUFE "VUPNPUJWF &NCFEEFE 4ZTUFNT t &MFDUSPOJDT 1BDLBHJOH 5IFSNBM BOE .FDIBOJDBM %FTJHO and Analysis t 3PCVTUOFTT 7BMJEBUJPO PG 4FNJDPOEVDUPS %FWJDFT in Automotive Applications t 6OEFSTUBOEJOH BOE 6TJOH UIF 4"& + "1* UP "DDFTT 7FIJDMF /FUXPSLT "MM TFNJOBST BSF BQQSPWFE GPS *"$&5 $POUJOVJOH &EVDBUJPO 6OJUT $&6T BOE GPS UIF QSPGFTTJPOBM FOHJOFFS 1SPGFTTJPOBM %FWFMPQNFOU )PVST 1%)T BMTP BWBJMBCMF BT BO F 4FNJOBS
For upcoming dates and to register, visit www.sae.org or call 1-877-606-7323. For more technical resources on Electronics, visit the SAE Store online at http://store.sae.org
USA TOLERANCE RINGS and Ididit, a manufacturer of custom steering columns for hot rod, race, show and specialty vehicles based in Tecumseh, MI, collaborated to develop a collapse ring for steering columns. The ring, designed to keep a driver safe in a front-end collision, is available chrome-plated or powder-coated and keeps the existing low-cost 16gauge DOM tubing. A flanged tolerance ring with an advance wave configuration is fitted between the tubes and retained by the outer tube while the inner tube slips axially inside the ring. The target axial collapse force of 550 lb Âą 100 lb is achieved while maintaining ease of assembly within components having a stack up tolerance of .020 inch.
USA TOLERANCE RINGS http://designnews.hotims.com/23097-506
PEPPERL+FUCHS’ X-SERIES PILE DRIVER™ Available in 12-, 18-, 30-mm diameters Pepperl+Fuchs’ X-Series Pile Driver™ Extended Range Inductive Sensors are available in 12-, 18and 30-mm diameters and deliver sensing ranges of 5, 10 or 15 mm. The 100 percent stainless-steel housing delivers 20 times more durability than brass and plastic housings. Black Armor™-coated weld-immune models are also available and are capable of providing long-range part detection with full immunity to ac and dc weld fields, and repelling weld splatter. X-Series Pile Driver™ sensors are IP69k-rated to withstand high-pressure washdown cleaning.
Pepperl+Fuchs Inc. http://designnews.hotims.com/23097-507 P90076
A8 AUTO M O T I VE / A S U P P L E M E N T T O D E S I G N N E W S MA R C H 2009
[www.d esignnews .com]
BEST OF THE ENGINEERING MARKETPLACE 61 65 66 68 69
E l e c t ro n i c s Fluid Power H a rd w a re / S o f t w a re Materials/Fastening M o t i o n C o n t ro l
Compiled by Elizabeth M. Taurasi and Sasha Brown-Worsham
»
ELECTRONICS
SCIT RELAY & SWITCH™’S A10 SERIES AUTOMOTIVE RELAY
SCRYSTEK’S 2850-3210 MHZ VCO Features typical phase noise, output power Crystek’s CVCO55CC-2850-3210 VCO (Voltage Controlled Oscillator) operates from 2,850 to 3,210 MHz with a control voltage range of 0.5V~14V. This VCO features a typical phase noise of -103 dBc/Hz @ 10KHz offset and has excellent linearity. Output power is typically +4.0 dBm.
Small, ultra-lightweight CIT Relay & Switch™’s A10 Series automotive relay is rugged enough to withstand operating temperatures up to 105C and is immersion cleanable. Small in size and ultra-lightweight at just 4 gm, the A10 Series is PCB pin-mountable. Also available in a dual relay style, the A10 Series offers coil voltage choices of 10 and 12V dc with 40A in-rush. CIT Relay and Switch™ http://designnews.hotims.com/23098-577
Crystek Corp. http://designnews.hotims.com/23098-575
ROBUST, DEPENDABLE MEASUREMENT INSTRUMENTS. TURCK instrumentation products provide reliable solutions that are fast, flexible and most importantly, easy to operate. • Highly accurate pressure sensors
SMINCO’S DESIGN KITS STURCK’S WIM45 MAGNETIC FIELD SENSOR For direct mounting on pneumatic T-groove cylinders The WIM45 detects the position of a piston on standard pneumatic cylinders by utilizing a series of Hall elements, which sense the piston magnet and send a signal back to the processor. Users can reverse the sensor’s analog output slope by rotating the sensor 180 degrees. TURCK Inc. http://designnews.hotims.com/23098-576
Allow for easy testing, prototyping Minco’s Flexible Heaters Prototype Design Kit allows for easy testing and prototyping a heater concept before starting on a journey of custom-built-toorder product. Filled with Thermofoil™ flexible heaters, instructions and technical data, this kit will help you move toward successfully integrating flexible heaters into your application. See firsthand how thin, lightweight, etched foil heaters can eliminate rod, ceramic, coil or other bulkier heater types in your designs. Minco http://designnews.hotims.com/23098-578
• Magnetic inductive and calorimetric flow monitors • Temperature sensors and probes • Level sensors: capacitive, ultrasonic and probes
Call us with your next application:
1-800-544-7769 email: turckusa@turck.com
www.turck.com
© 2009 TURCK, Inc.
