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NEW PRESSURE SENSOR APP An accordion goes high-tech, p18 ROBOTIC PENGUINS SWIM, FLY
Unprecedented motion profile, p29 BMW UPS ALUMINUM USAGE Layered alloy resists corrosion, p34
MAY 2009 $15.00
ACCELERATING ENGINEERING INNOVATION www.designnews.com
Plus SHOCK ABSORBERS CONVERT ROAD BUMPS INTO ENERGY, p49
2008
A Fit for All LOW-COST PROTOTYPING IS THE KEY, p42
ACCELERATING ENGINEERING INNOVATION www.designnews.com
contents May 2009 volume 64 no. 05
Features
Departments
GADGET FREAK
64 Security Robot Roams, Shrieks at Intruders
MADE BY MONKEYS
12 Moisture Causes Lithium-Ion Battery Bloat The seal on Glenn Gauvin’s MacBook was somehow breached, allowing moisture to get in and bloat it. BY KAREN AUGUSTON FIELD, Editor-in-Chief COVER STORY
42 Make Your Own Shoes Advanced product engineering at companies, such as New Balance Athletic Shoe Co. in Boston, show how computer-aided design, digital manufacturing and materials technology may soon lead to personalized sneakers. BY DOUG SMOCK, Contributing Editor, Materials and Fastening F E AT U R E
49 Boosting Fuel Efficiency with ... Shock Absorbers? Levant Power Corp. developed a prototype shock absorber that harvests energy when a car drives over bumps in the road. BY CHARLES J. MURRAY, Senior Technical Editor, Electronics THE FIELD REPORT
9 Have You Built a Better Mousetrap? It’s that time of year again — when DN’s editors start reviewing the entries for our annual Golden Mousetrap Awards. Did your company launch a cool new technology in 2008? If so, enter it today at www.designnews.com/mousetrap! BY KAREN AUGUSTON FIELD, Editor-in-Chief
The Searching Security Robot roams about and sounds its alarm if it detects moving objects.
17 GREEN SCENE Environmental News for Engineers
18 FLASH
New and Noteworthy Products
14 Readers Sound off Readers comment on the “Case of the Shorted Rotor Turns.” SHERLOCK OHMS
What caused a loading dock buzzer rung by a UPS driver to consistently dump a string of commercials during a 6 p.m. newscast? BY JOHN LOUGHMILLER, Contributing Writer
26 Fail Fast, Fail Early
38 TREND WATCH Stuff You Need to Know
53 EXPO DESIGN NEWS SUPPLEMENTS
U.S. industry should follow The Skunk Works’® model and help rebuild the economy through innovation, not bailouts. BY GEOFFREY C. ORSAK, Dean of Engineering, Southern Methodist University
A forklift driver at a tanning plant was fatally shocked after he broke a light fixture with his machine. BY MYRON J. BOYAJIAN, Contributing Editor
Trends, Developments, Breakthroughs
Best of the Engineering Marketplace
AT S TA K E
62 The Case of the Lethal Lamp
Unbelievably Useful Information from a Test Expert
29 NEWS
20 The Adventure of the Insidious Buzz
CALAMITIES
24 TIPS FROM TITUS
SENSORS/MACHINE VISION
More and more, robots are being designed to take over for humans in dangerous situations. This and the challenges facing manufacturers designing sensors for remote applications can be found between pages 16 and 17. MEDICAL T E C H N O L O G Y
From a mini, mobile robot that traverses the heart, to a football helmet designed to reduce sports-induced concussions, this supplement covers some of the latest advances in medical technologies. Look for it between pages 48 and 49.
COVER IMAGE: STEVE EDSON 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: RCS International, Box 697 STN A, Windsor Ontario N9A 6N4. E-mail: subsmail@reedbusiness.com.
D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 5
䊳 䊳 䊳
Gadget Freak®
Check Out Our New Blogs …
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
LOG IN
The Weird and Wonderful World of Wireless See what DN’s newest blogger Joel Young has to say, as he takes a look at the world of wireless — electronics on airplanes, microwave ovens, Wi-Fi and many other topics. http://designnews.hotims.com/23105-500
Recycled PlayStations Have Front-Row Seat in Reee Chair Design
Captain Hybrid Join Senior Technical Editor Chuck Murray as he launches DN’s newest online discussion with the latest news in electric vehicles, batteries and hybrid cars. http://designnews.hotims.com/23105-501
Mechatronics Zone
Pli Design leveraged 3-D CAD tools and a single-source plastics supplier to create the Reee ergonomic chair out of nine recycled Sony PlayStation®2 consoles. http://designnews.hotims.com/23105-503
GM, Segway Join to Reinvent Urban Transportation
Follow resident mechatronics expert Jon Titus as he interprets trends, analyzes tools and techniques, and explores cross-discipline skills for electronic, mechanical and system designers. Then, join the conversation. http://designnews.hotims.com/23105-502
General Motors and Segway are teaming up on a project that will bring two-wheeled, two-seater, electrically powered vehicles to city streets. http://designnews.hotims.com/23105-504
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WEBCASTS BLOGS PODCASTS
FREE WEBCAST: THE WORLD IS FLAT — EXCEPT IN DYNAMICS Listen to Kevin C. Craig, Ph.D., Robert C. Greenheck Chair in Engineering Design and professor of Mechanical Engineering at Marquette University, discuss why 3-D dynamics is important in mechatronic system design and how tools like ADAMS make it easier to understand and explain difficult dynamic concepts. http://www.mechatronicszone. com/fundamentals/all_articles.php?art_id=1161
HAVE YOU BUILT A BETTER MOUSETRAP? Let us know! Tell us about the most amazing product you designed in 2008 and it could be profiled, along with other great new products, in Design News’ Special Engineering Awards issue in September. When you submit your entry form and payment no later than May 15, we’ll make sure your entry makes it into the hands of our judges — Design News’ editors. Enter today at: www.designnews.com/mousetrap.
»
Product Catalog Stock Drive’s New M-Type Shaftloc® Rotating Fastening Components The new M-Type Shaftloc® is used as a locking device for rigidly mounting hubless gears, sprockets, pulleys, cams or any thin-walled components onto an inch or metric shaft. They feature infinite radial and axial adjustments and quick lock and release action. http://designnews.hotims.com/23105-505
Case Study Digital Manufacturing from RedEye Puts the Fun Back in Aviation ICON Aircraft recently unveiled its ICON A5, a small, recreational plane its founder, Kirk Hawkins, hopes will revolutionize a market already enamored with powerboats and motorbikes. He says the two-seater is able to reach speeds up to 120 mph. http://designnews.hotims.com/23105-506
Product Brief Z Corp. Introduces 3-D Printing Buyer’s Guide Tight economic times make a powerful argument for investing in 3-D printing capabilities. Not only does money spent on 3-D printing yield long-term strategic value, enhancing design capabilities and speeding time to market, it can also save money right now by raising productivity. http://designnews.hotims.com/23105-507
D E S I G N N E W S M AY 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
Have You Built a Better Mousetrap? THE EDITORS HERE AT DESIGN NEWS ARE
A W A R D S
busily covering the latest technologies in their beats all year round. But we especially like the month of May. The sun is shining. The birds are singing. The air is warm. Well, maybe not here in New England where Spring doesn’t actually arrive until June if it arrives at all, but we’re pretty happy nonetheless. That’s because this month marks the time when we start reviewing the entries for the Design News Golden Mousetrap Awards. Entering into its fourth year now, this annual new products contest recognizes the coolest and most significant technologies launched in the preceding 12 months. The Golden Mousetrap contest is open to companies that make products used and applied by design engineers and that fall into five categories — electronics, hardware/ software, materials, motion control/automation and rapid prototyping tools. We’ve had a lot of great entries and winners over the years — you can read about them on our website at www.designnews.com. Scroll down on the left-hand navigation bar and click on “Golden Mousetrap Winners.” One of the more memorable entries in recent years was an actual mousetrap (in fact a case of them showed up at our offices along with the entry form). Though this particular “better mousetrap” didn’t actually qualify for our contest, I completely understand the thought process that led to it getting entered into our competition. Once we’ve gathered together all the entries, our editors scrutinize each one, evaluating the functions and features that make the product a standout and why it is significant
2009
to design engineers. In particular, we’re looking for those new products that help make your jobs easier and designs better without incurring some ugly trade-off in the process! Based on our investigations, usually involving several phone calls and lively discussions among ourselves, we then pick the winners in each category. Next, we interview the engineers behind the winning designs for an article we’ll publish in our September issue and on our website. In addition to their Andy Warhol moment in Design News, the winning engineers will receive a plaque complete with tiny mouse catcher. If your company has introduced a product you think would be a great candidate for a Golden Mousetrap Award, it’s not too late to enter this year’s contest as the deadline is May 15, 2009. You can find the contest rules and entry form at www.designnews.com/mousetrap. And if you’re a few days late, we encourage you to check the link anyway — we usually have a grace period of a few weeks for late entries. The concept of a “real” deadline, as opposed to a published deadline, is something we in the publishing business are quite familiar with. And believe me, it’s come in handy quite a bit over the years!! Have You Built a Better Mousetrap?
Enter our Golden Mousetrap contest and get your Andy Warhol moment in Design News! Contest rules and entry form are available at www.designnews.com/mousetrap. Deadline is May 15, 2009 (with a minor grace period for late entries). Karen Field, Editor-in-Chief kfield@reedbusiness.com
D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 9
Advanced Control Made Easy
Made by Monkeys designnews.com/ »madebymonkeys
Moisture Causes Lithium-Ion Battery Bloat SOON AFTER READING MY EDITORIAL ON A PREGNANT IPOD IN THE APRIL ISSUE OF
High-Performance NI CompactRIO N
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©2009 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 2009-10825-305-101-D
Design News, reader Richard Sheryll came across his old Palm m500 in a pile of discarded devices. “The front casing was ripped off,” he wrote, “and the lithium-ion battery looked just as bloated as the one in your article.” Well at least it didn’t catch fire! Glenn Gauvin had a similar experience recently when he went to swap out the battery in his 17-inch MacBook Pro. Digging into his briefcase, he pulled out the battery (shown below, right) — amazed to see it had a newly acquired paunch. “My bag was not mishandled, mistreated, or exposed to extreme heat or cold and the battery was less than a year old,” wrote Gauvin. “The guys at the Apple Store replaced it without question, but would not answer my questions. Hmm!” “It looks like these were cases in which the hermetic packaging was breached somehow and moisture got in,” says Don Sadoway, a professor of Materials Chemistry at MIT and an expert in advanced battery technologies. Today’s thin-type lithium-ion batteries employ a flexible, pouch-style foil housing, and Sadoway speculates that the material may have become brittle or possibly something cracked. Whatever the cause, the housing was compromised. When moisture penetrates the inside of a lithium-ion battery, that’s a problem, says Sadoway. “The lithium salts that are used in the electrolyte will become destabilized. Essentially, they react with moisture and generate hydrogen fluoride, which causes the cell to begin gassing and the battery to bloat up.” In fact, Sadoway says, he has a research staffer who worked at a battery maker for four years. “They took the pains to inject with a syringe controlled amounts of water into flat pack batteries (some people call these ‘pouch cells’) to demonstrate that when water gets in, bloating occurs,” says Sadoway. Taken to the extreme, the battery may rupture and the liquid inside will ooze out, forming the kind of crusty residue most of us have discovered inside a long-lost flashlight with regular zinc alkaline batteries inside. Sadoway’s research at MIT is concentrated on alternatives to the electrolytes used in today’s lithium-ion batteries. Given the technology’s sometimes finicky nature, as demonstrated here, he would love to see more people involved in this effort. “The electrolyte is the common element in these problems we see with lithium-ion batteries,” he says, “and yet there isn’t much interest in doing anything about it.” Check out our new Made by Monkeys blog featuring all sorts of cheesy products and add your comments at: www.designnews.com/madebymonkeys. If you’ve had a run-in with a product that failed to live up to your expectations, we’d love to hear about it! Photos of the offending product with an amusing caption are appropriate fodder, and we will give extra credit for a brief analysis of what went wrong and what could have been done to avoid the problem. E-mail your examples to Karen Field at kfield@reedbusiness.com and we’ll feature the best of them in our Made by Monkeys blog and here in print.
PUBLISHER
Russell E. Pratt 781-734-8417 ASSOCIATE PUBLISHER
Al Schmidt 972-980-8810
WHEN OLD IS NEW AGAIN
I had to chuckle when I read the “Case of the Shorted Rotor Turns,” relayed in your editorial in the April 2009 issue of Design News, “Design Engineering Detectives,” (DN 04.09, http://designnews.hotims.com/23105-508), which describes the mystery device used to troubleshoot the motor. It is true, this could be considered tips and tricks of the trade, although it is hardly a “secret” as portrayed in the article. This method of testing rotor or armature windings has been commonly used since the very early 20th Century by automotive technicians and mechanics. Before the advent of alternators the technique was used on “generators,” and it is still used on starter armatures to diagnose loss of engine cranking torque. A simple case of everything old is new again — or so it would seem! Earl Bennett Design News Reader
R EADERS SOUND OFF
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
IT’S A GROWLER
In the “Case of the Shorted Rotor Turns,” Mr. Singh was using a “Growler.” This is a piece of automotive test gear about as old as the Ford Model A, maybe even older. The use in those days was the same as his applications, to find shorted turns in a starter or generator rotor. Ed Jacklitch San Jose, CA Editors Note: Thanks to Earl, Ed, Wesley, Stephen, Allyn, Thomas, Chris, Marv and all the other readers who enlightened us about the Growler device. You also are probably the type of guys who figure out the whodunits way before the culprit is revealed in the last chapter!
CAE Software & Hardware: Beth Stackpole Bstack@stackpolepartners.com Electronics: Charles J. Murray charles.murray@reedbusiness.com Embedded Systems: Warren Webb warren.webb@reedbusiness.com Motion Control/Automation: Karen Field kfield@reedbusiness.com Fasteners & Materials: Doug Smock doug.smock@reedbusiness.com Mechatronics: Jon Titus jontitus@comcast.net Fluid Power: Al Presher apresher@statejus.com CONTRIBUTING EDITORS
CALAMITIES Myron J. Boyajian, mboyajian@sbcglobal.net Ken Russell, kenruss@mit.edu GREEN SCENE Robert Spiegel, robspiegel@comcast.net TIPS FROM TITUS Jon Titus, jontitus@comcast.net Terry Costlow, tcostlow@comcast.net GRAPHICS
Norman Graf, Director of Creative Services Daniel Guidera, Illustrator PRODUCTION
ECONOMIC OUTLOOK CIRCA 1932
Reader Anton Vermaak shares this editorial he came across from a March 1932 issue of a magazine called “Instruments,” a year in which 1,493 banks suspended operations. The previous year, a Hoover Commission reported that Prohibition had become almost impossible to enforce.
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Sensors/Machine Vision
DESIGNED to Handle High Risk Situations Robots depend on myriad sensor technologies to investigate potentially dangerous scenes BY RANDY FRANK, CONTRIBUTING EDITOR
[ w w w. d es ig n n e ws.c o m]
SOURCE: QINETIQ
I
n place of first responders, robots are being deployed to scope out dangerous situations and avoid serious injuries and even loss of human life. To function in these hostile environments, robots need human senses of vision, extraordinary smell, hearing and more. The stakes are high, so traditional cost constraints do not apply, but cost is still a factor. More and more organizations, such as police and fire departments, are seeing the value of having a highly mobile robot perform tasks in high-risk environments to avoid harm to a human. While the military may have taken the lead in using robots in hazardous situations, domestic organizations dealing with hazmat, bomb/arson or sniper situations are also turning to robots for first response. Depending on the target activity, a variety of sensors come into play to help the robot perform its duties. “The sensors are everything. The sensors are what makes these things really, really useful,” says Susan Eustis, president and co-founder of WinterGreen Research, a market research firm. “When I call on the different robot companies and present to them, that’s what they tell me.” In its report, “Military Ground Robots and First Responder Robot Market Strategy, Market Shares and Market Forecasts, 2008-2014,” WinterGreen Research says the market for these robots was $441 million in 2007 and expects it to reach $43.7 billion by 2014 with growth of
Weighing in at about 115 lb (52 kg), QinetiQ’s TALON Responder robot can be easily transported to a location to check out a potentially dangerous situation.
92.8 percent compound annual growth rate coming from countries, law enforcement agencies, fire departments and first responders. These organizations are implementing an automated process to support existing manual processes. Several companies expect to play a key role in that growth and use a variety of sensors for their robots. DEPLOYED IN PUBLIC SAFETY, FIRE AND RESCUE SITUATIONS
To design a robot for law enforcement and first responder applications, Qin-
etiQ, North America’s Foster-Miller subsidiary, uses technology and insight from designing and manufacturing military robots. Cost reductions are also factored into the designs. The TALON Responder robot has four vision sensors including three infrared (IR) illuminated color cameras. “They’re automatic IR illuminated, so in low-light situations, three of those cameras will illuminate,” says Martin Foley, anti-terrorism manager, Technology Solutions Group, a subsidiary of FosterMiller, of QinetiQ North America. An
MAY 2009 S E NS O R S / MACH INE V IS IO N / A S UP P LE ME NT TO DE S I GN NE WS S1
Sensors/Machine Vision operator viewing with these cameras in a dark room has better sight capabilities than in a normally lit room. A fourth camera has a 300 to 1 zoom and an external light source. “The basic TALON has those four cameras on it and they all report back to either a laptop controller or an operating control unit, an OCU,” says Foley. “That’s all done wirelessly and that can be done from as far away as 800 meters.” Normal operation for the wireless system is anywhere from 300 to 500m from the OCU, depending on the location. “What you are looking for here is standoff,” says Foley, regarding the
remotely from about 8m away. An industrial hazard situation for the laserguided temperature sensor could involve drums that have been knocked over. “We can actually take the temperature of a drum and see if it’s getting ready to explode,” says Foley.