ELECTRONICS, Continued
SOSRAM’S BLUE LASER DIODE
SINTERSOL INDUSTRIES’ NEW LINE OF SOLENOIDS With dual coil construction Intersol Industries’ new line of highperformance solenoids consist of a dual coil construction offering initial high pull in force and high holding force with low power consumption. This allows the solenoid to remain energized for an extended period of time without overheating.
Optimized TO38 package An optimized TO38 package makes the blue laser diode from OSRAM Opto Semiconductors the smallest in its class. This takes the world one step closer to a vision of tiny projectors that can be integrated into mobile devices such as cell phones and digital cameras. Lasers are the first choice as light sources for these applications. OSRAM Opto Semiconductors http://designnews.hotims.com/23098-581
COLOR-CODED CONNECTORS SIMPLIFY FIELD INSTALLATION. Forget paging through pinout diagrams at every installation. TURCK has added color-coded and clearly labeled pinouts to the company's wide variety of connectors, so installation is faster and easier.
Intersol Industries Inc. http://designnews.hotims.com/23098-579
Connectors are available for: • DeviceNet™ • FOUNDATION fieldbus™ • PROFIBUS -DP ®
SMICROPOWER DIRECT’S SR7810 SERIES MINIATURE SWITCHING REGULATORS
SKAVLICO’S MODEL P992 AND P356 Measures airflow, propane or natural gas Kavlico has developed two new, highaccuracy, low-pressure sensors for pressure measurement applications in next-generation modulated furnaces. The model P992 is ideally suited to measure airflow, while the P356 measures propane or natural gas flow. Kavlico http://designnews.hotims.com/23098-580
Provide up to 12W of output power MicroPower Direct’s SR7810 series is a family of miniature, point of load switching regulators that provide up to 12W of output power. These converters are specifically designed to replace inefficient linear regulators (LM78xx type) for board level applications that require miniature size, high efficiency, high reliability and low cost. MicroPower Direct LLC http://designnews.hotims.com/23098-582
• AS-Interface
®
• Standard M12 connectors are also available
Call us with your next application:
1-800-544-7769 email: turckusa@turck.com
www.turck.com
© 2009 TURCK, Inc.
four-way, the “22” Series also features a three-position, four-way configuration with closed or exhaust centers to satisfy system requirements.
»
FLUID POWER
Pneumadyne Inc. http://designnews.hotims.com/23098-585
TBESWICK’S 2009-2010 CATALOG
SASHCROFT’S EXPLOSION-PROOF PRESSURE SWITCHES For harsh pressure media, demanding operating environments Ashcroft’s Type B700 explosion-proof pressure switches can be specifically configured for harsh pressure media and demanding operating environments. Enclosed in a NEMA 7/9-IP66 rated housing, Type B700 pressure switches can be used in Class 1, Division 1&2 and Class 2, Division 1&2 hazardous locations. Each pressure switch can be configured with a variety of diaphragm materials (including Monel) or with external diaphragm seals for especially caustic media. Ashcroft Inc. http://designnews.hotims.com/23098-584
TPNEUMADYNE’S ‘22’ SERIES SOLENOID, AIR PILOT VALVES Consume less power, offer variety of connector, voltage options Pneumadyne’s new “22” Series Solenoid and Air Pilot Operated Valves offer high flow three- and fourway valves with 1 ⁄8 NPT (F) ports. The 1W, 15-mm solenoid valves consume less power and offer a variety of connector and voltage options. In addition to the standard two-position,
With more than 200 new products Beswick Engineering announces the release of a new 2009-2010 catalog with more than 200 new products. These new products are highlighted for easy identification. Catalog #1008 describes Beswick’s expanding line of miniature valves, fittings, cylinders, tubing, pressure regulators, orifices, quick disconnects and other fluid power devices. Particularly noteworthy is the new Push-to-Connect fittings for ¼-inch OD, new Dry Break Quick Disconnects, new M3 Threaded Quick Disconnects, the addition of a patent-pending series of miniature diaphragm pressure regulators and an award-winning Pressure Compensated Flow Control Valve. These innovative products save space and weight, provide corrosion resistance and provide superior performance for demanding applications. Beswick Engineering Co. Inc. http://designnews.hotims.com/23098-586
TRED VALVE SERIES’ 75 PINCH VALVE Replaces ball, plug valves The Series 75 manually operated pinch valve is the number-one selling pinch valve in the world today. The Series 75 is a reliable, maintenance-free, cost-effective valve designed for tough slurries, abrasives and corrosive-chemical applications. The Series 75 full port design eliminates any dead spots or crevices, seats or bearings where slurry can hang up and impair operation or even cause complete valve failure. Red Valve Co. Inc. http://designnews.hotims.com/23098-587
ETHERNET SOLUTIONS FOR DEMANDING APPLICATIONS. TURCK Ethernet products enable data acquisition from field devices. Products include: • Ethernet expandable I/O platforms supporting EtherNet/IP™, Modbus TCP and PROFINET ®
• Fixed I/O for direct, on-machine installations • Environmentally hardened Ethernet switches—both managed and unmanaged • Shielded Ethernet cable with molded RJ45 or M12 eurofast connectors
®
• Integrated Ethernet switches within the fixed I/O platform
Call us with your next application:
1-800-544-7769 email: turckusa@turck.com
www.turck.com
© 2009 TURCK, Inc.
»
H A R D WA R E / S O F T WA R E
ABERDEEN’S NEW ONLINE DIGITAL PROTOTYPING ASSESSMENT TOOL Realistic 3-D simulation, reduces number of physical prototypes Digital Prototyping software enables a realistic 3-D simulation to optimize and validate a product before it is built, reducing the number of physical prototypes. The tool, which utilizes Aberdeen’s primary research in product innovation, helps companies identify their biggest product development challenges, compares their design practices to industry benchmarks and quantifies potential time and cost savings. LP-115.ai 1 1/14/2009 3:05:46 PM
Aberdeen Group http://designnews.hotims.com/23098-588
SAVX CORP.’S SPITANII SOFTWARE Upgrades Tantalum and Niobium Oxide capacitator simulation software AVX Corp.’s latest version of its SpiTanII software allows designers to view all basic characteristics and parameters for tantalum and Oxicap® (niobium oxide) capacitors. The company has also expanded the PSpice simulation software libraries it offers for its tantalum, tantalum polymer and niobium oxide chip parts, as well as introducing V6.0 of its Select-a-Cap software tool. AVX Corp. http://designnews.hotims.com/23098-589
SSTRATASYS’ SMOOTHING STATION Saves time, hours of labor The system’s semi-automated process provides a surface finish of 32 to 63 microns. Without the process, design and manufacturing engineers requiring an FDM part with this level of smoothness must manually fill, sand and paint the part. By using a Stratasys FDM additive fabrication system with the new Smoothing Station, injection molded-quality parts can be created in just a few minutes, saving hours of labor. Stratasys Inc. http://designnews.hotims.com/23098-590 66
»
MATERIALS/FASTENING
AQUAMULTI-LAM 2710 WATERRESISTANT ADHESIVE LAMINATE Handles various combinations of films The AquaMulti-Lam 2710 is an adhesive for wet-lamination applications. The product handles various combinations of films and foil to paper, as well as paper to paper, for numerous end-use applications. AquaMulti-Lam 2710 was designed specifically as a water-based adhesive for wet-nip laminating, using metallized PET or PP and it reportedly exhibits high water-resistance properties. ™
SFUJIPOLY’S SARCON XR-PE THERMAL INTERFACE PUTTY Helps improve semiconductor performance Fujipoly’s Sarcon XR-Pe’s putty-like thermal interface material is designed for broad-ranging commercial and consumer electronics’ applications. The material helps improve semiconductor performance by efficiently transferring unwanted heat to a nearby heat sink. Sarcon XR-Pe is a highly conformable, thermally conductive, non-flammable interface material. Its thermal performance is equal to our most highly rated GR-m and XR-e Silicone Gap Filler Pads. It’s available in 2.0- or 1.5-mm thick sheets with a maximum dimension of 300 x 200 mm and can be ordered in die-cut form to fit custom application specifications.