separation of the human observer from the robot responder and the situation it is exploring. “The farther away you get from them, the better off you are.” With the appropriate vision sensing in place, one of the next requirements is chemical sensing. “What we have the capability of right now is detecting chemical warfare agents, volatile gases, toxic industrial chemicals and explosives,” says Foley. TALON hazardous materials robots use JAUS (Joint Architecture Unmanned Systems) software for plug-and-play connection of up to seven detection devices. The robot can read temperatures
ENVIRONMENTAL SITUATIONS
For investigating hazardous chemical sites, the U.S. Environmental Protection Agency relies on the Hazardous Environment Robotic Observer (HERO) robot from First Response Robotics LLC. “The EPA uses your standard area array
Acoustic direction-finding microphones
Six-axis gyro onboard Laser rangefinder source
Microphone
300X zoom day/night (IR) camera Thermal Imager Driving camera
Laser rangefinder receiver
Jointly developed with BioMimetic Systems, A Boston University company, the RedOwl system on iRobot’s PackBot uses a deployable acoustic sensor with four or more microphones combined with behavioral models of hearing, computing technology and other sensors. RedOwl Sniper Detection is one of the sensor options for the company’s Negotiator robot for domestic applications. S2 SENSO RS/M A C HI NE VI S I O N / A S U P P L E M E N T T O D E S IG N NE WS MAY 2009
[www.d esignnews .com]
Sensors/Machine Vision
and MultiRAE and DataRAM,” says Mike Carderelli, president, First Response Robotics. “These are all chemical/biological warfare multi-use sensing devices.” These sensing technologies can provide information on carbon monoxide, hydrogen sulfide, volatile organic compounds (VOCs), oxygen, Lower Explosive Limit (LEL), carbon dioxide and air particulates including airborne dust, smoke, mist, haze and fumes. For its applications, the EPA specifies the type of equipment it requires, as well as the system interface that has to be mounted on the robot. “I spent a year with them designing a plug-andplay system so it can plug right into the robot,” says Carderelli. The EPA uses the Rapid Assessment Tool that allows for easy plug-and-play. “It’s also mounted into the robot,” says Carderelli. “All of the equipment, including GPS, is plugged into this interface and all of the live data is sent back wirelessly to their command center.” The EPA collects the data wherever the robot is at in real time. “I can log on to a secure website and see what the robot sees and what the instruments see live, also,” says Carderelli. MILITARY TESTED FOR CIVILIAN USE
In addition to its well-known home robot, the Roomba vacuum cleaner, iRobot also supplies highly mobile robots to the military, as well as state and local agencies for domestic surveillance and reconnaissance. The company’s Negotiator 200 robot with Civil Response Kit addresses dangerous scenarios for public safety professionals with a cost-sensitive version that takes advantage of technol-
ogy developed for military ADDING MORE SENSING robots including sensors. Once the robot can “see,” the next detec“There’s a lot to be tion enhancement involves explosives done on robotics on and chemical sensors. the optical side both in “We have deployed hundreds of explosive sensors for the military, some spreading the range, into for civil responders,” says Rymarcsuk. low light and thermal range,” In the chemical range, the sensors are says Jim Rymarcsuk, senior vice looking for industrial chemicals, or for president for business development, Government and Industrial Div., iRobot. the military, chemical warfare agents. To sense these chemicals, the MultiRAE “Over half the military applications Gas Monitor Adapter Kit and MultiRAE and a lot of civil applications are done Gas Monitor Detection System can be at night or in dark buildings or tunnels included on iRobot’s Negotiator 200. or caves or culverts, so having thermal “It’s an industrial chemical sensor, so imaging capabilities is important.” Robots operate at a disadvantage com- it can sense a wide range of chemicals,” says Rymarcsuk. The sensor can detect pared to human first responders. That O2, LEL and toxic gases. If there is an disadvantage is turned into an advantage area that may be dangerous for people to by increasing the capability of the vision enter because there is insufficient oxygen, sensors. “Robots today do not have the the robot’s sensor can detect it. The senfull eyes that we do, so you don’t have sor can also detect a variety of chemical full situational awareness,” says Rymarcspills in an industrial environment. suk. “They have tunnel vision.” This With the Negotiator 200, the ability to lack of peripheral vision and other vision hear and speak through the system is esshortcomings can be improved with sential. “That’s a basic sort of capability. You more sensors. “The first thing is to get want to be able to interact remotely with more comprehensive visual both in field people,” says Rymarcsuk. “That’s important of view and acuity,” says Rymarcsuk. for situational awareness.” Enhanced optical systems can be A more sophisticated audio system better than the human eye with the ability to zoom and see other wavelengths. With lasers, ranging capability can provide another vision option. “There are relatively inexpensive sensors out there that can give you point range information or designation information,” says Rymarcsuk. “They can also have built-in illumination in non-visible spectrum.” As a result, the suspect is unaware of the illumination and the robot The TALON Responder comes equipped with four vision is fully operational just sensors. Several other sensors are available as options, like in daylight. depending on the robot’s planned deployment.
S4 SENSO RS/M A C HI NE VI S I O N / A S U P P L E M E N T T O D E S IG N NE WS MAY 2009
[www.d esignnews .com]
SOURCE: QINETIQ
RAE Systems’ MultiRAE Plus combines a Photoionization Detector (PID) with the standard four gases of a confined space monitor (O2, Lower Explosive Limit (LEL) and two toxic gas sensors) into a single unit with a sampling pump.
Sensors/Machine Vision implemented for special-purpose robots. In some applications, very basic sensors can be added to robots for improved functionality. “In ďŹ re situations, we also put thermistors or temperature sensors on the robot itself to be careful that it does not get too hot,â€? says Rymarcsuk. This
sensing can ensure the robot’s safe operation by detecting its surface temperature and moving away from a heat source. Based on the need to meet the budget constraints of law enforcement and other ďŹ rst responder organizations, sensors developed for the military are not
Little Sensors. Big Ideas.ÂŽ 3DM-GX2ÂŽ Attitude Heading Reference Sensor Inertia-LinkÂŽ Inertial Measurement Unit Both units have six delta-sigma A/Ds sampling all sensors simultaneously, providing superior performance.
iRobot’s hazardous material sensing CUGV (Chemical, Biological, Radiological and Nuclear Unmanned Ground Vehicle) robot can detect ammonia, chlorine, carbon monoxide, oxygen levels, lower explosive limits, volatile organic compounds, gamma radiation rate and dose rate, temperature and humidity.
is part of the RedOwl system used for sniper detection that can hear sounds and locate them. “It has an array, so it can tell which direction they are coming from and it can classify them,� says Rymarcsuk. The system uses biomimetic technology, intelligent sound detection capability for robots, so it can react like an animal does to hear, locate and classify a potential threat. “When it hears a sound, it can tell you the direction, it can tell you what it is within its category of things and it can automatically turn to it,� says Rymarcsuk. “Police applications today are for sniper detection but it has the potential to do a lot more.� Other exotic sensors that can be added to robots include X-ray vision and radiation sensing. Radiation sensing is important for bomb threats. “It can reach its arm around things and X-ray things and remotely send it digitally back to the controller and tell you what’s inside of a bag or trash can or something like that,� says Rymarcsuk. For nuclear power plants, a robot with a radiation sensor can monitor critical areas and detect leaks. These are just two of the more sophisticated sensors that can be [ w w w. d es ig n n e ws.c o m]
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Sensors/Machine Vision necessarily the lowest cost alternative. Robots require sensors that are similar to consumer and industrial applications, with cost being a primary, but not the only, consideration. “The main drivers are rugged because of use in the real world, not in the laboratory environ-
ment,” says Rymarcsuk. “Small size is another one because you want to put these on small platforms.” In addition, digital systems are important for compressing and transmitting the information through a wireless network.
First Response Robotics’ HERO tackles a variety of tasks for the U.S. EPA using standard sensor arrays such as RAE Systems’ MultiRAE gas monitor interfaced with the EPA’s Rapid Assessment Tool.
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With these new domestic applications, Rymarcsuk envisions an endless stream of new payloads and sensing capabilities for robots. The starting point is duplicating, or at least simulating, human sensing with goals to go well beyond this capability for different hazardous situations. “So you can be at least as situationally aware as a person would be in that environment and then to exploit the other capabilities that are out there beyond what normal human sensing capabilities are,” he says. FOR MORE
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information
WinterGreen Research’s “Military Ground Robots and First Responder Robot Market Strategy, Market Shares and Market Forecasts 2008-2014” report: http://designnews.hotims.com/23103-500 QinetiQ’s TALON Responder robot: http://designnews.hotims.com/23103-501 JAUS software: http://designnews.hotims.com/23103-502 First Response Robotics’ HERO robot: http://designnews.hotims.com/23103-503 EPA sensing technologies: http://designnews.hotims.com/23103-504 EPA’s Rapid Assessment Tool: http://designnews.hotims.com/23103-505 iRobot’s Negotiator 200: http://designnews.hotims.com/23103-506 RAE Systems’ MultiRAE Gas Monitor Adapter Kit and Detection System: http://designnews.hotims.com/23103-507 iRobot’s RedOwl system: http://designnews.hotims.com/23103-508 Video explaining the hazardous materials sensors on the TALON robot: http://designnews.hotims.com/23103-509
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Sensors/Machine Vision
Breaking Down the Sensor
SIGNAL PATH By understanding the stages of an analog signal path, digital developers can more accurately capture sensor data for a wide variety of applications BY AARON GL PODBELSKI, CYPRESS SEMICONDUCTOR
E
mbedded systems are using sensors with increasing frequency. While industrial products have always used them for manufacturing control systems, consumer devices are starting to employ them more often, as well. Sensors are being integrated into consumer products to create better user experiences — ranging from adding accelerometers in mobile phones to adding water vapor sensors in microwaves. System designers, who previously worked only in the digital domain, are now finding themselves having to interface with analog sensors. A sensor’s analog signal needs to be digitized to be used by the system, and the signal path goes through several stages: amplification, filtering and digitization (see Figure 1, below). Once the signal has been digitized, the user can pass it to a control system on the microcontroller or can massage the data and pass it to a host processor via a communication protocol. The sensor data can be utilized as required. Each stage usually involves a component which must have passives around it to perform properly for the given application. Figure 1
designer must select a sensor that meets the requirements for the system, but if the requirements change during the design, a sensor change may also be in order. In addition, a new sensor with a slightly different output would necessitate altering the amplification and filtering stages. Since a majority of sensors output a low-level current or voltage-based signal, this article will assume this type of sensor is being used and that any current-based signal has been adapted into a voltage via a simple resistive network. Note: This article simplifies some concepts and the component selection process for efficiency sake. The output of a sensor can be as small as several millivolts or as large as several volts. In order for the signal to be properly digitized, it needs to be large enough for the analog-to-digital converter (ADC) to effectively read the signal. In most cases, the sensor signal will need to be amplified. For example, a typical type-K thermocouple outputs 41 μV/°C, which needs to be greatly amplified if the user would like to read 1C granularity. Thus, designers must take ADC resolution into account to ensure that signal is amplified enough to obtain the desired granularity. AMPLITUDE
SOURCE: CYPRESS SEMICONDUCTOR
A sensor’s analog signal path goes through several stages: amplification, filtering and digitization.
THE SENSOR
Every sensor has a different output signal and range. The output signal can be voltage-, current-, resistive-, capacitive- or frequency-based, but few standards exist, and they are only used in specific industrial systems. Even similar sensors from the same manufacturer can have different outputs, and these differences can create problems for systems designers. A
The selection of an amplifier is based mainly on the type needed — instrumentation amplifier, differential amplifier, OpAmp or Programmable Gain Array, as well as the amount of gain. The gain of an amplifier is set by a resistive network around the amplifier with feedback. The maximum gain for standard amplifiers is ideally limitless. The gain for a PGA is usually set by a digital signal to the device which alters an internal resistive network. The maximum possible gain for a PGA is more limited than a tradition amplifier, somewhere in the order of 0.5x to several 1,000x, but, in most cases, this range is more than acceptable. With amplifiers, another key specification needs to be taken into account — offset voltage (VOS). VOS is the amount of voltage a signal that is passed through the amplifier will be altered. For example, if a 500-mV signal is input into an amplifier with unity gain (1x) and a VOS of 10 mV, the resulting output would be 510 mV. If the output range of the sensor is 0-900mV, and the system does not need a very granular reading of the sensor, this offset may
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Sensors/Machine Vision
example, a generic gyroscope measures 360 degrees of rotation be negligible. If the range of the sensor is 450-550 mV, this offset at 0.67 mV per degree, resulting in an output range of 241 mV. is probably unacceptable. When selecting an amplifier, the smaller A hobby helicopter might need information from the gyroscope the VOS, the more costly it is. Since all amplifiers have an offset, at a granularity of 1 degree, but with a high throughput of what matters is whether the system can tolerate it. The VOS can 10Ksps to keep the helicopter upright. This requirement would also be reduced or eliminated using correlated double sampling. necessitate a 10-bit ADC which would provide 0.35°/bit (note In all systems, some noise will be imparted on the sensor’s that the signal will still have noise on it and ±1 bit is considered signal. Noise arises from a number of sources, including board acceptable). Conversely, a digital camera with image stabilizalayout, radios, thermal noise and even the sensor itself. Not tion might require a granularity of 0.02 degrees but with a only does signal noise cause inaccurate and unstable readings lower throughput of 5Ksps in order to adjust the image sensor by the ADC, the level of noise has been increased through the as a camera shakes. This requirement would necessitate a 16-bit amplification stage, which exaggerates the error in the signal. ADC which would provide 0.005°/bit. Signal noise can be qualified as low frequency, high frequency The accuracy of an ADC is rated in terms of integral nonor a specific known frequency. Most often, high-frequency linearity (INL), differential non-linearity (DNL), offset error, noise is the issue that needs to be dealt with. gain error and signal-to-noise ratio (SNR). When these terms Noise can be filtered via several methods, including passive analog filters, filter ICs and digital filtering. The most common are combined they offer an understanding of the ADC’s total method, passive filtering, involves creating a passive network of error. Figure 2, page S10, shows each of the errors individually resistors, capacitors and inductors. The issue with passive filters and then combined. For a majority of applications, looking into these ADC specifications is not needed, but a thorough is they need to be designed and are not easily altered. As filter engineer should have an understanding of these values for the design can be as cumbersome as the order of filter needed — a ADC being used. first-order Chebyshev filter will take much less effort to design When selecting an ADC, the user has the choice of using an compared to an eighth-order Bessel filter — designers should external ADC or a microcontroller with an integrated ADC. determine the order of the filter needed before selecting the External ADCs tend to be higher performance, both in speed method of filtering to be employed. and resolution, as well as accuracy specifications. But the maFiltering ICs, which allows the designer to digitally program the type of filter needed, exist. These ICs use different types of analog circuitry internally to create the filter and may have offset voltages associated with them. They also allow designers to move the filter process until after quantification with the ADC. Digital filter design can be complex, but many tools exist that allow for the easy design of high-order filters. Digital • Wide range of sensors and instrumentation backed filtering can be an ideal means of removby ISO 9001:2000 quality system ing noise; however, it often requires a • Four decades of development and healthy number of CPU cycles which applications experience also increase power consumption.
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In order to use the sensor’s filtered signal, it is necessary to quantify the analog signal into the digital domain using an ADC. Selection of an ADC mainly concerns the system’s requirements for sampling speed and resolution. The sampling speed required is related to the sensor’s bandwidth or how often the system needs to be updated. Resolution is dependent on the granularity needed to react to the sensor’s information. The system’s usage model defines this speed and resolution requirement. For [ w w w. d es ig n n e ws.c o m]
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Sensors/Machine Vision
Figure 3 SOURCE: CYPRESS SEMICONDUCTOR
jority of sensor application requirements are well-aligned with integrated microcontroller ADCs. Another option, configurable ADCs, are comprised of programmable logic blocks available within a microcontroller. Integrated digital and analog programmable blocks allow for the dynamic definition of configurable peripherals optimized for a particular sensor application, including: counters, PWMs, UART, SPI, amplifiers, filters, ADCs and DACs. Developers can also implement the amplification and filtering stages, integrating the entire analog
SOURCE: CYPRESS SEMICONDUCTOR
Figure 2 Developers can implement the amplification and filtering stages, integrating the entire analog signal chain onto a single device.
signal chain onto a single device (see Figure 3, above). Configurable ADCs can result in much cleaner designs compared to using passive components. In addition, given that these blocks can also be dynamically reconfigured, developers have the option of reusing these system resources for other functions. Sensors continue to penetrate a wide range of markets, bringing more control and greater flexibility to developers. Combining integral non-linearity (INL), differential non-linearity Sensors increase reliability through management of the en(DNL), offset error, gain error and signal-to-noise ratio (SNR) vironment (i.e., temperature monitoring), improved perforprovides an understanding of the ADC’s total error. mance through feedback mechanisms and enables new types of user interfaces, just to name a few applications. For many of these designs, the integrated ADCs on microcontrollers provide sufficient granularity and accuracy. Developers not familiar with analog design may encounter pitfalls along the analog signal chain between the sensor and the MCU. Implementing the multiple stages of the analog signal path can appear convoluted, especially to engineers accustomed T/TR family of absolute position to designing primarily in the digital sensors feature repeatability to domain. However, by breaking down 2μm. They are ideal for the analog signal path into the various amplification, filtering and ADC stages, machine automation digital developers can more easily and and control accurately capture sensor data for a wide applications Novotechnik’s T/TR family shares variety of industrial and consumer apwhere precise repeatability and long life these key specs: plications. In addition, readily available are requirements. These sensors offer ICs, configurable ADCs and filter design • Repeatability to ±0.002 mm a proven solution for applications with tools can greatly simplify sensor design. • Stroke lengths from 10 to 150 mm
Accuracy Is Nothing Without Repeatability
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alignment errors. T/TR position sensors are available with a return spring too for use in auto-retraction systems.