Aqua Based Technologies http://designnews.hotims.com/23098-592
SDSI’S NEW COATINGS
New high temperature dichroic spectral metal coatings Applied onto thin stainless-steel sheets via MicroDyn® sputtering technology, High Temperature Spectral Metal Coatings withstand temperatures up to 400C. Coated sheets can be cut and formed to specific sizes and shapes, depending on Fujipoly America Corp. customer requirements. Mounting feahttp://designnews.hotims.com/23098-591 tures, such as slots, screw holes and tabs, can be formed into mirror after coating is
68
applied and sized mirrors can be formed into precise curves and cylinders with radii as small as 25 mm. Deposition Science Inc. http://designnews.hotims.com/23098-593
TNORTHWIRE’S ENDURANCE CABLE ASSEMBLY PRODUCT LINE For vision system applications Northwire’s endurance cable assemblies are engineered with topquality connectors and Northwire’s advanced, industrialgrade cables. These rugged assemblies provide ultra-reliable interconnectivity in motion and vision system applications. Endurance products for vision system applications include CCXC Analog Video, MVC-800 FireWire, GEV-1000 GigE Vision and Camera Link cable assemblies. Northwire Inc. http://designnews.hotims.com/23098-594
TLM76’S MINUTEMAN™ SERIES
»
MOTION CONTROL
TMICRONOR’S MR190 UNIVERSAL MANUAL PULSE GENERATOR Weighs 200 gm, with maximum current consumption of 70 mA Micronor’s MR190 Universal Manual Pulse Generator/Handwheel (MPG) offers both A/A’B/B’ differential line driver and A/B pull-up quadrature outputs in a single unit. No longer does a CNC machine manufacturer, control panel fabricator, distributor or service center need to stock three or more handwheel models because of the non-standardized interface requirements of different manufacturers and models of CNC systems, PLCs and teach pendants. Micronor Inc. http://designnews.hotims.com/23098-595
SSTERLING’S NEW MAGNETIC CLUTCHES AND COUPLINGS No friction, uses no electricity A new series of magnetic clutches and couplings features no friction or wearing parts, uses no electricity and has no magnetic particles to leak. These units, identified as the S90MCC-MTL Series, are stocked in seven different bore sizes: .250, .375, .500, .625, 750, .875 and 1.000 inch. Unit lengths range from 1.65 to 3.11 inch. Their torque range is from .06 up to 25 lb inch. They weigh from .73 to 8.95 lb. Other features include being incredibly accurate, repeatable torque control, easy to adjust, easy to apply, perfect for continuous slip, zero “stick slip” and smooth with no friction.
Self-lubricating composite bearings Suited for applications that involve linear, rotary and/or oscillating motion, the self-lubricating Minuteman™ Series can be submerged; washed down with water, high-pressure steam or chemicals; and can operate in abrasive, contaminated environments. Users can select closed- or open-style composite bearings in 12 sizes ranging from ¼- to 4-inch ID. Shafting options include solid and hollow class L 304 stainless steel and ceramic-coated aluminum shafts in lengths to 12 ft. LM76 http://designnews.hotims.com/23098-597
Stock Drive Products/Sterling Instrument http://designnews.hotims.com/23098-596
69
LEE LINEAR’S NEW CATALOG Easy to use, features 30 products The new product catalog offers ease-of-use in a clear and concise format. With nearly 30 products offered within its pages, the Lee Linear catalog has been expanded and updated to include important information, such as technical specifications, ordering instructions and cross reference guides. The Lee Linear catalog spotlights the companies products, which are manufactured on-site, including: Shafting, Shaft Supports, Shaft Rail Assemblies, Linear Ball Bearings, Shaft and Rail Systems, Slide Systems and Accessories.
MOTION CONTROL, Continued
Lee Linear Inc. http://designnews.hotims.com/23098-598
Standard Or Custom Parts From A Single Source 68,000 Drive and Automation Components Ready-to-Deliver GEARS & GEARBOX ASSEMBLIES
3D CAD | eSTORE
< Precision & Commercial Quality
available at www.sdp-si.com
< AGMA & DIN Specs. < Fine to Medium Pitch < Prototype & Production quantities available.
SSTEINMEYER’S MT 105-50-LM HIGH-PRECISION MICRO MANIPULATOR STAGE Offers positional accuracy, repeatability Manufactured from anodized aluminum, the Model MT 105-50-LM micro manipulator stage offers positional accuracy of 1 µm, straightness/flatness runout of ±1 µm and repeatability of ±0.2 µm. The unit includes preloaded cross roller bearings, fixed stops and incremental linear encoder with 0.1 µm resolution. Measuring 105 x 151 x 25 mm, the product can be provided as XY stage without adapter plate and can also be configured as XYZ system with optional bracket. Steinmeyer Inc. http://designnews.hotims.com/23098-599
< Gear Types: Spur, Miter, Bevel, Worm & Worm Gear, Rack & Pinion, Helical & Internal. < Gearheads, Speed Reducers & Differentials < Inch & Metric < RoHS Compliant < In stock, modified or made to your specifications.
FREE Inch & Metric Catalogs
SSCHUNK’S LONG-STROKE ELECTRONIC GRIPPER
Our experienced team of engineering and manufacturing experts are ready to work for you.
Stock Drive Products/Sterling Instrument
ISO 9001:2000 Registered Sterling Instrument AS9100B Registered
Tel. (516) 328-3300 | Fax (516) 326-8827 | www.sdp-si.com 70
Meets packaging industry’s automation requirements SCHUNK Inc. has tailored its LEG longstroke electric gripper to meet the automation requirements of the packaging industry regarding lightweight gripping systems with flexible strokes. The LEG was developed as a lightweight gripper weighing only 8.8 kg. When operated with a single servomotor, it delivers a gripping force of 1,140N and a variable stroke from zero to 568 mm. SCHUNK Inc. http://designnews.hotims.com/23098-600
L I T E R A T U R E
P L U S
Get the latest in design guides, catalogs and other product information from every part of the OEM.