• Long life of >100 million movements • Linearity to ±0.075% • Plug or cable connection
For complete information on T/TR sensors visit www.novotechnik.com/ttr Novotechnik U.S., Inc. 155 Northboro Road • Southborough, MA 01772 Telephone: 508-485-2244 Fax: 508-485-2430
S10 SENSORS/ M A C HI NE VI S I O N / A S U P P L E M E N T T O D E S IG N NE WS MAY 2009
Aaron GL Podbelski is a project manager at Cypress Semiconductor. He manages several of the company’s PSoC products and focuses on marketing the PSoC’s analog capabilities toward customers utilizing sensors. He has a BS in computer engineering from Marquette University in Milwaukee, WI. [www.d esignnews .com]
Sensors/Machine Vision
ADVERTORIAL
IN THE MARKETPLACE BANNER’S IVU SERIES TG IMAGE SENSOR Does not require a PC to configure, change or monitor Banner Engineering’s iVu Series TG Image Sensor brings the simplicity of a photoelectric sensor and the intelligence of a vision sensor together to provide inspection solutions that can be applied and supported right on the factory floor. With three advanced sensors in one rugged package, it is easily configurable and has advanced capabilities, including menu-driven tools for guidance through inspection. The image sensor’s intuitive interface and features make powerful inspection capabilities simple. Its compact, rugged housing is available with or without a variety of integrated ring lights (red, blue, green and infrared). Banner Engineering Corp. http://designnews.hotims.com/23103-511
ENDEVCO’S MODEL 7286, 7287 SENSORS With 4,000 Hz frequency response Endevco’s model 7286 and 7287 sensors offer performance certified to specifications for critical test applications requiring accuracy, reliability and low cost of ownership. They offer the ability to predict error budgets as a result of specification to “max” or “min” values and feature a full scale range of 2,000g; frequency response of 4,000 Hz with resonant frequency of 20,000 Hz; a small, lightweight configuration; and a rugged PVC-jacketed cable less than 2 mm in diameter. The 7286 operates on 2V dc and provides a maximum output of 10 mV full scale. The 7287 features input voltage of 10V dc and output sensitivity of 0.10 mV/g. Endevco Corp. http://designnews.hotims.com/23103-512 http://designnews.hotims.com/23103-513
NOVOTECHNIK’S RFC 4000 SERIES ROTARY SENSORS Programmable electrical range to 360 degrees, 12-bit resolution Built with a 1-inch² thumbprint and 7-mm profile, the two-part design of the RFC 4000 Series Rotary Sensors combines a sensor and its magnetic position marker to offer unlimited mechanical life. Touchless technology utilizes the orientation of a magnetic field to determine measurement angle and analog output signal used to represent calculated angle is repeatable to ±1 LSB. Unaffected by dust, dirt and moisture, the unit has a programmable electrical range to 360 degrees, 12-bit resolution and independent linearity to less than ±0.3 percent. Novotechnik U.S. Inc. http://designnews.hotims.com/23103-514
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Sensors/Machine Vision
CONTINUED, IN THE MARKETPLACE
ADVERTORIAL
KEYENCE’S CV-5000 VISION SYSTEM HIGH-SPEED IMAGE PROCESSING Ultra-high-definition image processing The 11x high-speed camera transfers ultra-high-definition, five megapixel images (2,432 x 2,050 pixels) in 61.2 ms (16.3 times/sec). High-speed production lines can now harness the benefits of high-precision image processing. The new CV-5000 Series accepts up to four, 5 million-pixel cameras and transfers the images simultaneously, allowing for high-definition inspections of up to 20 million pixels. Keyence Corp. http://designnews.hotims.com/23103-515
RDP’S D5/D6 AND GT SERIES OF MINIATURE LVDT DISPLACEMENT TRANSDUCERS Uses the Linear Variable Differential Transformer principle These transducers are for displacement/position measurement. They make an accurate position measurement of the movement of the armature (the sliding part) relative to the body of the displacement transducer. The transducers use the Linear Variable Differential Transformer (LVDT) principle which, according to the company, means it is probably the most robust and reliable position sensor type available. RDP Electrosense http://designnews.hotims.com/23103-516
Working Class Hero OMEGA’S FW1000 WEDGE FLOW METER Offers high accuracy, repeatability OMEGA’s FW1000 Series Flow Meter is a low-cost, minimally invasive series of wedge flow sensors. This unit offers high accuracy and repeatability with no required inlet or outlet straight plumbing. The design allows users to install the meter in any full-pipe orientation (horizontal, vertical or inverted) and the CE-compliant series is offered with several flow ranges to accommodate the typical requirements in process water applications. OMEGA ENGINEERING Inc. http://designnews.hotims.com/23103-517
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CONTINUED, IN THE MARKETPLACE
ADVERTORIAL
NOVOTECHNIK’S MAP 4000 SERIES MULTIFUNCTIONAL PROCESS MONITOR/CONTROLLER 䊳 Can perform up to 40 measurements/sec Novotechnik’s MAP 4000 Series features include programmable input selection and mathematical functions, as well as up to four limit switches and analog outputs. It can perform up to 40 measurements/sec. The MAP 4000 Series’ limit switches are programmable and operate via relays. They are also programmable for potentiometers, dc voltage, current/voltage, resistance and temperature sensors. Novotechnik U.S. Inc. http://designnews.hotims.com/23103-518
DECAWAVE’S SCENSOR IMPLEMENTED BY MICROSTRAIN INC. Collaboration working toward the realization of widespread sensing network MicroStrain’s sensors are used in a wide range of applications, including knee/spine implants, bridges, unmanned vehicles, heavy machinery, fixed-wing aircraft and helicopters. The wireless nature of many of these applications necessitates ultra-low-power and energy harvesting. DecaWave’s ScenSor offers an ultra-low complexity coherent receiver, simultaneously giving MicroStrain the benefits of superior range at ultra-low-power consumption. MicroStrain Inc./DecaWave http://designnews.hotims.com/23103-519 http://designnews.hotims.com/23103-520
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A Vision of Durability Endurance™ vision cable assemblies are engineered with advanced, industrialgrade connectors and cables. These rugged assemblies provide ultrareliable interconnectivity in motion and vision system applications. Endurance vision products include: • CCXC Analog Camera • MVC-800 FireWire • GEV-1000™ GigE Vision™ • Camera Link® Stock cable assemblies can be purchased direct from Northwire. All are shipped fast, straight from the factory with no minimum quantity. © 2009 Northwire, Inc. All rights reserved.
+1 715-294-2121 • 1-800-468-1516 www.northwire.com/dnv S14 SENSORS/ M A C HI NE VI S I O N / A S U P P L E M E N T T O D E S IG N NE WS MAY 2009
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Sensors/Machine Vision
Q&A
Industrial Sensors Solve Cost Problems The right sensor involves more than simply a lower price BY RANDY FRANK, CONTRIBUTING EDITOR
Just like everything else these days, industrial sensor suppliers and their customers have to cope with the current economic conditions. Honeywell Sensing and Control’s Brad Kautzer provides insight into what it takes to continue to be successful, in spite of challenging times. What kinds of trends do you see today in industrial sensing and what is Honeywell’s response? The biggest trend that we are seeing is our customers are clearly looking for cost savings. We are trying to address that in a couple of areas. If you look at where our products have been applied and where we have success, it is where we drive three things. It’s productivity. It’s improved maintenance cost and improved safety. Brad Kautzer
What about simply providing a lower cost product? We can argue over the price of the switch. It may be a dollar or two cheaper by buying brand X versus brand Y, but it’s not what really allows our customers to see true cost savings. If you look at productivity, it’s how do we help make our customers more productive, especially now. It has to do with how we apply the right product over a life cycle of an application to both lower the installed cost, but also to work at that next level of performance. That’s the main thing. Productivity is clearly something where we can help our customers. Productivity was the first of the three areas. What about the other two? The second one is how do we improve or reduce maintenance cost challenges? Customers are looking to take cost out of their operation and how can we utilize sensors to do that, either manual versus automated or productivity related to just doing something better, more efficiently.
The third is safety, and this is more than just putting a device in to meet a compliance requirement. It’s really to reduce liability and doing that in a way that saves on the human cost side of things, but also without affecting machine uptime. We have examples where we are utilizing a safety guarding device that allows the machine to have greater uptime while also increasing the safety protection of the machine. So those are three of the areas that when you look at the real strong focus on cost, it’s going beyond that commodity cost game into true operational productivity or performance. Can you provide an example? We have a range of safety devices, safety switches, where we provide the compliance piece of safety, but we are also able to impact the machine uptime. Or, if you look at total installed cost, we can impact not only providing that switch to cover miles of conveyors, but also how you maintain it and the machine uptime associated with that product. What we try to have with our customers is those kinds of discussions so you’re looking at more than just the component, but the effect the component has in your applications. Is this a major transition that is occurring? I see the world changing in a significant way. The easy stuff has been done. Purchasing managers are good at finding a low-cost product to procure. The product (that addresses) productivity, safety and cost is really what they are looking for. Brad Kautzer is vice president and general manager of Honeywell Sensing and Control’s electromechanical line of business within the Honeywell Automation and Control Solutions group. FOR MORE
information
S E N S OR S
Honeywell Sensing and Control: http://designnews.hotims.com/23103-510
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green
Scene
Environmental news engineers can use
BY ROB SPIEGEL, CONTRIBUTING EDITOR
2010 Mazda Is an Eco-Car
LEAD-FREE
Zone
Come to the Lead-Free Zone blog for answers and updates and to exchange ideas with RoHS expert Rob Spiegel at www.design news.com/Lead FreeZoneBlog
Mazda Motor Corp. of Ircadmium have also been vine, CA recently debuted eliminated from the bill the 2010 Mazda3, a fiveof materials. door sedan that offers high The carmaker says tolgas mileage and numerous uene emissions from a environmental features. The new joint sealing comfour-speed automatic transpound are 90 percent mission was switched to a lower and recyclable materials are now 90 perfive-speed and subtle aero- The 2010 Mazda3 is eco-friendly. cent, up from 80 percent dynamic improvements in earlier models. Molded plastic parts are were made to gain a 10 percent mile-per-gallabeled with ISO identification to facilitate lon improvement. The vehicle also consumes sorting and recycling. Fascias, interior trim fewer hazardous materials in manufacturing. and the instrument panel are made of polyThere is no lead in its fuel tank, wiring harness propylene for simple reuse. or undercoating. Hexavalent chromium and
Haan Floor Sanitizer Is Chemical Free The Haan Corp. of Lancaster, PA has released its FS-20 Steam Cleaning Floor Sanitizer, which was designed to use only steam — no chemicals — to destroy germs and allergens. The sanitizer can be used on any sealed floor surface, including hardwood, laminate, vinyl, ceramic, linoleum, marble, slate and on soft surfaces such as carpets and mattresses. The simple Haan’s steam technology for the appliance cleaner does not is based on ancient cleaning use chemicals. solutions. The idea came from Romi Haan, a Korean woman. “For 2,000 years, the Korean ondol culture has revolved around heated floors and a central room for eating, sleeping and gathering. As a result, homemakers must clean their floors several
times a day,” she says. “I knew there had to be a better alternative to the standard mop and pail, so I set about finding a solution.” After three years of development, Haan brought her first floor sanitizer to market. That evolved into the Haan FS-20. By emitting steam at 212F, the sanitizer kills germs and allergens, including dust mites, E. coli and salmonella bacterium.
China’s Sun Group Develops Li-Ion Battery The China-based Sun Group High-Tech Co. has developed a new product, lithium iron phosphate, which was designed to be used as an anode material for the production of newgeneration lithium-ion (Li-ion) batteries. The company is currently procuring and preparing production equipment for lithium iron phosphate and plans to set up two new production lines with capacities of 500 tons per year. The product was introduced to the global electric auto market in March.
D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 1 7
FLASH
NEW AND NOTABLE PRODUCT DESIGN
By Terry Costlow, contributing editor
Sensors are radically transforming entertainment. They measure snowboard leaps, lighten couch potatoes’ workloads and bring accordions into the 21st century. SNOWBOARDING MADE SIMPLER Ski jumps and half-pipe alley-oops are getting easier. Or at least measuring them is. Microsport’s Airtime Sensor measures the quantity and duration of snowboarders’ and skiers’ jumps. An elastic strap holds the Airtime Sensor on your thigh so it’s easy to see the backlit display. It uses an Analog Devices’ ADXL322 accelerometer, which has enough resolution to measure the jump duration to within ¹/ı₀₀ of a second. The sensor also stores an airtime history of the last 15 jumps, as well as trip and daily airtime. http://designnews.hotims.com/23105-511
MAKING TV VIEWING EASIER
Searching for the TV remote may become a thing of the past. Hitachi is promoting a prototype television that can be controlled by open-air hand gestures. A rapid wave will power up the set and a circular motion will change the channel. The technology understands both single- and twohand gestures, providing a broad range of commands. A small 3-D sensor from Canesta Inc. can watch people as far away as 9 ft, regardless of room décor or lighting. The imaging sensor can tell the difference between a human hand and a sweatshirt or photograph with images of life-size hands. http://designnews.hotims.com/23105-512
BRINGING ACCORDIONS INTO THE 20TH CENTURY Accordion players can now get all the flexibility of an electronic instrument without sacrificing acoustic accordion sounds. Roland Corp.’s V-Accordion reproduces accordion tones with sensors and digital devices. The virtual accordion does not alter the way components, like the bellows, are used. However, air pumped by the bellows no longer excites reeds. Instead, it drives a pressure sensor from Freescale Semiconductor. Freescale highlighted its support for accordionists by sponsoring the V-Accordion Festival in Rome last year. http://designnews.hotims.com/23105-513
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The Adventure of the Insidious Buzz
BY JOHN LOUGHMILLER, CONTRIBUTING WRITER Have you applied your deductive reasoning and technical prowess to troubleshoot and solve an engineering mystery that even the fictional Sherlock would find most perplexing? Tell us about it in 600 words and we’ll pay you $100 if we publish your case. E-mail Karen Field at: kfield@reedbusiness.com
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Several years ago I worked for a company that manufactured professional grade videotape recorders used by television stations throughout the U.S. The recorders used an arrangement of four heads positioned every 90 degrees on a disk. A 2-inch-wide videotape was pulled past the rapidly rotating disk and each head recorded about 17 lines of video. The whole thing worked very well most of the time because the basic engineering was settled, having been around since 1956, albeit vastly improved by the 1980s when the problem described below occurred. One particular model used a vacuum loading system to position the tape in the transport and there were two transports, side-by-side. Used for playing commercials, the normal procedure was to initiate a dual transport load, shortly before the commercials were scheduled to play, via a large rotary storage drum that held 24 cassettes. Additional cassettes would be loaded as the preceding ones were played, rewound and placed back in the rotary drum. Late one afternoon, I was the senior engineer on duty providing telephone support and received a call from a station complaining that their machine would be happily playing a string of commercials and then suddenly stop in the middle of a sequence. When it stopped, it would ignore the rest of the sequence, rewind the two cassettes previously loaded in the transports and place them back in the drum. The problem only happened during the station’s six o’clock news program which was really bad because, like most TV stations, the newscast’s commercial slots were premium placements and the loss of an entire two minutes of commercials was a very bad thing. The station management was not happy, which meant the chief engineer was really unhappy and threatening to drop the VTR off his loading dock into the Dumpster. I poured over the logic diagrams trying to find some failure sequence that could cause such strange behavior but came up dry. The next day found me on an airplane
D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
and by 6 p.m. I was perched on a stool in front of the machine. The first commercial break went fine, but the next one dumped everything midway through the second cassette. There was no warning, it just dumped. Diagnostics found nothing wrong. The next day’s six o’clock newscast found me with a four-channel storage scope probing the logic bay and, once again, the machine dropped the sequence, this time a bit later in the newscast. Again, no clues were present. It was time to recalibrate my approach. The third day I positioned myself between Master Control and the room where the VTR lived. I could see both the person initiating the commercial playbacks and the machine. I watched closely as each playback was initiated. This time, the sequences played fine until the last one with the machine hiccupping at the precise moment a buzzer sounded indicating the arrival of the UPS man at the loading dock. Buzzer sound = machine dump. But why? As it turned out, the station personnel ran an unshielded twisted pair remote start cable from Master Control to the machine and placed it in the same cable tray with an equally unshielded twisted pair from a push button on the shipping dock to a high-intensity buzzer. The crosstalk between the two cables was enough to reach the machine’s logic circuits and trip the cancel function that shared a multi-function IC with the remote start function. Had I not gone outside of the VTR room and observed the machine dump when the buzzer sounded, I’d probably still be on site. John Loughmiller is the owner of Technical Support Group, a consulting company in Kentucky. Previously, he worked as an engineer for Ampex Corp., Sony Corp. and TV One Inc. A suspected Luddite and know curmudgeon, his spare time is spent terrifying hapless students who want to learn how to fly airplanes. You can reach him via our Sherlock Ohms blog comments at www.designnews.com/Sherlock.
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As Solid State Lighting (SSL) products move rapidly into our homes and offices, we find that some things are not as easy as they used to be. Specifically, I’m talking about controlling these HBLED (high-brightness LED) based lights with ordinary, off-the-shelf dimmers. For many years, if you wanted to add dimming capability to the incandescent lights in your living room ceiling, all that was required was a low-cost dimmer, fifteen minutes of time and a screwdriver. There are rotary, push button, programmable and extremely low-cost dimmers available everywhere. As you replace older lights with cleaner, “greener” HBLED lighting, it’s natural to expect the preexisting dimmers in your home to function just as well as they did before. However this is unlikely- at least with the first generation of HBLED luminaires. The problem actually lies in the dimmers themselves. Most inexpensive AC mains dimmers used in residential buildings are phase-controlled triac circuits. At each half-cycle zerocrossing of the AC mains input, a small variable delay is introduced. During that period, the output to the lamp is held off, and then switched on for the remainder of the halfcycle. As more delay is introduced, a smaller portion of the AC cycle is passed on to the lamp, and it grows dimmer. When you turn the dimmer’s knob, you are controlling the off-time period. This technique is often called leading-edge phase angle control. It can be a bit noisy.
or turn off suddenly as it is dimmed. This behavior is rarely seen with incandescent lights, since they present a significant resistive load during all portions of the cycle. But HBLEDs are a much smaller load. I have seen many HBLED driver circuits that claim to be dimmable, but only down to the last 20% or so, when they begin to flicker annoyingly. Even if the AC mains HBLED driver works well with one brand of phase-controlled dimmer, there is so much variability in these products, it is hard to predict the system’s behavior with another brand. Of course where there are problems, there are opportunities for innovation. In the last few months, a new generation of AC mains HBLED driver ICs have been introduced to eliminate the potential flickering caused by common phase-angle dimmers. One of them is the LM3445 from National Semiconductor. Essentially, their part allows the HBLED light to emulate an incandescent load. It monitors the cycle and switches in a resistor when needed to ensure the minimum load is always present. The LM3445 is a constant-current switching driver that operates directly off of line voltages from 80 to 270 VAC. It controls the current (and thus intensity) of a string of series-connected HBLEDs through pulse width modulation (PWM). In a switching mode driver circuit, the inductors are usually the largest physical components; their size is inversely proportional to the PWM switching frequency. Because the LM3445’s frequency is several hundred kilohertz, the complete circuit is very compact. It offers built-in thermal protection and even master-slave capability for dimming a series of HBLED luminaires. National Semiconductor has a small reference design available, pictured below.
Cary Eskow is director of LightSpeed, the solid state lighting and LED business unit of Avnet 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 illuminationfocused engineers called “Illumineers,” experienced
Figure 1 – Leading-edge phase angle control
in thermal, drive stage and
An improved technique uses the converse approach; after each zero-crossing, the output to the lamp is held on, and then switched off for the remainder of the period. This is called trailing-edge phase angle control. Trailing-edge designs are electrically “quieter” but are more expensive. Regardless of whether the dimmer is a leading or trailing edge type, they typically require a minimum lamp load during the entire cycle to operate properly. Depending on the dimmer’s design, that hold current might range from a few mA to over a hundred mA. The symptom of an undersized lamp load on these kinds of dimmers is quite noticeable- the light will start to flicker
optics design. Prior to LightSpeed, Cary was Avnet’s technical director and managed Avnet’s North American Figure 2 – Evaluation board for the LM3445 dimmable driver
The LM3445 data sheet and documentation on the reference design are on the LightSpeed website. If you have questions or comments on dimming or anything else related to HBLEDs, feel free to send me a note at LightSpeed@Avnet.com
FAE team. To submit questions or ideas, e-mail Cary at LightSpeed@Avnet.com
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 Jon Titus, a former designer and chief editor of EDN and Test & Measurement World magazines, remembers when “fast” signals operated at 10 MHz and programs came on
Keep an Eye on Vibration Phases THE PREVIOUS TIPS COLUMN, “INTERPRET ACCEL-
eration Data Several Ways,” (DN 04.09, http://designnews.hotims.com/23105-514), provided a brief introduction to accelerometers and how they provide useful acceleration, velocity and displacement information. Although you can integrate acceleration and velocity over time to yield velocity and displacement, you can also differentiate vibration information with respect to time. When you take that approach, you plainly see the phase relationships between these values.
paper tape. 1:3.0
Suppose you express the displacement caused by a vibration as:
1:3.0
1:2.5
1:2.5
1.2.0
1.2.0
1:1.5
1:1.5
+ _ 5%
1:1
1:1
1:-1:5
1:-1:5
Ratio of Input to Output
Natural Frequency
+ _ 3 dB 1:-2.0
1:-2.0
1
10
100
1000
10K
100K
Frequency (Hz)
Source: Honeywell Sensotec
An accelerometer’s useful frequency range covers the linear portion between end points measured in percent or decibels that note the variation from the 1-to-1 acceleration input-to-signal-output ratio.
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X = X0*sin(ƹ*t) where X0 equals the maximum displacement, ƹ represents the frequency in radians/sec and t equals a given time in seconds. If you differentiate this equation:
dX/dt = (X0*ƹ)*cos(ƹ*t) = velocity Then differentiate again to obtain acceleration: d2X/dt2 = (X0*ƹ2)*(-sin(ƹ*t)) = acceleration you see a 90-degree phase angle between velocity and acceleration (sine and cosine), and a 180-degree phase angle between displacement and acceleration (sine and -sine). When you use accelerometer information to track down problems in machinery, the problem you detect as a velocity or displacement value can be out of phase with the acceleration information. As a result, you might look for a problem at the wrong place or time. And during testing,
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you might draw incorrect conclusions unless you consider the phase relationships. An accelerometer has a useful frequency range over which its output is equally proportional (linear) to the acceleration, regardless of frequency, as shown on the graph at left. That range varies depending on the accelerometer’s construction and vendors specify the useful range in several ways. Typically, the range goes to the ±3 dB points on the frequency-response curve, but manufacturers could specify a percent instead. That spec, say ±5 or ±10 percent, refers to percentage difference between actual acceleration and the expected sensor output. An accelerometer’s natural frequency represents the frequency of the highest ratio disparity. Accelerometers also have a specific dynamic range, for example ±10g, over which the sensor will produce a linear output for the acceleration it experiences. Applying an acceleration outside this range will produce nonlinear results and may permanently damage the sensor element. Accelerometer construction and mounting techniques also affect performance — topics for another column. In the Freescale application note referenced in the April 2009 column, the author invoked the Nyquist limit and suggested engineers sample at a rate twice the frequency of the highest frequency present. Column readers should know to sample at a much higher rate. For More
REFERENCES
information
1. Accelerometer Glossary of Terms: http://designnews.hotims.com/23105-515 2. Endevco has many technical papers on vibration and shock measurements. (Registration required): http://designnews.hotims.com/23105-516 3. “Frequency Analysis in the Industrial Market Using Accelerometer Sensors,” AN3751, Freescale Semiconductor: http://designnews.hotims.com/23105-517
STAKE
AT
Visions for the Engineering Century
Fail Fast, Fail Early Lessons from the Skunk Works’® Frank Cappuccio
F
ailure is not an option — so the famous originally housed in a circus tent in Burbank, NASA saying goes. But is it really the right CA. From these humble and odorous beginperspective for us today? nings arose a powerful vision for engineering Just look around. We are starting to see the — one built on “speed, simplicity and cooperareal effects of our national fear of failure in techtion.” Kelly’s 14 rules for innovation have been nology innovation. Our bedrock companies are the cornerstone of the Skunk Works® for more than 65 years and have been emulated and studlosing their edge. Nowhere is this more evident ied for decades. than in the big three automotive companies The model behind the Skunk Works® who have ceded cutting-edge ideas to is more relevant to our country today our international competition. than ever before. While they are famous You hear the question often: What for their successes, the reality is that would our auto industry look like if it was they have achieved the extraordinary based in Silicon Valley? Yes, the notion of because of their willingness to fail. As guaranteed employment might be a thing Frank put it, they fail at least as often as of the past (isn’t it already), but would the they succeed. He says simply, “fail fast, relentless drive to innovate found in the valley have been able to thrive in a large Geoffrey C. Orsak fail early.” Unfortunately, as U.S. “big industry” engineering organization? As a nation we are all struggling to find ways has shown, we have become increasingly risk to deliver more innovation with smaller staffs, adverse. Blame the quarter-to-quarter reporting that drives company leaders or blame recent on much tighter time constraints. Seems like generations who have lacked big challenges. We a nearly impossible task — but let me share have seen the erosion of organizations willing to with you an example that has not only stood embrace failure as a necessity of innovation — the test of time, but “We have seen the thus creating the economy built on incrementalalso actually thrived ism. That is just not going to cut it in a world in nearly every ecoerosion of organizawhere a new breakthrough piece of technology, nomic environment. tions willing to emfrom an unknown team halfway around the The iconic Skunk brace failure as Works® has been kick- globe, can literally change everything overnight. a necessity of innova- ing out one innovation It might seem counterintuitive, but the folks tion — thus creating after another for 65 at the Skunk Works® have created an environthe economy built years. In fact, the head ment where you can “successfully fail.” This not of the Skunk Works®, only applies to advanced aircraft, but also to enon incrementalism.” Frank Cappuccio, who trepreneurism, education — you name it. is also executive vice president at Lockheed MarIf we are going to rebuild this economy tin, accepted the 2007 National Medal of Techthrough innovation and not bailouts, we must nology and Innovation from President Bush on become more “skunky” to launch ourselves behalf of the Skunk Works’® remarkable impact ahead of our global competition. on our country. We all fail, as organizations and individuals; We recently hosted Frank here at the SMU we just need to do it successfully. Lyle School of Engineering and he was generGeoffrey C. Orsak is dean of the Southern Methous enough to open the kimono on the Skunk odist University Lyle School of Engineering. He Works®. Founded in 1943 by the legendary can be reached at dean@lyle.smu.edu. Kelly Johnson, this top secret R&D shop was
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INSIDE NEWS 32
Electronics
34
Materials & Fastening
36
Design Tools
37
Automotive
TRENDS BREAKTHROUGHS DEVELOPMENTS
NEWS
» ELECTRONICS CASHING IN ON EUREKA MOMENTS NI’s Medical Device Grant Program provides $25K worth of software and services to companies that use NI products to develop medical innovations. Page 32
» MATERIALS THE NEW ALUMINUM Novelis’ Fusion is being used to construct one-piece door “inners” on some BMW models, giving the car a new level of corrosion resistance. Page 34
» DESIGN TOOLS CALLS ARE UNDER REVIEW AT CMU Researchers at Carnegie Mellon are designing a football and gloves employing sensors and 3-D tracking technology. Page 36
Festo’s robotic penguins are built out of flexible struts connected at their joints by a series of rings, allowing them to move in three dimensions. MOTION CONTROL
Festo’s Robotic Penguins Swim, Fly Flexible moves inspire new pick-and-place technology By Karen Auguston Field, editor-in-chief
» AUTOMOTIVE QNX CAR DRIVES DASHBOARD DESIGN QNX Software Systems’ QNX CAR enables automotive engineers to speed the design of a dashboard, which can be configured to provide directions and weather via the Internet. Page 37
As two giant electric-powered penguins glided gracefully by overhead, Marcus Fischer explained to me that the design group he heads up at Festo often takes its cue from nature when developing new technologies. No kidding. An animatronic super-arachnid. A robotic jellyfish. And now this year’s penguins. Two that fly and two that swim underwater (unless I missed some other acrobatics) reinforced once again that a visit to Festo’s booth at the Hannover Fair never fails to entertain. Researchers at this German automation company, says Fischer, were inspired by the anatomy of real penguins in their work on advanced motion systems. Although penguins cannot fly, they have wing surfaces that make for high efficiency when swimming. The seaworthy penguins sport wings of spring steel embedded in an elastic matrix of silicon, producing a sleek profile and the ability to twist to the most efficient pitch angle with each stroke. The flat, flexible wings of the airborne penguins are made of polyurethane foam and are suspended by a strut at the pivot point of the creature’s torso. But it’s more than flexible wings that give these birds their nearly unfettered freedom of motion. Their torsos are able to move flexibly in any direction because of specially designed head, neck and tail segments that mimic the tail fin of a fish. I grew up in Minnesota, D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 2 9
N EWS MO TIO N C O N T RO L , Co n t i n u e d
land of 10,000 lakes, so I know something about fish and the way they can flop around on a boat deck. Looking to mimic that motion, Festo engineers constructed the penguinsâ&#x20AC;&#x2122; key body parts out of flexible struts connected at their joints by a series of rings, allowing the structure to move in three dimensions. Continuous variable control of the wingâ&#x20AC;&#x2122;s digital actuators, along with advanced navigation and communication, allow the birds to explore their environments, either freely or within a defined motion profile. They can even swim backwards â&#x20AC;&#x201D; something even their natural counterparts cannot do. No doubt about it, the penguins wowed the crowd. But the real story for engineers is how Festo is extending the penguin technology to a form-fit gripping technology called the â&#x20AC;&#x153;BionicTripod.â&#x20AC;? Currently in the prototype stage, this futuristic
pick-and-place system is based on the same principles as the robotic penguinsâ&#x20AC;&#x2122; ultra-flexible anatomy, namely a series of lightweight, fiberglass rods and connecting links that form a tripod from which an adaptive gripping device is suspended. As the rods are manipulated, the tripod can be oriented in any direction within a 90-degree envelope, providing huge flexibility in pick-and-place applications. The gripper itself is made up of a pneumatic bellows and three fingers. Like the tripodâ&#x20AC;&#x2122;s design, each finger consists of two flexible bands that form a triangle with connecting links so it has a wide range of motion. The lightweight device is made of polyamide and is fabricated from the same selective laser sintering process used in rapid prototyping. Lower weight translates to a higher degree of energy efficiency. And, of course, there is the flexibility in motion.
â&#x20AC;&#x153;With this design, itâ&#x20AC;&#x2122;s possible to grasp objects of different forms and even fragile parts as the gripping fingers adapt to the partâ&#x20AC;&#x2122;s contours,â&#x20AC;? says Fischer. To wit, the company is currently embarking on an experimental project involving plant bulbs. This kind of field work will help Festo engineers optimize the technology and work out a cost structure for successful commercialization. As for whatâ&#x20AC;&#x2122;s in store for next year at the Hannover Fair, with Festoâ&#x20AC;&#x2122;s ongoing focus on speed and new innovations like its fast-switching valve terminals and integrated linear motors, Iâ&#x20AC;&#x2122;m guessing robotic cheetahs. Or possibly cockroaches. For More
MOTION
CONTROL
information
Video of Festoâ&#x20AC;&#x2122;s penguins: http://designnews.hotims.com/23105-518 Festoâ&#x20AC;&#x2122;s robotic jellyfish: http://designnews.hotims.com/23105-519 Hannover Fair: http://designnews.hotims.com/23105-520
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» ELECTRONICS
A Boost for Medical Device Developers National Instruments’ program provides $25,000 in software and services for medical innovation
By Charles J. Murray, senior technical editor, electronics
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Thanks to a renewed grant program from National Instruments (NI), medical device developers may now be able to find a new source of technical and financial support for their eureka moments. Known as the 2009 Medical Device Grant Program, it provides $25,000 worth of software and services to makers of medical systems that use, or intend to use, NI products. The products include NI’s graphical system design platform, known as LabVIEW, and CompactRio, its embedded control and data acquisition system. “As a company, we’re looking to support the technology phase of medical device development,” says P.J. Tanzillo, medical segment lead for NI. Indeed, NI has supported medical device development in the past. Last year, the giant virtual instrumentation company issued 21 of the grants, 17 to U.S.-based entities. Recipients included researchers at McGill University who created McSleepy, an automated anesthetic system for use by anesthesiologists during surgery. Other grant recipients from 2008 included KC Biomedix, creator of a “computerized pacifier” known as NTrainer, which helps premature babies learn oral feeding, and Kitasato University, which developed a cancer-detecting medical instrument using optical coherence tomography. National Instruments also awarded grants to such companies as Sanarus Medical, College Park Industries and OptiMedica for innovations ranging from data acquisition systems for amputees to laser systems that treat retinal diseases.
McSleepy, developed with software and tech support from National Instruments, automates the anesthesia process.
National Instruments’ engineers say many of the grants have gone to start-up companies, but they emphasize the program is open to engineering teams at large firms, as well. Moreover, they say the possibility of receiving such grants is good. “We have a committee that meets monthly to evaluate grant applications,” Tanzillo says. “And the acceptance rate — about 30 percent — is higher than most grants we’re aware of.” For More
ELECTRONICS
information
NI’s Medical Device Grant Program: http://designnews.hotims. com/23105-521 McGill University’s “McSleepy” automated anesthetic system: http://designnews.hotims. com/23105-522 KC Biomedix’s NTrainer: http://designnews.hotims. com/23105-523 How FPGAs will aid embedded design: http://designnews.hotims. com/23105-524
» MATERIALS
Rolled Aluminum Alloy Features Multiple Layers BMW uses Novelis Fusion for door inners to achieve a combination of formability, corrosion resistance
By Doug Smock, contributing editor, materials and fastening Aluminum is making significant gains among automotive engineers, who, in some cases, are using novel new materials. One notable example is the new BMW 7 Series, which features extensive use of conventional aluminum for the roof, doors, bonnet, side panels and some structural reinforcements. The car also uses one-piece door “inners” with integral window frames, employing a design that is not achievable with conventional aluminum sheet. The inners are made with a new multi-layer alloy called Novelis Fusion that can provide a unique combination of core properties and surface characteristics. Design benefits include both a high degree of formability and superior corrosion resistance — a combination that was not previously available. Novelis Fusion is based on a conventional direct chill (DC) mold that is modified in order to allow multiple metal streams to be cast into one single aluminum sheet ingot. High requirements for corrosion resistance and joining processes mean a perfect metallurgical bond between the
alloy layers helps eliminate the delaminating of the protection layer and corrosion creep. A new study by Ducker Worldwide, commissioned by The Aluminum Assn., says the percentage of aluminum in cars now averages 8.6 percent, an all-time high. That’s up from just 2 percent in 1970 and 5.1 percent in 1990. The use of aluminum in cars and light trucks is projected to be nearly 11 percent of curb weight by 2020. Globally, the amount of aluminum content for light vehicles is 7.8 percent of the average worldwide light vehicle curb weight of 3,185 lb in 2009. According to the study, growth in aluminum content is predicted to continue at a rate of 4 to 5 lb per vehicle per year and approach 300 lb per vehicle worldwide in 2020. For More
MATERIALS
information
Novelis’ Fusion: http://designnews.hotims. com/23105-525 New aluminum features multiple layers: http://designnews.hotims. com/23105-526 Source: Novelis
Novelis’ Fusion is a new multi-layer aluminum alloy that provides better corrosion resistance. One-piece door “inners” integrate window frames with unique design.
» DESIGN TOOLS
Smart Football Automates Ref Calls Sensors, wireless protocols, 3-D animation software help track the ball in real time
By Beth Stackpole, contributing editor, design tools What football fan hasn’t, at one time or another, wanted to throw something through the TV screen when a referee miscalled a play that cost their team the game. Priya Narasimhan, a die-hard Pittsburgh Steelers fan, put her frustrations to good use. The associate professor at Carnegie Mellon University’s Electrical and Computer Engineering Dept. and 15 undergraduate students are immersed in a series of research projects to design a smart football that would deliver enhanced, realtime tracking and motion analysis. The goal — to eliminate ambiguities that result in decisions that adversely impact the outcome of the game. The “Myron” smart football project uses a combination of sensors, wireless protocols, embedded devices and 3-D software to track the football in real time, even when it’s obscured under a pile of players. Unlike other sports that employ camera
systems to track ball movement, football is unique in that it’s not always clear who has possession of the ball or if the ball was caught before it actually hit the ground. “You need to have the ball talk back to you to see where it landed,” Narasimhan says. Currently, CMU’s smart football leverages touch sensors, GPS receivers and accelerometers to do just that. Using measurements like trajectory and acceleration, the smart football calculates its position and Zigbee wireless communications capabilities relay that information to a computer, where it can be tracked and visualized using a homegrown animation and 3-D visualization engine. The Myron smart football project is still in the research stage, but Narasimhan’s engineering team is planning to launch pilot tests this fall with Carnegie Mellon’s own Tartans Div. 3 football team. The team is also working on smart gloves that employ
The “Myron” smart football and gloves employ a combination of sensors, wireless protocols and 3-D tracking technology.
similar technology to determine, for example, exactly how someone caught a ball, facts that could come in handy on calls related to control versus possession. Both the smart ball and smart gloves have training applications, as well, helping coaches and individuals assess their performance. For More
DESIGN
TOOLS
information
Carnegie Mellon’s “Myron” smart football: http://designnews.hotims.com/23105-527 Video of how the smart football and gloves work: http://designnews.hotims.com/23105-528 Fox Sports’ “Sport Science” puts athletic performance in engineering terms: http://designnews.hotims.com/23105-529
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» AUTOMOTIVE
New Platform Speeds Dashboard Design QNX CAR simplifies creation of infotainment systems, instrument clusters
By Charles J. Murray, senior technical editor, electronics QNX Software Systems has rolled out a pre-integrated hardware-and-software platform aimed at helping tier-one suppliers develop automotive instrument clusters and infotainment systems. Known as QNX CAR, the new platform was created to enable design engineers to save development time and differentiate their dashboard products more effectively. The company’s executives say QNX CAR provides the technical expertise needed to do the low-level software and silicon integration, thereby freeing up automotive engineers to concentrate on product features. “We are shipping a hardware platform to the car companies and tier-ones that’s already pre-integrated and working,” says Andrew Poliak, automotive business manager for QNX, a maker of embedded operating systems. “The reason we’re providing this platform is that we thought through the experience from the point of view of a car company. Some of their developers know certain software tools but they don’t necessarily know C or C++.” QNX executives say the new product includes a connected application platform, sample applications and reference implementations. The application platform includes integrations with consumer devices, music management systems, Internet radio, Bluetooth and other third-party technologies. On its website, QNX says it has at least 10 participants in the QNX CAR program, including such industry heavyweights as Daimler, GM, Microsoft, Volkswagen, Adobe and Apple, among others. “It makes it easy to develop the instrumentation for rendering the gages and needles for the speedometer and tachometer,” Poliak says. “We’re trying to enable the tier-ones to really show what they can do in terms of innovation.” For More
Using QNX CAR, dashboards can be configured by design engineers to provide directions and weather via the Internet.
AUTOMOTIVE
information
Video demonstration of QNX CAR: http://designnews.hotims.com/23105-530 QNX CAR: http://designnews.hotims.com/23105-531 For more automotive news, go to: http://designnews.hotims.com/23105-532
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LEDS
TREND WATCH//ELECTRONICS
Better Control for LEDs
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New chips endow LEDs with greater efficiency and improved performance BY CHARLES J. MURRAY, SENIOR TECHNICAL EDITOR, ELECTRONICS
TI’S
POWER MANAGEMENT CHIPS BOOST LED EFFICIENCY
Unlike incandescent bulbs, light-emitting diodes (LEDs) often need dedicated controllers (MCUs) and power management ICs. Without them, engineers say maintaining the quality, intensity, uniformity and efficiency of LED lighting would be difficult or impossible. “If you’re talking about high-quality light and tunable color, then you need control,” says Lance Zheng, applications manager for NEC Electronics America’s Multi-Purpose Microcontroller Group. Control happens in a number of ways. Light intensity is a function of current, color is a function of mixing and controlling multiple channels of lights. MCUs provide control in both those areas. New power management ICs, meanwhile, enable engineers to create LED-based systems with greater power efficiency. Using such products enables the development of a variety of applications, ranging from signage and ambient light systems to automotive headlights and medical devices. Here, we’ve collected recently introduced controllers and power management devices from National Semiconductor, NEC Electronics Corp. and Texas Instruments, all of which are aimed at building high-quality LED systems.