Please enter reader service number at www.designnews.com/info for additional information from manufacturers. TO ADVERTISE CALL 800-387-3469
BOKER’S FREE 2009 WASHER CATALOG
SPIRAL RETAINING RINGS & WAVE SPRINGS
Boker’s FREE 2009 Washer Catalog has over 23,000 non-standard sizes available with no tooling charges. Outside diameters of 0.080” to 5.140”, a wide range of IDs and thicknesses, and 2,000 material variations provide millions of possibilities. Materials include low-carbon sheet steel, five types of spring steel, stainless steel, aluminum, brass, copper, nickel silver and non-metallics. ISO 9001:2000 Registered
Smalley’s complete product line is now available in one easy to navigate catalog. The new catalog includes over 7,000 standard wave springs, spiral retaining rings and snap rings. Smalley’s new catalog offers simplified part selection, special design and engineering tools and the latest applications of Smalley products.
Smalley Steel Ring Company T: 847-719-5900 E-mail: info@smalley.com Web: www.smalley.com/catalog.asp
Boker’s, Inc. T: 888-927-4377 • F: 800-321-3462 Email: sales@bokers.com Web: www.bokers.com/dnlw Go to http://rbi.ims.ca/23099-6000
Go to http://rbi.ims.ca/23099-6001
ATN® CONVERTIBLE PROFILE TIMING BELT DESIGN
POSITION TRANSDUCERS
BRECOflex, the world leader in the polyurethane timing belt industry, has developed a patented timing belt concept that allows the customer to rapidly and easily attach, interchange, or reconfigure timing belts in house or in the field with a multitude of profiles using simple hand tools. BRECOflex also offers a full range of accessories including pulleys, clamps, tensioners and slider beds. For free catalogs (print or CD), samples, and/or technical support call 732-460-9500 or visit our website today!
16-page Engineering Guide describes how to select and use Inductosyn® and Electrosyn® position transducers for demanding applications. Rotary Inductosyn® and Electrosyn® transducers provide absolute and incremental position information accurate to ±0.5 arc seconds or better. Resolution to 26 bits. Linear transducers are accurate to ±40µ inches or better, with sub-µ inch resolution.
Farrand Controls Valhalla, NY USA T: 914-761-2600 • F: 914-761-0405 E-mail: sales@ruhle.com Web: www.ruhle.com Go to http://rbi.ims.ca/23099-6002
PRECISION ALUMINUM EXTRUSIONS NEW! An informative brochure from MINALEX, the leader in precision shapes to 3½” circle size with tolerances to ±.001” and walls down to .008”. Brochure illustrates a wide variety of typical applications and describes capabilities including short and prototype runs. MINALEX, the quality leader of the industry, delivers on time, every time.
Go to http://rbi.ims.ca/23099-6003
MINIATURE & SMALL MECHANICAL CABLES, CABLE ASSEMBLIES, & PULLEYS
Web: www.minalex.com
Carl Stahl Sava Ind Inc.
Precision Cable Assemblies Miniature & Small Cables Small MIL-SPEC Wire Rope Push-Pull Controls Plastic & Steel Idler Pulleys Wire Rope Terminals Fittings & Hardware Ferrous & Nonferrous Alloys
Design Guide for Cable Solutions ™
www.savacable.com DG0508
C
SO
MINALEX
CABLE SOLUTIONS! Call SAVA Industries to request our comprehensive 36-page Design Guide featuring miniature & small steel cable from .006- 3⁄ 8”, push pull varieties, high fatigue drive & low stretch cables, plastic & steel idler pulleys from 3⁄8” to 6”, a huge selection of end terminals for steel cables & much more. Visit: www.savacable.com
ABLE
S
Web: www.brecoflex.com
N
BRECOflex
LU IO T
®
ISO 9001 Certified
4 North Corp. Dr. • Riverdale, NJ 07457 T: 973-835-0882 • F: 973-835-0877 Untitled-1 1
Go to http://rbi.ims.ca/23099-6004
9/30/2008 9:37:04 AM
Go to http://rbi.ims.ca/23099-6005
LP1
L I T E R AT U R E P L U S
FREE LITERATURE – PYRATHANE POWER TRANSMISSION STRETCH BELTS
ELECTRIC ACTUATORS
Brochure describes the physical properties and characteristic of PYRATHANE power transmission stretch belts and offers application suggestions. Advantages are excellent abrasion resistance, high tensile strength, cleanliness of operation, resistance to oils, greases and ozone and the ability to eliminate idlers and tensioning devices. Metric, O-ring and fractional equivalents are offered.
RACO Ball & ACME screw Electric Actuators cover a broad range of applications, are environmentally friendly, robust & low maintenance replacements for hydraulic/ pneumatic cylinders. The modular system design allows for Straight/Right-Angle/CDesign variations. Thrust up to 225,000 lbs, speeds up to 30”/sec, and strokes up to 20 feet. For fast linear movements up to 400”/sec RACO produces a belt driven LM-Actuator.
Pyramid Inc.
RACO International, L.P.