Texas Instruments’ three new power management chips are targeted at increasing efficiency, voltage and output current in LED designs. The new products include a high-power dc/dc boost LED driver (TPS61500), a high-voltage dc/dc boost converter (TPS61175) and an expanded dc/dc converter series (TPS62110). The devices can support input voltages of up to 18V and offer smaller voltage references for improved LED circuit design. The three devices work across a variety of LED applications, including signage, ambient light, office light, general illumination, military, medical and sensors. http://designnews.hotims.com/23105-533 http://designnews.hotims.com/23105-534 http://designnews.hotims.com/23105-535
NATIONAL SEMICONDUCTOR’S TRIAC DIMMABLE LED DRIVER
National Semiconductor’s LM3445 is a constant-current controller that enables offline uniform flicker-free dimming of high-brightness LEDs with a conventional TRIAC (Triode for Alternating Current) wall dimmer. That’s significant because TRIAC wall dimmers are designed to interface with resistive loads, such as incandescent or halogen light bulbs, and typically do not yield optimum performance with LEDs. The LM3445; however, provides a full 100:1 range of dimming capability and can maintain more than 1A of constant current to large strings of LEDs in a variety of residential, architectural, commercial and industrial applications. National Semiconductor says the LM3445 also maximizes light output for systems while maintaining ENERGY STAR® power factor requirements. http://designnews.hotims.com/23105-536
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NEC ELECTRONICS’ 8-BIT MCU LINEUP FOR LEDS NEC Electronics’ new 8-bit, All Flash MCUs are designed for energy-efficient fluorescent and LED lighting devices. The family of devices is targeted at reducing energy costs for users by providing a more advanced form of control than would be available from a dedicated IC. The lowpower 78KO/Ix2 devices incorporate two, 16-bit timers with high-speed pulsewidth modulation (PWM) output, three channels of internal comparators, a one-channel operational amplifier with programmable gains and an extended operating temperature range of -40 to 105C. The 14-device lineup includes 78KO/IY2 MCUs in 16-pin packages, 78KO/IA2 MCUs in 20-pin packages and 78KO/ IB2 MCUs in 30-pin packages. http://designnews.hotims.com/23105-537
TREND WATCH//MATERIALS
PLASTICS High-End Thermoplastic Tackles Toughest Jobs New grades target medical applications BY DOUG SMOCK, CONTRIBUTING EDITOR, MATERIALS AND FASTENING
MACHINED SHAPES ARE IMPLANTABLE
PEEK (polyetheretherketone) polymers are carving out niches to replace metals in a variety of applications, particularly medical. A semicrystalline thermoplastic, with excellent mechanical and chemical resistance properties at high temperatures, PEEK is used to make bearings, piston parts, pumps, compressor plate valves and cable insulation. It’s one of the few plastics compatible with ultrahigh vacuum applications. “This material greatly improves the life span of sealing elements in the valve,” says Tim Bremner, vice president of materials technology at Hoerbiger Corp., explaining the selection of PEEK for a new application. “There is a dramatic increase in overall reliability and high-temperature performance when compared to other commonly used valve plate materials.”
Stock shapes made of Zeniva PEEK from Solvay Advanced Polymers offer a combination of broad chemical resistance, high strength, stiffness, excellent toughness and fatigue resistance. They are aimed at close tolerance machining of finished components and for prototypes used in injection-molding applications. PEEK is one of four polymers comprising the company’s family of biomaterials being offered for use in implantable medical devices. They comply with ISO 13485 manufacturing and meet current Good Manufacturing Practices (GMP). http://designnews.hotims.com/23105-538
CFRP PEEK MAKES A TOUGH VALVE
Hoerbiger Corp., the world’s largest independent compressor valve manufacturer, is using low-flow, carbon-fiber-reinforced PEEK compound from RTP Co. to create a tough compressor valve plate with high thermal and dimensional stability. Tim Bremner, vice president of materials technology at the OEM, says: “Valve plate materials must provide a high degree of physical strength, while maintaining high impact and cyclic fatigue resistance. In many instances, compressor plates compress highly acidic or caustic gas streams, posing serious challenges for the chemical compatibility of the valve plate material.” The primary benefit of the PEEK compound is the high flexural modulus achieved through the careful incorporation of carbon fiber into the resin matrix during compounding. http://designnews.hotims.com/23105-539
NEW SERIES TARGETS MEDICAL
A combination of mechanical properties and excellent resistances with biocompatibility are creating options for Vestakeep aromatic PEEK polymers in medical applications. A new medical series from Evonik is described as suitable for short-term body contact. The series includes a medium-viscosity grade, a high-viscosity compound and a powder grade. Engineers often specify PEEK as an inexpensive alternative to metals and other materials. PEEK is resistant to gamma rays or X-rays, and offers X-ray transparency. Target applications include surgical instruments and endoscopes. http://designnews.hotims.com/23105-540 40
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COVER STORY
New developments in CAD, digital manufacturing and materials could create a huge breadth of design opportunities
Make Your Own
SHOES
Materials tests at New Balance simulate running conditions.
SOMEDAY A JOGGER MAY WALK INTO A SHOE STORE, PICK OUT A STYLE, AND THEN ORDER SPECIFIC
STORY_DOUG SMOCK, CONTRIBUTING EDITOR, MATERIALS AND FASTENING
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soles and other shoe components based on their weight, running style and other factors. There’s an emerging convergence of computer-aided design, digital manufacturing and materials technology that may be bringing very personal athletic shoes closer to reality. A close look at advanced product engineering at New Balance Athletic Shoe Co. in Boston, MA, gives some insight into why. A single shoe sole may have 1,300 features, requiring a like number of molds and dies. Some sole designs may contain up to 1,800 features. “The complexity at New Balance is due, in part, to the large number of sizes for each shoe, thanks in part, to an insight to offer wide sizes,” says Sean Murphy, manager of advanced product engineering. New Balance is unusual among shoe manufacturers in offering the majority of its shoes in a wide range of widths. For example, men’s sizes range from six to 20 with a width range of 2A to 6E. Styles include: running, walking, tennis, training, basketball, sandals and cleated. “For the 993 (a men’s running shoe with a blown rubber outsole), we offer 156 unique
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There’s an emerging convergence of computer-aided design, digital manufacturing and materials technology that may be bringing very personal athletic shoes closer to reality. sizes,” says Matt Dunbar, senior CAD designer for New Balance. “Even infant sizes are offered in wide and narrow.” That’s when it gets interesting because molds and dies are produced for every unique size. What’s even more interesting is that New Balance cuts steel molds even for prototype parts. “We have rapid prototyping equipment, but they are used more for look and feel prototypes,” says Dunbar. Look and feel doesn’t cut it for athletic shoe prototype testing. To say they take a pounding would be an understatement. In a “smash lab” in the basement below a shoe manufacturing plant in Lawrence, MA, a jig built on a Z Corp. rapid prototyping machine pounds into a prototype shoe sole hundreds of times to test the material’s performance. The MTS System is capable of replicating the exact force pattern applied by athletes over the course of a marathon to a shoe in 15 min. Based on a hypothetical 95 right foot strokes per minute, the winner of the 2008 Boston Marathon would have had more than 12,000 right foot strikes. But it took Robert K. Cheruiyot of Kenya 2:07:46 to finish the race. And it’s more than just materials performance. “On some of these we will design the cushioning for runners that land on the heel. For others we will test a design where the runner may land farther forward, and possibly even roll in from the side as their foot lands,” says Pedro Rodrigues, one of the experts in biomechanics who runs New Balances’ brand-new $2 million Sports Research lab in the basement of the former mill building located next to the Merrimack River. Also at the 3,000 sq ft testing center is a Qualisys motion capture system capable of analyzing movement quantitatively or qualitatively at more than 1,000 pictures per sec. Separate sensors detect exactly what’s happening with various muscles from a runner’s thighs to his feet. Other sensors detect Photo: Steve Edson pressure on the soles of the foot, as well as temperatures in the shoes. Prototype shoes are also tested in the field by runners who send shoes into the lab for testing. Other tests measure how the prototypes perform for players in various sports, such as basketball and tennis. At any given time, some 10,000 pairs of shoes are being tested for periods averaging about six weeks. Another piece of equipment in the lab is a glass-top Kistler Force Plate capable of analyzing forces athletes apply to the ground in all directions, while a camera captures foot landing on a plate from below. The number of molds and dies cut just for prototype purposes is mind blowing. More than 1,000 for a single shoe sole? It’s possible because New Balance uses tool builders in China, and tools aren’t built for large part runs like they are for most injection molded parts. A single tool
may only need to produce a few thousand parts. And the prototype tools aren’t built with a lot of bells and whistles, or even cooling for that matter. Murphy attended a mold cost estimating program at nearby UMass Lowell’s Plastics Education Dept. recently, and laughingly recalled the high numbers being discussed for tools, like $150,000 and up. New Balance pays a very small fraction of that for its prototype tools. The New Balance system clearly works and its approach to shoes is a winning model. New Balance is one of the largest suppliers of sports footwear in the world, with global sales of $1.63 billion in fiscal 2007. But it doesn’t run with the pack in many important respects. According to Reuters, Nike spent $260 million on sponsorships last year. The Adidas Group, which includes Reebok, spent $90 million sponsoring the Beijing Olympics last year. New Balance eschews expensive sponsorship programs. New Balance also makes a different mark through a substantial U.S. manufacturing presence, even though much of the manufacturing and materials technology has migrated to the Far East. The New Balance World Design Center is located in Lawrence, MA, and also features shoe manufacturing. Other manufacturing plants are located in Norway, ME, Skowhegan, ME and Norridgewock, ME. The company was founded in 1903 in Boston by an English immigrant named William J. Riley. Shoes don’t have jazzy names, just numbers like the 1500 and the 1306. The strategy helps gives the feel of an old-fashioned company that puts emphasis on products and good engineering. Next Step: Direct Digital Manufacturing
One of the hottest areas of technology development that could impact design and manufacturing at a company, such as New Balance, is direct digital manufacturing. It’s based on the idea that you can develop short run parts with complex designs using additive fabrication technology that work directly from CAD files. As Murphy and Dunbar indicate, New Balance has significant complexity in its shoe sole designs alone. Murphy was asked if New Balance considered using the approach as an alternative to making short-run steel molds. To date, it wasn’t part of the New Balance plan. And given the deals in China today, maybe the economics aren’t quite there yet. But they soon may be. At least Engineers are that’s the impression finding materials given by execucapabilities are tives at
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rapidly expanding for prototyping materials. One new grade offered by Z Corp. is elastomeric. Source: Z Corp.
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COVER STORY companies that make the equipment and the materials. The capabilities of the equipment rise exponentially almost yearly. And the big-name players in the materials’ business are getting interested, developing special grades for the technology. Consider this:
• Ultem 9085 polether imide can now be used to make production parts on Stratasys additive fabrication equipment. • PEEK from Victrex is being used on EOS laser sintering
New Balance Takes off with 3-D CAD To accommodate the complexity of organic shapes, SolidWorks’ models can have up to 3,000 features By Beth Stackpole, contributing editor, design tools
T
hink about a running shoe and the construction seems pretty basic — there’s the upper part, complete with laces, the side walls and, of course, the rubber sole. Building a 3-D CAD model of this configuration has to be a far simpler task, as conventional wisdom would have it, than creating a similar 3-D model for a complex engine or machine part. Well, that’s not necessarily the case. New Balance, which had global sales of $1.63 billion in fiscal 2007, can have anywhere from 500 to 3,000 features in a single 3-D model, and that’s mostly to accommodate the rubber sole on the bottom of its athletic shoes. A typical CAD model, which New Balance produces in SolidWorks, has anywhere from 1,300 to 1,800 features — a striking number, due to the increasingly complex nature of today’s footwear designs. “No one is really doing a single SolidWorks’ part file that has anywhere close to that many features,” says Matt Dunbar, senior CAD designer for New Balance’s Advanced Products Div. “Even though there are only a few components in a shoe sole, they are really organic shapes and that means a high level of complexity.” The growing complexity in footwear design and the need for faster turnaround pushed New Balance to move from 2-D design to 3-D CAD design nearly eight years ago. Prior to using SolidWorks, it could take up to 15 days to create a 2-D drawing of a shoe design. Today, with 3-D CAD, that same process takes about five days. “Given the complexity of modern shoe soles, 2-D CAD is not an option,” Dunbar says. “2-D data would have so many cross sections that it wouldn’t be practical.”
systems. • Players can design unique creatures using the Sprue Creature Creator on the Internet. The creatures are then produced on Z Corp. systems for $49.95 and shipped to the customers. “As all of us get better and better, there is a blending in this whole industry between what is a concept model and what is a production part,” says Scott Harmon, vice president of business development at Z Corp., Burlington, MA. Z Corp. is a good C ONTI NU ED ON PAGE 4 6
SolidWorks’ 3-D model, Dunbar says. For example, consider the bottom of a typical running shoe sole, which has dozens, maybe hundreds, of little lugs. Each lug might be made up of five to 20 features and the lug sizes will vary, depending on where they are located on the shoe. This variability adds to the difficulty of using 3-D CAD, Dunbar says, because his team can’t take advantage of patterning or other capabilities offered by parametric 3-D modeling programs like SolidWorks. “It’s difficult to use patterning, not just because 3-D patterning tools could use some work, but because each of these lugs is not identical, on purpose,” he says. The feature tree adds another layer of complexity. If you have a feature tree with 1,300 features, and you need to make a change to feature 12, you could be asking for trouble. “You have to hope the software can rebuild the other features and maintain some relationship to the original underlying surfaces,” Dunbar says. In addition to SolidWorks, New Balance employs Rhino, which is more of a free-form 3-D modeler, to handle some of the more difficult organic shapes. For instance, Rhino is better suited for modeling the “stability web” area of the shoe, which is the raised area under the arch. “It’s more in tune with doing an organic shape like that because you don’t have to worry about the history tree,” Dunbar says.
Taking Shape One of the primary challenges to building a shoe sole in CAD has to do with organic shapes. Companies like New Balance are continually pushing the envelope in terms of shape and construction as a means of creating visual interest in their shoes in addition to the features that enhance performance. “Twenty to 30 years ago, athletic shoe soles were straight walls and a die-cut piece of foam cemented to the upper with a slab of rubber,” Dunbar says. “That design has progressed with the evolution of 3-D CAD and CAM. Now we can model and mill all these organic shapes to add value.” Because there are few flat surfaces with today’s designs, the organic shapes mean little tiny features, many of which To accommodate dozens, sometimes hundreds, of lugs, different slopes aren’t noticeable to the untrained eye. Closers, differand other organic shapes, the average New Balance shoe sole is creent slopes and countless nooks and crannies are what ated in a SolidWorks part file that can have up to 3,000 features. constitute the different features in a typical New Balance
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COVER STORY case in point. Its building block material for prototypes is an engineered plaster with numerous propriEngineers at Reebok use etary additives that encolors on rapid sole prototypes hance surface finish. The to achieve more realistic models material provides high for evaluation. strength, but virtually no flexural modulus. But Z Corp. has also developed an elastomeric material that offers rubbery properties like those required for shoe soles. In fact, virtually all of the major athletic shoe companies use Z machines, as well Source: Z Corp. as other prototyping equipment, but just for aesthetic prototypes. The elastomeric material allows creation of shoe soles for look and feel before committing to a steel mold. The fabrication process is interesting. A bed of material is placed on a build table, but a cellulosic material replaces the plaster. Also included are specialty fibers and additives. An inkjet printer head, directed by a CAD file, then prints a binder on the material creating the cross sectional area for the first, or bottom, slice. A piston then lowers the build platform 0.1016 mm (0.004 inch) and a new layer of powder is spread on top. The printhead then starts applying binder for the next cross section, which adheres to the first and so on. The printing process creates an exact physical model of the CAD geometry. The Z printers typically build 1 to 2 inches per hour. Z machines also print in color. Binders are typically made of water. For the elastomeric material, the parts are moved to an adjacent infiltration chamber, where a two-part reactive system is applied. The resin infiltrates the model, consuming the cellulosic compound. The standard zp131 powder with functional infiltrant will produce parts with the following characteristics: tensile strength = 24MPa, flexural strength = 43MPa, flexural modulus = 10,400MPa, shore hardness = 87D and compressive strength = 98MPa. “With the elastomeric zp15e powder and a flexible infiltrant, you can get a range of performance depending on the exact urethane product you use to infuse the parts,” says Joe Titlow, director of product management at Z Corp. “A shore hardness range of 20A to 70A is achievable, typically with 100-200 percent elongation.” Urethanes from Pathway Partners are often used. Is it ready for prime time as a production material? “We’re not up to their requirements for finished parts yet,” says Titlow. There’s another way to skin the cat though. Titlow says it’s possible to make molds for parts such as shoe soles from the Z process using the plaster-like materials. Then short-run prototypes can be shot in low-pressure equipment that simulates injection molding machinery. No one is in production on that type of process, but tests are underway at undisclosed locations. 46
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“This is the real bleeding edge of where this type of technology is being used,” says Titlow. The key material for athletic shoe soles is thermoplastic polyurethane. There are several important product lines such as Estane (Lubrizol), Elastallon (BASF), and Desmopan, Texin and Utechllan (Bayer MaterialScience). Dow sold its TPU business to Lubrizol in January. BASF has been partnering with Adidas to develop an improved cooling effect through use of fine-mesh ventilation panels. A special TPU insole performs like a fan, reducing heat generation by 20 percent while fine membranes allow any moisture build-up to escape. Another trend for athletic footwear is the use of different TPUs in the same part, such as a shoe sole, through a co-molding or other assembly process. “Engineers now have more flexibility in design,” says Tim Jacobs, NAFTA TPU market channel manger for Bayer MaterialScience. For example, there are new grades of Texin TPU that have a very high modulus that can be mated with soft grades. The stiffer material forms the structural backbone, while the softer material provides cushioning. Some of the co-molded parts even use micro sections that can be soft or hard, depending on the requirement. “Engineers are also pushing the envelope to find material that is as soft and clear as possible,” says Jacobs. A new Utechllan grade, for example, is transparent even in a 100 mm section used for testing. None of the sources contacted by Design News; however, see development of a TPU for direct digital manufacturing on the near-term horizon. However, considering the complexity of sole designs, relatively short product life and huge range of prototype tools required, it just may be coming some day. For More
information
New Balance Athletic Shoe Co.: http://designnews.hotims.com/23105-541 Z Corp.: http://designnews.hotims.com/23105-542 Qualisys motion capture system: http://designnews.hotims.com/23105-543 Kistler Force Plate: http://designnews.hotims.com/23105-544 Video of Matt Dunbar describing the wide variety of design iterations for shoe soles: http://designnews.hotims.com/23105-545
MEDICAL TECHNOLOGY
Semiconductors: The Heart of NEXT-GENERATION
Medical Devices Highly integrated chips are paving the way for smaller, more portable equipment BY PATRICK O’DOHERTY, ANALOG DEVICES INC.