T: 641-792-2405 • F: 641-792-2478 Web: www.pyramidbelts.com
T: 1-800-BUY-RACO Web: www.racointernational.com Go to http://rbi.ims.ca/5706-6006
YOU DON’T HAVE TO BE A CWM CUSTOMER TO ACCESS ANY OF OVER 70 DESIGN GUIDES
Go to http://rbi.ims.ca/5706-6007
NEW PRODUCT LINE BROCHURE AVAILABLE
Like this updated OEM 16-page condensed, comprehensive Die Casting Design & Specification Guide. Valuable aid to more cost-effective custom housings & components for Al, Mg & Zn die casting. One of over 70 PDF design aids downloadable 24/7 from CWM’s OEM web Resource Center. For more on this “Design Guide” and the entire Resource Center, go to: www.cwm-lit.info/dg32
Our NEW product line brochure details the design and manufacture of Servometer® - PMG, LLC, precision, electrodeposited, custom metal bellows and assemblies, zero backlash flexible shaft couplings, gold-plated flexible bellows contacts and unique, structurally rugged precision electroforms. The advantages of Servometer’s electrodepositon process over other types of bellows are explained. Design assistance is available.
Chicago White Metal Casting
Servometer® - PMG, LLC
For Co. Profile: www.cwmdiecast.com
T: 973-785-4630 Web: www.servometer.com Go to http://rbi.ims.ca/23099-6008
Go to http://rbi.ims.ca/23099-6009
NEW ELECTRIC HEATER CATALOG
THOMAS GLOBAL PRODUCTS CATALOG
Hotwatt manufactures electric heaters including cartridge, air process, immersion, strip and finned strip, tubular and finned tubular, band, crankcase, foil, flexible glasrope and ceramic heaters. We have been manufacturing resistance heating elements since 1952 and offer a wide variety of heaters for OEM, industrial, commercial, medical and military applications.
Thomas Products Division of Gardner Denver is the world leader in the production of vacuum pumps and air compressors for OEM applications. The Global Products Catalog features complete performance and specifications on our standard models for pistion, diaphragm, rotary vane, linear, rotary lobe, and liquid pumps and compressors. Also included is a detailed Technology Selection Guide and Model Selection Guide.
Hotwatt, Inc.
Thomas Products Division
T: 978-777-0070 • F: 978-774-2409 E-mail: sales@hotwatt.com Web: www.hotwatt.com
T: 920-457-4891 • F: 920-451-4237 E-mail: tpd.leads@gardnerdenver.com Web: www.gd-thomas.com Go to http://rbi.ims.ca/23099-6010
ENERGY MANAGEMENT LITERATURE FOR THE AEROSPACE INDUSTRY
L2 P 2
Go to http://rbi.ims.ca/23099-6011
11TH EDITION TECHNICAL HYDRAULIC HANDBOOK ON CD
Taylor Devices offers a four-page, full-color brochure featuring energy management components and systems for the aerospace industry. It includes product information on devices used for energy absorption and control, weapons effects isolation, nuclear weapons effects, seismic energy dissipation, aircraft arrestment, umbilical handling, stores and payload deployment, control damping/delay and cargo transport/handling.
The Lee Company’s new 11th Edition Technical Hydraulic Handbook is now available on a CD as a fully indexed PDF file. Featuring many new innovative products, the CD allows easy navigation of Lee’s extensive line of precision microhydraulic products such as Lee Plugs, solenoid valves, single and multi-orifice restrictors, nozzles, safety screens, check valves, relief valves, flow controls and shuttle valves. Also included are sections on installation and engineering reference material.
Taylor Devices Inc.
The Lee Company
T: 716-694-0800 • F: 716-695-6015 Web: taylordevices.com
T: 860-399-6281 • F: 860-399-2270 Web: www.theleeco.com Go to http://rbi.ims.ca/23099-6012
Go to http://rbi.ims.ca/23099-6013
DIGITAL MANUFACTURING MADE EASY
Astro Met’s unique advanced ceramics provide cost effective solutions to material performance problems in a wide range of demanding applications. “Amalox 68” a 99.8% alumina ceramic and “Amzirox 86” a yttria stabilized zirconia provide superior wear resistance, corrosion resistance, high temperature stability, low thermal expansion, high stiffness to weight ratio, biocompatability and high dielectric strength.
RedEye delivers your entire digital manufacturing experience - from functional prototypes to fixture and assembly tools to low volume production. Online, on your schedule. Just upload your CAD file and go. Save Time. Get delivery the next business day with Overnight Build. Cut Costs. No need to purchase capital equipment. Get More Materials & Options. Get access to a large selection of engineering grade thermoplastics and additive fabrication systems.
Astro Met, Inc. Cincinnati, OH 45215 T: 513-772-1242 • F: 513-772-9080 Web: www.astromet.com
RedEye On Demand Web: www.redeyeondemand.com Go to http://rbi.ims.ca/23099-6014
Go to http://rbi.ims.ca/23099-6015
SORBOTHANE®…SHOCK AND VIBRATION SOLUTIONS
SAVE UP TO 50% ON QUALITY PRODUCTS
New 8-page brochure describes the damping and isolation properties of Sorbothane®. This brochure features images and information on standard and custom molded components. Test data details Sorbothane’s performance compared to other elastomers. No other material can dissipate energy as effectively. Sorbothane® is specified worldwide for engineering applications requiring shock absorption, vibration isolation and acoustic damping.