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utting-edge technology, developed by semiconductor companies, is enabling the design of medical devices that improve the care of millions of people around the world. Soaring health care costs, the prevalence of obesity and chronic diseases, and a dramatic increase in the elderly population are creating a growing demand for affordable and reliable medical devices, including those for patient monitoring, medical imaging and instrumentation. Today, more than any other time in modern history, the semiconductor industry is paving the way for the advancement of medical devices that are saving countless lives and greatly reducing health care costs. The large medical devices of yesterday have been redesigned as the portable units of today, some of which are now the size of a cell phone or even smaller. Some medical devices, such as ultrasound systems, which were once available only in hospitals and large urban medical clinics, are now commonly used in rural doctors’ offices and ambulances. As the miniaturization and portability of medical equipment occurs, semiconductor manufacturers are challenged to develop highly integrated chips that will provide the enabling technology for next-generation medical devices, including increasingly lighter and smaller portable systems. PATIENT MONITORING SYSTEMS
Patient monitoring equipment enables the continuous observation of critically ill patients, regardless of their location within the hospital, and often at a lower cost than using traditional bedside systems. Patient monitoring involves electrocardiogram (EKG), blood pressure, temperature, oxygen-saturation, respiration and, sometimes, automated external defibrillator (AED) functions that typically contain high-resolution analog-to-digital converters (ADCs), low-noise amplifiers, instrumentation amps and the combination of analog functions that have been around for many years. These are mature, high-performance systems in which major semiconductor manufacturers have invested a great deal of research dollars to develop innovative chips. While these systems used to reside on the bedside, they are now becoming small enough to be hooked onto a person’s belt. In the near future, EKGs, blood pressure and activity monitors will be combined with wireless communication functions that allow patients to
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MEDICAL TECHNOLOGY
The first integrated analog front end ultrasound chip was announced by Analog Devices in 2007. It enables medical equipment designers to reduce the size of the signal path for mobile ultrasound systems by 50 percent and lower power requirements by 25 percent.
be in their homes and still get safe and reliable vital-sign monitoring in real time. This will, in essence, lower the total cost of care. The need for home-based patient monitoring devices is expanding due to the increasing number of aging baby boomers who require intensive home care. According to the World Health Organization, the worldwide number of persons aged 60 and older was 650 million in 2006. This figure is expected to reach 1.2 billion by 2025. In the U.S., people 65 and older now comprise a greater share of the population than ever before and this number is expected to steadily increase during the 21st Century. “Due to an increasingly aging population, the health care sector is facing soaring costs for the care of chronically ill patients,” says Paul Errico, worldwide strategic marketing manager for Analog Devices’ Healthcare Segment Team. “Today’s medical devices, designed for home use, can monitor blood pressure, glucose levels and heart rates, and alert doctors to problems. This eliminates or reduces the need for costly office and hospital visits, and provides big benefits for patients who don’t live near a doctor or hospital.” To become a main factor in the way health care is managed, patient monitoring systems must be fully interoperable with one another and with other needed sources of patient information. While broad interoperability has not yet been achieved, it is a priority for the medical and information technology industries. The Continua Health Alliance, for
example, is an organization working with technology, medical device and health care industry leaders to establish a system of interoperable solutions. MEDICAL IMAGING
The use of medical imaging equipment, including CT (computed tomography) scanners and ultrasound systems, continues to grow as technology improvements render clearer, more detailed pictures of the human body for physician analysis and diagnosis. The medical imaging arena has seen a dramatic rise in channel counts-per-system and a commensurate focus by semiconductor companies on integration, low power and reducing cost-per-channel. Ultrasound, CT, magnetic resonance imaging (MRI) and positron emission tomography (PET), are all high-performance systems pushing standard components in terms of power, speed, accuracy and dynamic range. A few years ago, portable ultrasound systems resembled a notebook PC. Today, ultrasound systems are using PDA or cell phone form factors and are small enough for doctors to carry in their pockets and use at will. This is greatly changing the use of ultrasound technology in terms of patient care. Needless to say, the power and footprint requirements for portable ultrasound systems are also dramatically different for today’s systems. “Medical equipment designers are being called upon to deliver high image quality and reliable performance without compromising power efficiency in devices that are sometimes scarcely larger than a human hand,” says Scott
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Pavlik, worldwide strategic marketing manager for Analog Devices’ Healthcare Segment Team. “To do so, designers are capitalizing on significant improvements in underlying technologies, particularly in semiconductor component integration. IC ultrasound innovations are not only easing designers’ tasks, but are also enabling significant advancements in the performance, size and power of ultrasound equipment — yielding greater product possibilities and expanded market opportunities.” There are four major components that comprise an ultrasound system: low-noise amplifier (LNA), variable gain amplifier (VGA), anti-aliasing filter (AAF) and a high-speed analog-to-digital converter (ADC). In 2007, the first integrated analog front end ultrasound chip was announced by Analog Devices. The AD9271 replaced previous discrete solutions with a single integrated circuit that combined eight channels, each comprising an LNA, VGA, AAF and a 12-bit ADC. This unprecedented level of integration enables medical equipment designers to reduce the size of the signal path for mobile ultrasound systems by 50 percent and lower power requirements by 25 percent, all while achieving noise levels and other performance metrics required in critical care settings. Integration is not the only key element that must be achieved in the design of today’s portable ultrasound systems. The system also needs to be flexible and be able to adjust to the needs of various types of ultrasound probes, as well as provide ease-of-use in terms of programmable gain, filter cut-offs and system termination. It isn’t enough for semiconductor manufacturers to define these very sophisticated parts and hand them out to customers with samples, evaluation boards and data sheets. Software tools that allow these products to be easily evaluated are also needed. All of this is evidence that semiconductor manufacturers are moving closer to the system designer’s world. It is estimated more than 62 million CT scans are done annually in the U.S. CT imaging combines special X-ray [www.d esignnews .com]
equipment with sophisticated computers to produce internal 2-D and 3-D images of the human body to diagnose problems that include cancer, cardiovascular disease and musculoskeletal disorders. In a CT system, large numbers of data acquisition channels are arranged in slices. Higher slice counts are what makes CT scanners able to more quickly provide detailed images, while exposing patients to a lower X-ray dose. Current and next-generation CT scanners require a massive channelcount increase, but the system size and cost cannot grow at the same rate as the channel count. The analog front end, the most complex part of the system, is critical to the system’s performance. Thus, to enable massive channel counts, semiconductor designers must look at ways to integrate higher functionality while lowering power consumption and cost. The partnership between semiconductor designers and system designers is absolutely critical in the CT space. During the past several years, there has been a tremendous amount of innovation and progress in CT development and a great deal more is expected to occur in the coming years. Analog Devices, for example, recently introduced a new medical imaging chip that enables high slice-count CT systems to capture realtime moving images — such as a beating heart — with a high degree of accuracy and detail. The ADAS1128 offers 128 data conversion channels and enables diagnostic system designers to develop CT scanners that produce clearer images of internal organs and bones while reducing radiation exposure compared with older machines. This is invaluable in critical care areas, such as cardiology, neurology and angiography. MEDICAL INSTRUMENTATION
This segment of the medical device market includes blood analysis, blood pressure meters, infusion pumps and dialysis machines, as well as a wide variety of other in vitro functions. One example of using cutting-edge semiconductor technology in an otherwise very mature measurement system is
Analog Devices’ ADAS1128 allows diagnostic system designers to develop CT scanners that produce clearer images, while reducing overall scan time compared with older machines.
the use of tri-axis accelerometer technology in blood pressure meters. The most common way to get an inaccurate blood pressure reading is to have your arm at the wrong level relative to your heart. Using a tri-axis accelerometer (identical to that used in current computer games) to measure the tilt of your arm helps ensure the blood pressure reading is accurate. A typical way to analyze blood for diagnosing medical conditions is to examine its DNA characteristics. When a virus is present, the DNA characteristics of the blood typically change and so does the impedance of the sample in complex form. By mapping virus strings to those impedance profiles, medical professionals can identify and detect viruses in the blood. System designers are being asked to design spectrum analyzers into handheld meters, but cannot accomplish the task with available discrete devices. So, they must work with the semiconductor industry to see if this function can be integrated onto a single chip as is currently available in recent impedance metering analog front ends. Semiconductors can generally do what is needed to enable high-performance systems. The real key is to achieve the required performance while keeping within an aggressive system power budget, footprint requirement and being able to provide other high value functions that can be combined onto one piece of silicon to provide the greatest benefit to the system. It is this applications’ knowledge that semiconductor companies are constantly striving to
M4 M EDI C A L T EC HNO L O GY / A S U P P L E M E N T T O D ES IG N N E WS MAY 2009
develop. In this respect, our customers are our teachers and the end result is that semiconductor companies, system manufacturers and, most importantly, patients benefit from effective communication between the major technology stakeholders. Medical design engineers creating the latest health care systems aimed at disease management, health and wellness, and drug delivery are using semiconductors as the foundation to invent next-generation products that change lives. Communication between medical system and semiconductor designers is vital because the more semiconductor companies learn about what medical equipment designers need, the more everyone around the world who may need medical care will benefit. Patrick O’Doherty is healthcare segment director at Analog Devices, a world-leading supplier of analog, mixed-signal and digital signal processing integrated circuits. O’Doherty oversees the design, sales and marketing teams responsible for developing signal chain solutions for the medical imaging and patient monitoring markets and identifying new medical market opportunities for Analog Devices. FOR MORE
MEDICAL TECHNOLOGY
information
Analog Devices’ ADAS1128: http://designnews.hotims.com/23104-500 Analog Devices’ AD9271: http://designnews.hotims.com/23104-501
[www.d esignnews .com]
SOURCE: ANALOG DEVICES
MEDICAL TECHNOLOGY
SPECIAL ADVERTISING SECTION
Listen Up a hearing aid
With Flair Phillips Plastics partnered with Starkey Laboratories to decorate parts for a new series of hearing aids that blend cutting-edge technology and exquisite design ost people don’t associate wearing hearing aids with making a fashion statement, but a Minnesota medical company has created a new line that is changing that thinking. The new Zǀn™ series of hearing aids gives Starkey Laboratories, Eden Prairie, MN, a jump on the competition in one of the medical field’s toughest markets, thanks in large part to stylish design and an eye-catching color palette made possible by a strong partnership with Phillips Plastics. Under a very tight project schedule, the Precision Decorating arm of Phillips investigated, tested and implemented a Plasma Surface Treatment process that allows Phillips to paint the chemical-resistant nylon used in the Zǀn’s components. Result: A distinctive product that sets Starkey apart in the marketplace. “There was a lot of excitement surrounding this project, but we were cautious, too, because of past problems companies had in trying to paint nylon,” recalls Andre Oldberg, Phillips Plastics project engineer. “But both Phillips and Starkey were committed to meeting the challenge.”
M
Taking on such challenges isn’t unusual for Starkey Laboratories. Founded in 1967, the company has become a world leader in the design, development and distribution of comprehensive hearing products. With 35 facilities in more than 24 countries, Starkey offers high-quality diagnostic equipment, hearing protection products, wireless technology and unique hearing solutions for every environment. Innovations for a global market To maintain its position as an industry pacesetter, Starkey keeps a close watch on changes in consumer tastes. For example, in-the-ear (ITE) hearing aid devices have dominated the U.S. market for decades. Meanwhile, European consumers have tended to prefer the open-fit, behind-the-ear (BTE) devices. In recent years, however, demand for these BTE designs has increased among North Americans, a trend that some attribute in part to the popularity of Blue Tooth headsets now worn by young and old alike. In response to such changing preferences, Starkey created the Zǀn with BluWave™ SP series, which it
M6 MEDICAL TECHNOLOGY / A SUPPLEMENT TO DESIGN NEWS MAY 2009
Zǀn hearing aids from Starkey Laboratories feature an elegant curved shape and a sophisticated color palette to complement hair and skin tones. Plasma Surface Treatment by Phillips Plastics opened the door to painting the nylon used in the new hearing-aid line. Colors include metallic and pearlescent finishes.
calls the first hearing aid to combine leading-edge technology and exquisite design. Starkey touts the Zǀn as the only receiver-in-canal hearing solution in its class to offer extraordinary beauty, comfort and top performance. Zǀn’s BluWave signal processing system allows the hearing aid to be made as small as possible, while optimizing performance in challenging situations, such as picking up a child’s voice or listening to speech in a restaurant or car. A new active feedback intercept system erases whistling, squealing and other irritating sounds, and a Directional Speech Detector provides extraordinary directional performance and better understanding in noisy environments. In telephone conversations, Zǀn virtually eliminates feedback, while automatically adjusting
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for optimal communication. Along with technical innovations to boost performance, Starkey also wanted to capitalize on the styling possibilities created by the growing interest in behind-the-ear devices. Together with California’s Stuart Karten design firm, Starkey created a hearing aid with two tiny parts: a curved behind-the-ear component that houses Zǀn’s electronics and an earmold placed inside the ear canal. Forging a partnership With its own state-of-the-art production facilities, Starkey was well prepared to manufacture these components, but it needed a vendor that could paint the parts. That led the company to Phillips and its Precision Decorating facility in Medford, WI. “Our design goal was to bring the best technology with high-quality styling,” notes Jim Grossmann, director of mechanical engineering for Starkey Laboratories. “While we have the capability to perform molding in house, Phillips brought decorative painting and chrome plating capabilities to the table.” Still, painting the tiny parts was easier said then done. The nylon in the Zǀn series features superior strength characteristics and excellent chemical resistance. “Any material exhibiting chemical
Zǀn Captures National Design Award colors that complement the Starkey Laboratories knew it wearer’s hair and skin tones. had a winner in its new Zǀn Best of all, the Zǀn’s form hearing aid, but that confidence was confirmed this embraces the body’s geompast October when the device etry for a secure fit with opreceived the prestigious 2008 timal comfort and ergonomic People’s Design Award, sponaccuracy.” sored by the Smithsonian’s Such innovations, note muCooper-Hewitt National Deseum officials, can go a long sign Museum. way toward making people The work of Stuart After nearly 120,000 votes more comfortable with the Karten’s Californiawere cast on the museum’s idea of wearing a hearing aid. based industrial design firm embraces website for many of the They point to research showmedical devices, such ing that hearing impaired nation’s top designs, Zǀn as the Zǀn hearing individuals wait up to eight emerged the winner. The aid, as well as prodyears before being fitted with hearing aid was designed by ucts in such fields as a hearing aid because of its the California-based Stuart consumer electronperceived association with Karten industrial design firm. ics, housewares, and disability and weakness. The nomination statement transportation. “I’m delighted that the pubnoted: “The Zǀn looks more lic has chosen to honor an like a luxury fashion accesobject that marries design with technosory. The 1.3-inch-long Zǀn is coated in logical innovation,” said Cooper-Hewitt high-gloss metallic paint, with chrome Director Paul Warwick Thompson. “The accents that add an extra sparkle. When success of Zǀn demonstrates that good placed behind the ear, the Zǀn becomes virtually invisible due to its size, sleek design can indeed have a transformative shape and a palette of six understated impact on our everyday lives.”
resistance also resists paint adhesion,” explains Oldberg, the Phillips project engineer. As a result, the initial focus of Phillips’ program was investigating methods to get paint to stick to the parts. While Phillips has vast experience painting polycarbonate resins, it hadn’t painted Starkey’s choice of chemical-resistant nylon. “In our initial attempts, no matter what type of paint we used, we had trouble with it flaking off,” Along with their stylish recalls Oldberg. looks, Zǀn hearing aids boast BluWave™ signal processing for more clarity and better speech audibility in a variety of environments.
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Plasma unlocks the door Ultimately, Phillips and Starkey concluded that to paint the hearing aid components, their inherent surface energy needed to be changed. To accomplish that, Phillips enlisted the help of a California supplier, which applied Plasma Surface Treatment to the parts. The process temporarily alters the molecular structure of the resin, allowing paint to adhere before the material returns to its original state. “Once the Plasma Surface Treatment method proved itself, we invested in our partnership with Starkey by purchasing our own Plasma Surface Treatment equipment,” says Oldberg. Housed in Phillips’ Precision Decorating facility, the equipment, which represented an investment of more than $100,000, enables Phillips to perform all deco-
M AY 2 0 0 9 M E D I C A L T E C H N O L O G Y / A S U P P L E M E N T T O D E S I G N N E W S M7
SPECIAL ADVERTISING SECTION
A Commitment to Medical Solutions Besides its Precision Decorating facility used in the Zǀn project, Phillips offers a wide range of services for engineers in the medical field. Phillips has made an extensive commitment to the industry, including: • FDA registration both as a device manufacturer (21CFR part 820) and
as a drug packager (21CFR parts 210 and 211). • Over 130,000 square feet of production space dedicated to medical, including extensive clean room facilities. • Dedicated engineering teams assigned to medical manufacturing. • Robust Quality Systems and produc-
A worker assembles a medical device in a class 100,000 clean room, one of three such facilities that Phillips Plastics maintains at Menomonie, WI.
“Partnering with Phillips enabled us to meet our design objectives and achieve a successful launch of the product.” — Jim Grossmann Director of Mechanical Engineering Starkey Laboratories
rating-related tasks for the parts in the Starkey program. Says Grossmann: “The Zǀn program was the first time Starkey required precision decorating on its product. Partnering with Phillips enabled us to meet our design objectives and achieve a successful launch of the product, which has been very well received in the marketplace.”
Phillips also considers the Zǀn project to be a great success, says Oldberg, particularly the close relationship formed with Starkey. Besides decorating the hearing aid parts, Phillips also handles the company’s extensive Zǀn replica program, which involves creating inoperative hearing-aid models for product demonstration purposes. Moreover, the experience gained with Plasma Surface Treatment, adds Oldberg, promises to open the door to more decorating projects involving chemical resistant materials — not just for medical, but for automotive, consumer electronics and other markets. “Nylon is a preferred material for many engineering applications because it offers high strength even in thin-wall designs,” explains
M8 MEDICAL TECHNOLOGY / A SUPPLEMENT TO DESIGN NEWS MAY 2009
tion controls supporting the company’s medical operations. • Secondary operations, including sonic welding, spin welding, laser etching and ultrasonic cleaning. With these comprehensive facilities, Phillips has provided medical design, production and assembly services for companies ranging from start-ups to industry giants like Medtronic and Eli Lilly. In fact, medical now accounts for 40% of Phillips business volume. Among the long litany of devices Phillips has produced over the years: • High-tolerance molded parts for pens and syringes used for insulin injections. • Infusion pumps, glucose meters and lancet devices for diabetics. • Surgical instruments for endoscopic and laparoscopic procedures. • A spinal surgery kit requiring more than 40 components. • An epinephrine injector for allergy suffers. Phillips’ engineers stand ready to take on your project, providing a whole gamut of services from industrial and mechanical design to prototyping, tooling and volume production and assembly.
Oldberg. “And now we have a process that allows us to take that chemical-resistant material and add more value by offering new decorating options.”
For more information on Phillips decorating services: http://designnews.hotims. com/23104-130 To read more about Phillips partnership with Starkey: http://designnews.hotims. com/23104-131
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MEDICAL TECHNOLOGY
Miniaturized
HeartLander Mobile robot driven by ultrasonic vibration motors traverses the heart BY AL PRESHER, CONTRIBUTING EDITOR
T
he development and construction of a mobile robot, driven by tiny ultrasonic piezoelectric motors for minimally invasive cardiac therapy, illustrates the capabilities, challenges and future direction of miniaturized motion systems. The robot design builds on the basic success of previous prototypes of HeartLander, a miniature mobile robot that moves in an inchworm-like fashion to reach any targeted location on the beating heart surface. It was developed jointly by The Robotics Institute at Carnegie Mellon University and the Div. of Cardiac Surgery at the University of Pittsburgh. While the current HeartLander design was developed as a proof of concept to demonstrate mobility on the cardiac surface, conclusions point to more product development, and research will be required to make the procedure a longerterm reality. Key areas for improvement include a smaller size control system and the ability to operate the ultrasonic vibration motors at lower voltages. The goal is to develop a miniaturized motion control solution including motors, driver and position sensors to achieve closed-loop control utilizing very small modules. The HeartLander robot presents an alternative solution to some of the problems surrounding robotic, minimally invasive, cardiac techniques. This miniature tandem-bodied mobile robot travels on the heart surface, or epicardium, by alternating suction and the extension length between two bodies. “The innovation we are pursuing is [ w w w. d es ig n n e ws.c o m]
The HeartLander OMNI prototype, shown here on a porcine heart, has two ultrasonic piezoelectric motors in the rear body. Mounted side-by-side, the motors spin a mating threaded rod and produce linear motion that moves the mobile robot across the heart.
replacing the external drive wires with internal motorized actuators,” says David Henderson, CEO of New Scale Technologies Inc. “It is feasible and promising, but there is more to be done. We have a proposal pending to continue the research — to make the actuators smaller, improve force, reduce operating voltage, seal the unit and protect the mechanism from body fluids.” Henderson says other improvements could provide position sensing to properly calculate motion trajectories and increase the robot’s turning capabilities. Despite the effectiveness of the prototype, problems still exist, especially related to the tether the unit utilizes. The tether consists of several components including a drive-wire mechanism that allows for the
extension and retraction motions. This mechanism, in combination with the other components, increases the stiffness of the tether. As the robot turns, the tether pulls the robot toward its original heading orientation, causing a loss of traction and efficiency. Tether stiffness causes difficulty when moving across areas with high curvature. “If you want to move on the heart with the current drive wires, it’s necessary to back up and turn instead of turning and moving,” Henderson says. Increased mobility would provide an ability to follow a trajectory on the heart and potentially do electrocardiogram mapping and treatment. The HeartLander OMNI (Onboard Motor Navigational Instrument) was
MAY 2009 ME DICAL T E CH NO LO GY / A S UP P LE ME NT TO DE S I GN NE WS M9
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MEDICAL TECHNOLOGY demonstrated in 2008 by Peter Allen and Professor Cameron Riviere at The Robotics Institute, Carnegie Mellon University. The design uses ultrasonic piezoelectric motors for robotic actuation to provide high axial forces, compact size and robust operation. Squiggle motors from New Scale are The TRACKER position sensor small linear actuators (7.0 x boasts a higher resolution and 3.4 x 3.4 mm) that use minute smaller size than miniature oporbital vibrations in the nut tical encoders for non-contact to spin a mating threaded rod, position sensing. providing linear translation of the rod with a high axial force. The motors have no gears or cams, which allows for small construction and efficient operation as a linear actuator. Because the motors advance a threaded rod, stroke is only limited by the length of the rod. The motors use a flexible, printed circuit board for power and communication with motor control circuitry located in an enclosure. The design of the front body of the robot is sloped to a point to create a space underneath the pericardium, the sac of fibrous and serous tissue surrounding the heart, as it is advanced by the motors. The front body contains two ball bearings to decouple the rotating rods from the non-rotating front body, and a port for diagnostic and therapeutic tools. The rear body accommodates two SQL-3.4 linear motors placed horizontally side-by-side. Each threaded rod has an attached length of nitinol wire connecting to the miniature ball bearings on the rear portion of the front body. The total HeartLander OMNI robot measures 76.1 x 15.5 x 8.8 mm. A graphical user interface manages all of the robotic functions, including motor controls and the alternation of suction between the two bodies. The program also allows the physician to modify several parameters of the robotic locomotion, including step length and number of steps to provide control over the robotic movement. Improvements planned for the HeartLander redesign specifically target further miniaturization. A decrease in height would result in a decrease in friction among the robot, the heart surface and the pericardium sac. A decrease in length would reduce the negative effect of the heart’s curvature on the robot’s prehension of the surface. The application of a hydrophilic coating to the robot would allow for increased lubricity and is another option to reduce friction. Miniature Hall Effect sensors could be added to the design to incorporate closed-loop control. Pressure sensors could be added to detect loss of suction seal with the surface, according to Henderson. Future testing will include in vivo porcine testing on a beating heart. Henderson says New Scale has plans to customize the Squiggle motors for this application. The motor typically pushes the load with the bias force in one direction on the screw, to eliminate backlash in the threads. In this case, the goal would be to both push [www.d esignnews .com]
MEDICAL TECHNOLOGY and pull as an actuator, achieving more force and reducing the height. Since the unit moves under the pericardial sac, the higher the profile of the robot, the harder it is to move around. Keeping it thin reduces the force and makes it more mobile. The target height for the application is 5-6 mm. Today, the unit stands 8-10 mm tall. New Scale is focused on moving beyond its motor technology to providing complete miniature motion systems. The company has developed a close relationship with austriamicrosystems AG, an analog IC company in Austria. They are working together to develop motor driver and position sensing ASICs. One ASIC, called the Tracker, is a position sensor Henderson says is the world’s smallest linear position sensor. It offers a tiny, single chip solution and comes in a chipon-board version that is very thin. The chip uses a moving magnet’s North-South poles to encode the magnet and can measure accurately to two microns. New Scale also Prototypes of has a driver ASIC ultra-thin actuator family custom piezo that drives two motors are less than SQUIGGLE mo1-mm thick. Piezo tors with a built-in ceramics integrate dc boost from 2.8 multiple actuator to 40V. functions and independent electrical “We also recently connections into a announced a strasingle co-fired cetegic relationship ramic component. with EPCOS, a manufacturer of multi-layer piezo ceramics,” says Henderson. “These ceramics can be used in New Scale motors to operate at reduced voltages, so that in the same physical FOR MORE
size multiple layers of metal and ceramic can be added to reduce the operating voltage just like a ceramic capacitor.” Henderson says piezoelectric elements are essentially ceramic capacitors that change shape when they charge and discharge. EPCOS makes piezo ceramic capacitors in very thin layers to maximize
performance and they have already demonstrated motors working at 2.8V directly from batteries. Lower voltage is a much better solution because running at lower voltage and higher current is preferred in most applications, and the design eliminates the dc boost while also reducing the number of parts, size and overall cost.
MEDICAL TECHNOLOGY
information
HeartLander OMNI: http://designnews.hotims.com/23104-502 New Scale Technologies Inc.: http://designnews.hotims.com/23104-503 austriamicrosystems AG: http://designnews.hotims.com/23104-504 EPCOS: http://designnews.hotims.com/23104-505
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MAY 2009 ME DICAL TE CH NO LO GY / A S UP P LE ME NT TO DE S I GN NE WS M11
MEDICAL TECHNOLOGY
Growing the Medical Device Industry by Shrinking It Extreme Resolution Micro Flex Circuits address growing field of medical application devices with unique material, dimensional requirements BY LUKE VOLPE, METRIGRAPHICS® DIV., DYNAMICS RESEARCH CORP.
SOURCE: METRIGRAPHICS
I
n the medical device industry, design/manufacturing engineers typically begin with a preliminary vision of the design of a particular device or component. However, a lack of available resources, tools or the process and application knowhow often puts limitations on these visions. In their quest to find an effective solution, engineers are often forced to change aspects of their original idea due to these restrictions. A particular challenge is creating components on a small enough scale that they can adhere to the increasingly minute requirements for medical devices used inside the body. A strong partnership with a components manufacturer, with the unique capability to create these miniature parts, can open the door to make a manufacturer’s vision a reality. Implantable medical devices fall into two categories: Those intended to be in the body for short periods of time, such as angioplasty probes; and those intended to be semi-permanent implants like heart stimulating systems. Both types of devices are subject to similar critical chemical reactivity and physical size issues. Here we address physical size and configuration issues effecting the development of 21st Century implantable medical devices. The semiconductor industry has made great progress in building more complex semiconductors with more memory and logic, while at the same time reducing their physical size. Unfortunately, until recently, the same cannot be said about the flexible interconnect systems, such as traditional flex circuits (TFC), that interconnect IC chips and often become part of the packaged system. The overall size of the flexible interconnect system is a function of the number and size of chips, complexity of I/O connections, and minimum trace and space width and aspect ratios. For decades, the generally accepted TFC minimum conductive trace and space has been 0.075 mm. This limitation can be further complicated by current carrying requirements, i.e. the greater
This image shows a section of a high-density electroformed induction coil. This device has 0.010-mm traces and spaces with 0.025 conductor thickness. This type of high-density electrical circuit will typically have a flexible polyimide substrate and can be built with several layers interconnected through holes in the polyimide interlayers.
the current requirements, the greater the trace cross-section required. Since TFC trace thicknesses are generally fixed, wider traces are required to meet cross section/current carrying needs. TFC manufacturing is a mature technology with a long history of improving and optimizing materials, manufacturing equipment and processes for the medical device industry. It is widely used in hundreds of applications where flexibility, weight and reliability are critical requirements. Such applications include non-intrusive medical devices, space-based systems, cell phones and digital cameras, to mention a few. However, the TFC process does not address the needs of
M12 M EDI C A L T EC HNO L O G Y / A S U P P L E M E N T T O D E S IG N N E WS MAY 2009
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MEDICAL TECHNOLOGY
SOURCE: METRIGRAPHICS
This image shows the micro size of ERMF Circuits in comparison to a dime.
the latest generation of intrusive medical device that require significantly smaller conductive traces and pitch dimensions. A NEW TECHNOLOGY
During the past few years a new technology has emerged, capable of forming trace and space widths routinely to 0.005 mm with aspect ratios as high as 5:1. These advances were accomplished by combining three mature technologies: 1. Semiconductor UV photolithography, 2. thin film metal processing (controlled sputter deposition and ion beam removal) of a variety of metals, 3. and electrochemical metal deposition. The result of this work is a new category of flex circuitry called Extreme Resolution Micro Flex Circuits. The ERMF Circuit category does not replace TFC. This technology is intended to address the growing field of medical application devices that have unique material and dimensional requirements not possible with TFC. This allows designers to now consider devices not possible before ERMF. For example, circuits used for angioplasty procedures must be small enough and sufficiently flexible to be rolled into a cylinder for insertion into a blood vessel. Other leading-edge applications include implantable RF coupling transmitting and receiving systems used for monitoring critical life signs, drug dispensing and retinal implant imaging data. In this last example, the RF coupling coil is integral to the ERMF Circuit.
able nature of the technology holds great potential because of the enabling effect it affords the designer of implantable medical devices and other applications that have similar size and material limitations. Working closely with the manufacturing company can often result in improved overall design approaches that take better advantage of the properties of these processes. This technology, as applied to micro-sized medical devices, is quite new. As more medical device designers become aware of this capability, it will likely have an even more dramatic impact on the overall growth of the medical device industry. Luke Volpe is the director of engineering at the Metrigraphics Div. of Dynamics Research Corp. He has worked with DRC for more than 25 years, serving in positions such as research & development manager. FOR MORE
ME DI CAL
information
Metrigraphics® Div. of Dynamics Research Corp.: http://designnews.hotims.com/23104-506 Extreme Resolution Micro Flex Circuits: http://designnews.hotims.com/23104-507 Traditional Flex Circuits: http://designnews.hotims.com/23104-508
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The specific capabilities/advantages of the ERMF technology that make it ideal for current and next-generation implantable medical devices are: 1. Extreme resolution, micron level trace and space capability, 2. trace conductivity to match device requirements, i.e. signal or power, 3. suitable implant material options, 4. and extreme flexibility. These advantages allow the device engineer greater design freedom to build less intrusive devices with more functionality within a single package. Disadvantages include cost, lead time and current fabrication techniques that limit extremely high-volume applications, but approaches are being devised to resolve this. GREATER POTENTIAL
ERMF is still a relatively new process that holds far more potential than is currently being tapped. The precise and repeat[ w w w. d es ig n n e ws.c o m]
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MAY 2009 ME DICAL TE CH NO LO GY / A S UP P LE ME NT TO DE S I GN NE WS M13
MEDICAL TECHNOLOGY
Unique Helmet Design Could Reduce Concussions Xenith™’s shock-absorbing head protection system minimizes impact BY JOHN WILLIAMSON, CONTRIBUTING WRITER
A
new helmet designed by Massachusetts-based Xenith™ LLC is targeting safety through innovation and education, and may, the company says, decrease the number of concussions sustained by even the hardest-hit football players. Vin Ferrara, MD, MBA, founder, president and CEO of Xenith™ LLC, says players experiencing injuries commonly described as “bell-ringers” or “dings” are players who have actually suffered concussions. Therefore, the number of these injuries is much higher than previously believed. A major cause of concern is that players who have experienced concussions do not always report them. Coaches, parents, officials and medical staff may be unaware of the injury. Repeated injuries can occur more easily and with worsened long-term consequences. A concussion is a type of traumatic brain injury resulting Figure 1
SOURCE: XENITH™ LLC
Polyurethane shock absorbers are fitted into grommets placed in the helmet bonnet, which is affixed to the helmet shell. The design allows air to circulate freely around the player’s head.
from the sudden violent movement of the head during impact. Sudden movement of the head causes the brain to move inside the skull, which may result in disrupted brain function, leading to the signs and symptoms of concussion. A NEW APPROACH TO HELMET FUNCTION
Football has come a long way since the first so-called football game was played between Rutgers and Princeton in 1869. The format has evolved, as well, as that game was played under Rugby-style rules. The Harvard-McGill game in 1874 and the Tufts-Harvard game of 1875 marked an evolutionary point between a rugby-soccer format and the game we know as American football today. As the game evolved, so did helmet design. Xenith™’s stated mission is to advance safety and activity through innovation and education. To do this, it started by creating its own unique approach to helmet design. Helmets widely in use today employ foam or other padding as a means of dissipating impact energy. These helmets and other head protection systems are tested by impacting a crash test dummy head, which measures the sudden movement in units of G or SI — a severity index, Ferrara says. The dummy head registers an acceleration curve, representing the force the head experiences. The lower the peak, the lower the G or SI. A lower, flatter curve indicates a more gradual movement and less likelihood of an injury. However, performance on standards does not necessarily correlate with the risk of concussion. The challenge with helmets is trying to minimize the peak G and SI during any impact, which is usually unpredictable with regard to magnitude and direction. According to Xenith™, a helmet’s effectiveness is dependent upon the energy management system it uses and how well the system relates to the impact. If the system is too soft, it collapses too quickly and could result in a skull fracture or brain injury. If the system is too hard, it won’t collapse enough, resulting in a sudden, jolting impact that can cause a concussion. Thinking inside the helmet, the Xenith™ team applied principles employed in automotive shock absorbers to a new head protection system called Xenith™ Adaptive Head
M14 M EDI C A L T EC HNO L O G Y / A S U P P L E M E N T T O D E S IG N N E WS MAY 2009
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MEDICAL TECHNOLOGY Figure 3
Figure 4
SOURCE: XENITH™ LLC
Figure 2
ready for the next hit (see Figures 2, 3 and 4, left). The improvement in performance is shown by a wider, flatter acceleration curve. Further, the shock absorbers show essentially no decline in function over repeated impact. A NEW APPROACH TO HELMET FIT AND COMFORT
Figure 2, far left, shows a shock absorber. The thicker section comes in contact with the helmet shell and the thinner section comes in contact with the player’s head. Figure 3, middle, shows when force is exerted. Figure 4, right, shows air escaping from the hole, providing a cushion against impact. The harder the impact, the slower the air escapes, which further cushions the head. Re-inflation is immediate.
Protection™, which is the basis for the company’s new X1 Football Helmet. Shock absorbers work by adapting to the impact to minimize the force to the car resulting from the variable bumps in the road, and Xenith™ applied this principle to what the company calls the Aware-Flow™ Shock Absorber. The Aware-Flow™ Shock Absorber replaces traditional foam or padding in the helmet. Multiple shock absorbers are embedded in a flexible bonnet with a series of holes where the anti-bacterial thermoplastic polyurethane disc-shaped shock absorbers are placed (see Figure 1, page M14). The absorbers’ energy attenuation air chambers are fitted with a small hole allowing air to escape when impact occurs. The engineering principle involved is somewhat like that of a bicycle tire pump. Pushing the handle slowly allows air to Figure 5.1
Figure 5.2
enter the tire relatively easily, but when the handle is pushed rapidly, resistance is encountered. This is because of air turbulence. Similarly, in a low-impact situation, air flows out smoothly from helmet shock absorbers, which behave like something soft. In a high-impact situation, the air becomes turbulent and the shock absorbers behave like something stiff. This principle allows the shock absorber to adapt to impact energy, and the bonnet suspension allows the system to adapt to impact direction. The system deflects in relation to the magnitude and direction of impact, dissipating impact energy and reducing the sudden movement of the head, thus reducing the likelihood of brain injury. The absorbers refill instantly after impact by simply springing back to shape and inhaling the air around them, Figure 5.3
Football helmets may look sharp on team members’ heads and may reduce impact energy, but they also need to be comfortable and well-fitting. Xenith™ addressed the comfort and fit factor through its Fit Seeker™ design, utilizing the flexible bonnet and a cable system that integrates with the chinstrap and chincup. The cable travels from the back of the helmet through the bonnet and down toward the chincup, which acts as a redirection pulley. When the player pulls the chinstraps, the chincup is pulled up toward the chin and the bonnet is pulled snugly down around the head. The straps are then snapped onto the helmet shell. The result is a custom fit, which makes helmets less susceptible to being knocked off during impact. Ferrara also points out that other helmet fit systems require pumps to inflate bladders, which is often a bane to coaches and equipment managers. Fit Seeker™ eliminates the need for pumps (see Figures 5.1, 5.2 and 5.3, below left). Furthering the comfort factor, air is permitted to circulate freely through the helmet, including moving upward from the player’s neck, and is vented from slots on each side.