AutomationDirect’s volume 12 catalog offers 6,500 industrial automation products for a wide range of applications. The latest volume, with over 2,000 pages, features product descriptions, technical data, photos, and price lists for PLCs, touch screen monitors, AC drives/motors, general purpose motors, text panels, sensors, encoders, pushbuttons, switches, and more. For a free copy or more information, visit www.automationdirect.com or call 800-633-0405.
Sorbothane, Inc.
L I T E R AT U R E P L U S
ADVANCED CERAMIC SOLUTIONS
AutomationDirect
T: 800-838-3906 • F: 330-678-1303 E-mail: sales@sorbothane.com Web: www.sorbothane.com
T: 800-633-0405 • F: 770-889-7876 Web: www.automationdirect.com Go to http://rbi.ims.ca/23099-6016
Go to http://rbi.ims.ca/23099-6017
ELECTRIC HEATERS, CONTROLS & SENSORS Tempco’s 864 page catalog offers Electric Heaters, Temperature Sensors & Controls, Turnkey Process Heating Systems & Accessory Items. New products include Gemini® Twin Bore Quartz Tube Heaters, VS Glow Infrared Heaters & PPR-1800 Video Graphic Data Recorders. Select from stock items or have Tempco custom design & manufacture for your application.
G
ADVERTISIN
PAYS
Tempco Electric Heater Corporation T: 800-323-6859 • F: 630-350-0232 E-mail: info@tempco.com Web: www.tempco.com Go to http://rbi.ims.ca/23099-6018
L I T E R A T U R E
P L U S
ADVERTISERS INDEX ASTRO MET, INC. . . . . . . . . . . . . . . . . . . LP3
HOTWATT, INC. . . . . . . . . . . . . . . . . . . . . LP2
SORBOTHANE, INC. . . . . . . . . . . . . . . . . . LP3
AUTOMATION DIRECT . . . . . . . . . . . . . . . LP3
MINALEX CORPORATION . . . . . . . . . . . . . LP1
TAYLOR DEVICES INC. . . . . . . . . . . . . . . . LP2
BOKERS, INC. . . . . . . . . . . . . . . . . . . . . . LP1
PYRAMID INC. . . . . . . . . . . . . . . . . . . . . . LP2
TEMPCO ELECTRIC HEATER CORP. . . . . . . LP3
BRECOFLEX . . . . . . . . . . . . . . . . . . . . . . LP1
RACO INTERNATIONAL . . . . . . . . . . . . . . . LP2
THE LEE COMPANY . . . . . . . . . . . . . . . . . LP2
CARL STAHL SAVA IND INC. . . . . . . . . . . . LP1
REDEYE ON DEMAND . . . . . . . . . . . . . . . LP3
THOMAS PROUCTS DIVISION . . . . . . . . . . LP2
®
CHICAGO WHITE METAL CASTING . . . . . . . LP2
SERVOMETER - PMG, LLC . . . . . . . . . . . . LP2
PUBLISHER DOES NOT ASSUME ANY LIABILITY
FARRAND CONTROLS . . . . . . . . . . . . . . . LP1
SMALLEY STEEL RING CO. . . . . . . . . . . . . LP1
FOR ERRORS OR OMISSIONS IN THIS INDEX.
LP3
CALAMITIES
MYRON J. BOYAJIAN PRESIDENT ENGINEERING CONSULTANTS
Tr u e S t o r i e s
THE CASE OF THE RAVING RACER Spring fatigue causes a race car to surge ahead at full throttle
I learned that not only did all these impecunious drag racers flee the area, they removed all the race goodies from the car, leaving the stripped hulk in the rented garage. This left only the carburetor manufacturer from which monetary damages could be recovered. I dug into the police reports and pored over a bevy of photos taken by a police evidence technician of the car, engine and accident site. I noted the new carburetor with its throttle shaft and operating lever to which a stub shaft was mounted. The accelerator pedal linkage connected to this shaft. The stub shaft had a small, cross-drilled hole through which the eye of a tension spring was installed. The eye hung loosely as it broke from the body of the throttle return spring. With the spring eye trapped in the hole of the stub shaft, each rotation of the throttle shaft produced a bending stress where the eye joined the body of the tension spring. I surmised these racers used the existing spring from their prior race setup and long usage with improper installation fatigued the spring. Accident Case Return Spring Setup Motion to Open Throttle Linkage Pin Single Throttle Return Spring
Linkage to Accelerator Pedal Throttle Arm
A CHICAGO-AREA DRAG RACING TEAM DECIDED TO
“go pro” by upgrading its car from a time handicapped “bracket racer” to run in all-out races. These racers lightened their car and installed a new camshaft, new cylinder heads and a new carburetor. Like many auto racers of every class and type over the past 100 years, they chose to defy the adage, “to make a small fortune in racing, you must start with a large fortune.” The Scene of the Crime
Modifications complete, they readied to go to the track. Firing up, they eased down the driveway from a rented garage to their trailer. On the street, the driver decided to do a tire-smoking burnout. The driver lifted his foot from the accelerator, but the car continued to surge forward at full throttle, overcoming the car’s brakes. Just missing the trailer, the car veered toward the curb. The car ran across a lawn striking a neighbor who came out to see the racers’ antics. The car then struck the injured man’s house and stopped. The injured man was hospitalized and the racers were ticketed. The smashed car was returned to their rented garage. The injured man sued, citing the race team for negligent vehicle operation, and the manufacturer of the carburetor, citing negligent design of the throttle system. I was retained to inspect the vehicle to determine the cause of the accident. The Investigation
With little success, the attorney attempted several times to arrange a time for me to inspect the car. As time dragged on, 74
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
Carburetor Throttle Shaft Spring Broke Here Spring Eye Trapped in CrossDrilled Hole as Linkage Moved, Caused Fatigue (Arrow) and Broke
This diagram shows an accident case return spring setup. For a comparison between this and a recommended (but not used) spring setup, go to http://designnews.hotims.com/23098-570.
The Smoking Gun
Considering a possible failure-to-warn issue, I viewed the carburetor installation manual. Clearly shown, but not used by these racers, were dual springs connected with a bracket that isolated the throttle springs from the stub shaft rotation. Also, contrary to good racing practice, the racers failed to install a readily accessible steering wheel mounted ignition “kill” switch. The responsibility for this needless accident all fell on the shoulders of the now elusive racers. With no hope of recovery of monetary damages, the attorney dropped the case.
Myron J. Boyajian, P.E., (mboyajian@ sbcglobal.net) is president of Engineering Consultants, a consulting service for forensic and design activities. Cases presented here are from his actual files. Illustration: Daniel Guidera
T H E G A D G E T F R E A K ® F I L E S
C A S E
# 1 3 7
AttentionGrabbing ‘Blue Light Special’
Check out Gadget Freak Case #136: John’s Jet Engine Fits in Your Garage John Tindall’s pulsejet engine employs a cyclonicvalve radial design, which makes for smoother airflow. http://designnews.hotims. com/23098-571
䊳 For complete schematics and build instructions, go to www. designnews.com/GadgetFreak.
䊳 To view the Gadget Freak archives, go to www. designnews.com/gfarchives.
illiam Grill wanted to draw attention to a trade show booth. He considered a big neon sign, loud music and a provocative attitude, but instead he created this attention-getting gadget — his “Blue Light Special.” Grill made this gadget with a mere $15 in materials. It is built around Microchip Technologies’ 16F505 controller. The application uses a single button to set off two rotating arrays of eight LEDs. Using PVC or metal tubing, the beacon can be mounted on almost anything. For Check out the Blue Light in action at www.designnews.com/GadgetFreak. packaging, Grill uses a small pickle jar.
W
ADVERTISEMENT “LIGHT IT UP” Amt
Part Description 2.7K Ω ⁄4W, ⁄8W SMD or Axial
832-0421
1
270Ω 1⁄4W, 1⁄8W SMD or Axial
832-0263
1
Controller, PDIP or SMD Equivalent, PIC 12F505-I/P, PDIP
383-0386
2
SPST Button, Red or Black Momentary N.O. or Equivalent
948-7199
2
Perf Board, Copper Pad 1 or Both Sides or Equivalent
977-0088
1
Additional Parts Required For a complete list of parts, go to www.designnews.com/GadgetFreak.
ARE YOU A GADGET FREAK?
Design News and Allied Electronics would like to send you a check for $500 to spend on Allied’s website at www.alliedelec.com/gadgetfreak or anywhere you please. Design News will pay an additional $100 if you camcord your backyard invention and supply us with the video file. E-mail Design News your proposed project (must incorporate electronic components and involve sensing, motion, timing and/or networking elements) to elizabeth.taurasi@reedbusiness.com, along with a description of how it works and a parts’ list. If your project is selected, you’ll receive a $500 check from Design News and will be featured in an upcoming issue of the magazine with your invention.
76
D E S I G N N E W S M A R C H 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
Allied Part #
1
1
For parts’ information, call (800) 433-5700 or go to www.alliedelec.com/gadgetfreak SPONSORED BY »
Photo: Don Ipock
LATE DELIVERY A PROBLEM? SHIPS SAME DAY
10
PM
EST 3
Place your order by 10PM EST for same day shipping.* No questions asked.
Allied provides on-time delivery.
* UPS Ground only.
Find all your product solutions @ Allied 1.800.433.5700 We do more than take your order © Allied Electronics, Inc 2009. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
SM