SOURCE: XENITH™ LLC
EDUCATION AND PREVENTION — THE BEST SOLUTION
Fit Seeker Design, Figure 5.1 Fit 1, shows the interior view of the Xenith™ X1 helmet with the flexible bonnet and cable system, far left. Figure 5.2, Fit 2 shows that by pulling on chinstraps (blue), a player causes the flexible bonnet and shock absorbers to fit snugly over the head (green arrows), middle. Figure 5.3, Fit 3 shows a helmet providing a custom fit. The chinstraps are snapped to the helmet shell, far right. M16 M EDI C A L T EC HNO L O G Y / A S U P P L E M E N T T O D E S IG N N E WS MAY 2009
Although its new design goes a long way to reducing the risk and severity of concussion, Xenith™ makes no claim its helmet will eliminate the concussion epidemic. Players, parents, coaches, officials and anyone else involved in the sport must be aware of the signs and symptoms of concussion, the company cautions. Signs such as loss of consciousness or balance, obvious confusion or vomiting are observable by others. Symptoms, which are far more common than signs, [www.d esignnews .com]
THE ORIGINAL MEDICAL PUSH-PULL CONNECTORS
are experienced only by the player. They include nausea, blurry vision, unusual sweating, headaches and disorientation, indicating a possible concussion. Unfortunately, in many instances players ignore symptoms to stay in the game. Ignoring the symptoms can have long-term consequences with effects lasting for days, months or becoming permanent. The dangers are increased with repeated impacts. Xenith™ says the new helmets are sparking interest among the hundreds of teams that wore them during the past football season, including nearly 100 colleges and more than 400 high schools. “Players are saying a lot of great things, including a reduction of headaches and stating that they feel the impacts less,” Ferrara says. He also cautions that the real key to reducing the burden of traumatic brain injury is an improvement in technique and rule enforcement. “While rules are in place to discourage head-to-head contact, which is the main cause of concussions and neck injuries, they are rarely enforced,” he says. To emphasize this point, Ferrara found a picture of himself as a high school player, leading with his head while being tackled by another player doing the same. Ferrara included this image in the Xenith™ product catalog and other promotional materials, as a way of showing what not to do. “There is an official in the picture looking right at us and not making a spearing call,” he says. “We need officials and coaches to take a role in eliminating this injury, and I’ve found that many people are ready to do this. If we can actually make the game safer, it will increase participation and the quality of play. Then the benefits of an innovation and education approach can be applied to other sports, as well.” For More
MEDICAL TECHNOLOGY
information
Xenith™’s Adaptive Head Protection™: http://designnews.hotims.com/23104-509 Xenith™’s Aware-Flow™ Shock Absorber: http://designnews.hotims.com/23104-510 Xenith™’s Fit Seeker™ Design: http://designnews.hotims.com/23104-511
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MEDICAL TECHNOLOGY
ADVERTORIAL
IN THE MARKETPLACE MAXON MOTOR’S MINIATURIZED EPOS2 MODULE 36/2 Designed to control brush dc, brushless ec motors maxon motor’s new plug-in module, the EPOS2 Module 36/2, offers full motion control functionalities, suits miniaturized single- and multiple-axis applications and is designed to control brush dc and brushless ec motors. The module is flexible and can be operated as a position, speed or current controller, making it useful in a wide range of drive systems. It is 54 x 29 x 9 mm, performs at 36V max and 2A, and has been developed to command and control within a CANopen network. The EPOS2 can also communicate via USB or RS232 interface. maxon motor usa http://designnews.hotims.com/23104-512 KNF’S NEW NF5KTDC-B4 MICRO-DIAPHRAGM PUMP Can be customized to meet specific OEM performance requirements KNF Neuberger’s new NF5KTDC-B4 Micro-Diaphragm Pump includes a 12-24V dc input range motor, measures 31 x 26 x 28 mm, has a service life of more than 10,000 hours and requires less than 1W of power. A 0-5V control signal controls the brushless motor’s speed and flow rate between 5 and 70 ml/min and an integrated pulse generator allows the operator to monitor the motor speed of the pump, keep track of the liquid dosage and calibrate the pump. The NF5KTDC-B4 features a suction height of 13 ft and it will pump back pressures up to 14 psig. It is suitable for pumping and dosing neutral and corrosive liquids. KNF Neuberger Inc. http://designnews.hotims.com/23104-513
AEROTECH’S LASERTURN ® 1 INTEGRATED LINEAR-ROTARY LASER MACHINING Includes standard front and rear tooling platforms The LaserTurn® 1 is an integrated linear-rotary motion subsystem that combines automated material handling with high-performance, direct-drive linear and rotary motion to provide the highest throughput, highest accuracy cylindrical laser processing system available. It includes standard front and rear tooling platforms and uses direct-drive non-contact motor and encoder technology for both the linear and rotary axes. The LaserTurn® 1 also includes an automated, pneumatically actuated Type D collet closer, which has a clear aperture for product feed-through and can support tubing diameters from 0.1-7.9 mm in dry-cutting applications and up to 3 mm when configured for wet-cutting operation. Aerotech Inc. http://designnews.hotims.com/23104-514 QOSINA’S SELF-SEALING STERILIZATION POUCHES Suitable for autoclave or EtO sterilization Qosina’s self-sealing sterilization pouches are available in a variety of stock sizes from 3 x 9 to 12 x 18 inch and are suitable for autoclave or EtO sterilization. They are composed of blue-tinted PET polypropylene front and a surgical paper back. A ¾-inch medical grade tape closure provides a quick and easy seal. Custom printing and sizing options are available. Qosina Corp. http://designnews.hotims.com/23104-515 M18 M EDI C A L T EC HNO L O G Y / A S U P P L E M E N T T O D E S IG N N E WS MAY 2009
[www.d esignnews .com]
TOSHIBA Robots & IIS Servo Systems
MEDICAL TECHNOLOGY
CONTINUED, IN THE MARKETPLACE
ADVERTORIAL
TECH-ETCH’S NEW BROCHURE For advanced manufacturing techniques Tech-Etch manufactures high-reliability, flexible printed circuits on polyimide substrates using advanced manufacturing processes. The company specializes in single and double-sided circuits, as well as multi-layer and flex circuit assemblies. Tech-Etch Inc. http://designnews.hotims.com/23104-516
SCARA Robot Series Load Capacities to 70Kg Accurate Placement Reach to 1950mm Fast Response Times Built-in PLC Expansion I/O Synchronization Options Vision Interface Simulation Software Easy Programming Full Support Clean Room Rated Option
SUNNEX’S NEW LED ‘COOL TOUCH’ LIGHT Provides better illumination than a 20W halogen light The new LED “Cool Touch” light has a high-end LED element with a lens that will provide better illumination than a regular 20W halogen light. The light output in Lux is more than 200 percent higher and the energy savings is 40 percent better compared to a 20W halogen spotlight. The shade has been designed to meet customer requirements of compact light with high light output. Sunnex Inc. http://designnews.hotims.com/23104-517 TOSHIBA MACHINE, IIS MERGE PRODUCT LINES Companies market both as integrated system
Up to 16 Axes per Master Multiple Slave Functions HMI Interfaces Hi-speed I/O to Robot Use for: Auxiliary Servo Systems Takeoff Conveyor Systems Load and Unload Operations Synchronized Motion
The Toshiba Machine Co. and Industrial Indexing Systems Inc. merged two product lines in an effort to market both as an integrated system. Toshiba SCARA TH robots provide quick material handling motion and IIS Emerald Multi-Axis controllers provide real-time machine coordination for transforming raw material into finished goods. In a typical IIS system, SCARA robot tasks are divided into multiple sets of sequential operations that can execute autonomously before intervention is needed by the Emerald controller. This design philosophy allows overlapping of crucial real-time machine control functions with efficient material handling operations without causing major collisions.
Services
Toshiba Machine Co./Industrial Indexing Systems Inc. http://designnews.hotims.com/23104-518 http://designnews.hotims.com/23104-519
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Integration/Design Expertise Software Programming Comprehensive Training Full Panel Shop Facility Give us a call today or visit our website.
Industrial Indexing Systems 626 Fishers Run Victor, NY 14564 Phone: (585) 924-9181 Fax: (585) 924-2169 www.iis-servo.com info@iis-servo.com
EXERGEN’S IRT/C-HB SERIES OF INFRARED THERMOCOUPLES Provides boost in throughput, accuracy Exergen’s IRt/c-HB series of infrared thermocouples for medical applications provides a boost in throughput and accuracy, resulting in smaller heat exchangers. The noninvasive temperature sensors can measure fluid temperature through metal or plastic walls and also have the ability to measure the internal temperature of the target material noninvasively. The sensors can be used in transfusion and IV warming systems, dialysis systems, cardio-pulmonary bypass systems, ECMO systems and blood analyzers. Exergen Corp. http://designnews.hotims.com/23104-520 [www.d esignnews .com]
MEDICAL TECHNOLOGY
Diaphragm Dosing Pump High Accuracy â&#x20AC;˘ Long Lifetime â&#x20AC;˘ Quiet Operation advanced diaphragm pump technology - why settle for less?
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For dosing, transfer, waste removal, recirculation Compact 2â&#x20AC;?W x 3â&#x20AC;?L x 2.5â&#x20AC;?H envelope, 15 W draw Maintenance-free, no peristaltic tubing to replace Speed control and tach pulse feedback available Corrosion-resistance and pressure-relief valve options KNF welcomes your unique OEM requirements
KNF applied its 60+ years of diaphragm pump experience to bring you a new pump designed to provide a high level of dosing accuracy, repeatability and long term reproducibilty makes these pumps ideal for applications where long life and no maintenance are important.
KNF NEUBERGER, INC. Trenton, NJ 08691 609-890-8600 datasheets at www.knfOEM.com
PUMPS
Panasonic PhotoMOSâ&#x201E;˘ relays offer high reliability with stable performance. Fast switching speed, low capacitance and small package size ensure they meet the requirements of high-performance switching applications, such as ATE, instrumentation and medical equipment. According to Panasonic, these relays offer the lowest on-resistance available in a SSOP package with CxR=5 and low power consumption. They are high power with a capacity up to 2.5A, 60V load. Panasonic Electric Works Corp. of America http://designnews.hotims.com/23104-521
FUSION SPLICING TECHNOLOGY AVAILABLE FOR LEMO ÂŽâ&#x20AC;&#x2122;S HDTV CONNECTORS AND CABLES Company partners with 3SAE Technologies LEMOÂŽ has an exclusive partnership with 3SAE Technologies, offering a breakthrough technology allowing for both factory and on-site termination by replacing the fiber-optic connector polish process with a spliced fiber contact inside a 3K.93C LEMOÂŽ connector. LEMOÂŽ http://designnews.hotims.com/23104-522
SPECIAL DIMENSION BEARINGS / EXTRA THIN METRIC / INCH SERIES / METRIC SERIES
MICROMOâ&#x20AC;&#x2122;S BX4 SERIES BRUSHLESS DC SERVO MOTORS With integrated speed controller or integrated encoder
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Thanks to its electronic commutation, the brushless servo motor series is characterized by a much longer service life than mechanically commutated drives. In the basic version, the commutation is provided by an external control. The flexible motor concept of the BX4 series also offers versions with an integrated speed controller or integrated encoder. The encoder version is available in four different preset resolutions: 32, 64, 128 or 256 quadrature impulses per revolution. MicroMo Electronics Inc. http://designnews.hotims.com/23104-523
SPB-EZO manufactures a wide range of precision miniature bearings, extra thin and ďŹ&#x201A;anged bearings, in medium and large bore sizes and available in inch and metric series. SPB bearings are ideal for, AC-DC motors, motion control and precision medical product applications. All bearings are available in high grade c o r rosion resistant stainless steel and high carbon chromium steel.
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QUICKPARTS LAUNCHES DESIGN SERVICE Free for customers working on Quickpartsâ&#x20AC;&#x2122; projects The new DFM service allows customers to take advantage of the vast manufacturing experience and knowledge of the dedicated Quickpartsâ&#x20AC;&#x2122; manufacturing team. The service (valued at $300) is offered free to customers working with Quickparts on new rapid prototyping and injection molding projects. A comprehensive DFM report is available, which includes process flow details, expectations for the build and final DFM recommendations. Quickparts.com http://designnews.hotims.com/23104-524
M22 M EDI C A L T EC HNO L O G Y / A S U P P L E M E N T T O D E S IG N N E WS MAY 2009
[www.d esignnews .com]
Source: Donna Coveney, MIT
Levant’s Zack Anderson: “The key is to get customers to say, ‘This is something we want on a vehicle.’”
Boosting Fuel Efficiency with …
Shock Absorbers?
Hydraulic system turns bumps in the road into energy at every wheel
STORY_ C H A R L E S J . M U R R AY, SENIOR TECHNICAL EDITOR, ELEC TRONIC S
S
hakeel Avadhany was driving his car over some reflectors atop an asphalt road in 2007, when an unlikely thought crossed his mind. “I turned to my friend and said, ‘Wouldn’t it be cool if we could generate power from the suspension by going over these bumps?’” he recalls. Cool indeed. Avadhany’s off-hand comment launched a discussion among his friends, all of whom happened to be engineering students at Massachusetts Institute of Technology (MIT). As it turned out, the group had already been looking for ways to scavenge unused energy from vehicles, and this one seemed an especially strong candidate. After a few “back-of-the-envelope calculations,” the idea grew, and then reached a level of near-obsession among the students. Today, that obsession has led to the creation of a company, Levant Power Corp., which makes a prototype shock absorber that enables heavy vehicles to boost fuel efficiency by as much as 10 percent, simply by recovering the energy generated from bumps in the road. AM General, the Indiana-based maker of the Hummer, is taking a hard look at applying the technology in its next-generation military assault vehicles. Honda, Bentley Motors, General Motors and a few unnamed heavy truck manufacturers are also talking with Levant. Levant engineers describe their product as an industry first. “Instead of providing damping to the suspension and burning it as heat, we provide the same damping and then we sap the energy from the spring as electric power instead of heat,” says Avadhany, who now serves as the chief executive officer of Levant. “It’s just a smarter thing to do, especially considering the new pain point of fuel prices.”
‘Like Plugging into a Wall Socket’
Levant’s journey into the world of energy scavenging began after three of the students decided to push themselves beyond the theory of textbooks and into the world of product creation. Their goal was to find a way to recover some of the energy that’s wasted by today’s typical automobile. According to some estimates, only about 15 percent of the volume of a gas tank is used to propel a car forward. The remainder of the energy is lost as heat through internal combustion engines, as well as in air drag, driveline friction and rolling resistance.
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D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ] 4 9
SHOCK ABSORBERS So
“We asked, ‘Out of all the places where we are losing this energy, where can we recover it?’” Avadhany says. Their investigation then took them into an examination of engine blocks and brake systems, without success. Finally, they rolled over the aforementioned road reflectors and an idea was born. Then their analysis hit second gear. A quick search of patent records revealed there was little in the way of energy-scavenging shock absorbers. Using some funds borrowed from Avadhany’s father, they rented some cars, outfitting the suspensions with sensors and calculating the potential for energy recovery. What they found shocked them. Assuming 1-cm deflections at 1.5 Hz, with a spring constant of 160,000 N/m in a 3,000-lb sedan, they learned that there were 1.45 kW-hr available from the suspension. “It’s like plugging into a wall socket,” Avadhany says. “So we looked at a 60,000-lb trailer and it became even more convincing.”
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Instead of channeling fluid through piston orifices, GenShock reroutes the fluid through an external circuit. A hydraulic motor and electric generator harvest the energy from the shock absorber.
of clean, 12-V current coming to the battery. Along with the energy recovery system, Levant engineers have also endowed the GenShock with the ability to provide active damping to a vehicle’s suspension system. The company’s engineers accomplish that by employing sensors, a microcontroller and proprietary software algorithms to determine the position of the shock’s piston, as well as its velocity. By knowing the position and taking advantage of back-electromotive force (back EMF) from the generator, Levant is able to dynamically adjust the damping characteristics of the shock. As a result, damping can be stiffened or relaxed, depending upon the weight or sensitivity of the load. “The underlying theory is that you want the wheel on the road,” Anderson says. “Having a wheel on the road at all times is definitely preferable. You don’t want liftoff.”
Hydraulic Solution
The trick, however, was to find a way to harvest all that energy. Over time, they settled on a hydraulic system that serves as both a shock absorber and an energy-recovery device. To make such a system, they added a manifold, hydraulic motor, generator, check valves and an external hydraulic circuit to the piston-type shock absorber. The shock absorber, known as GenShock, reroutes fluid through the external circuit as it compresses and relaxes. The check valves allow the hydraulic fluid to travel in only one direction, thus forcing it to the outside circuit and enabling it to power the hydraulic motor that’s coupled to the generator. “This is the industry’s first shock absorber to convert the vertical motion of the vehicle to the rotary motion of a custom-designed hydraulic pump,” Avadhany says. “It’s the result of a bunch of iterative design schemes we created on paper and we think this is the best way to recover the energy.” To optimize its choice of fluid power components and to minimize the size of the fluid power circuit, Levant says it is teaming with fluid power equipment giant Parker Hannifin Corp. Currently, Levant engineers are considering the use of gear motors, gerotor motors and vane pumps for the production version of the GenShock system. Parker Hannifin officials acknowledge they are working with Levant, but as yet are declining to offer any details on the pending design. Whichever hydraulic motor is chosen, the system will generate electrical current and use it to recharge vehicle batteries. To do that; however, Levant engineers have had to take pains to ensure all current from the generator is usable by the vehicle’s battery. They’ve accomplished that by employing boost converters and voltage regulators. “The shock absorber produces spikes of high energy,” says Zack Anderson, chief operating officer and electronics designer of the GenShock. “Dumping that into the car battery can be tough on the battery, so you have to do filtering to take out the intermittent spikes.” The filtering, he says, provides a steady stream 50
D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
Broad Appeal
Levant says its studies show that if installed in a heavy truck with six shock absorbers, each GenShock will generate approximately 1 kW as the vehicle passes over the bumps in a standard road. Plans are for the shock absorbers to recharge vehicle batteries and run accessories, such as hybrid trailer refrigeration units. AM General is currently considering the GenShock as a vehicle feature to help the company secure an expected $40 billion contract for the Joint Light Tactical Vehicle. Expectations are that the GenShock could help vehicles reduce fuel consumption by up to 10 percent, which would, in turn, reduce the frequency of fuel runs in battle. Levant is also targeting Class-8 trucks, where it estimates the GenShock could boost fuel economy by 3 to 5 percent, and is focusing on container cars, all-terrain vehicles and hybrid cars. Assuming that over-the-road trucks travel 100,000 miles per year, Levant engineers say their shock absorber would pay for itself in two years. “This is a value-added device,” Anderson says. “After those first two years, it’s saving money for the owners, year after year.” The start-up company is apparently optimistic about its chances of success. Its employment ranks have recently grown to six full-time and three part-time engineers. “We’re thinking big,” says Anderson. “The key is to get customers to say, ‘This is something we want on a vehicle.’” For More
information
Levant Power Corp.’s GenShock: http://designnews.hotims.com/23105-546 AM General: http://designnews.hotims.com/23105-548 Parker Hannifin Corp.: http://designnews.hotims.com/23105-549
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BEST OF THE ENGINEERING MARKETPLACE 53 55 57 59 60
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
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ELECTRONICS
TSIGNAL TRANSFORMER’S NEW CATALOG Features power transformers, magnets The 56-page, four-color literature offers photos and detailed specifications pertaining to the company’s portfolio of power transformers, high-frequency magnetics and custom options. Offered to provide EOEMs with a single reference for all their magnetics requirements, the catalog details more than 1,000 distinct models of in-stock chokes and transformers with capabilities from 1 VA to 10 kVA. Information pertaining to custom designs, with capabilities to 45 kVA, is also presented.
SPROTEK’S ‘S’ SERIES SWITCHMODE POWER SUPPLIES
Signal Transformer Inc. http://designnews.hotims.com/23105-550
Can be operated in constant-current or constant-voltage mode With features such as a 0.01 percent line/ load regulation, a remote sensing input and an efficiency of better than 70 percent, the S Series of benchtop switchmode power supplies from Protek can be operated in either constant-current or constant-voltage mode. Ripple and noise in voltage mode is less than or equal to 5 mV (rms), and in current mode less than or equal to 10 mA (rms). Measuring 5.4 x 6.4 x 1.4 inch, available versions include the 30-A, 0-12-V Model 1230; the 20-A, 0-18-V Model 1820S; the 10-A, 0-36-V Model 3610S and the 6-A, 0-60-V Model 6006S.
-PHJD Siemens provides a clear advantage in performance. Logic control is expected of an automation controller. However, when performance is critical to the success of your application, SIMATIC S7 Controllers deliver:
• Built-in Diagnostics • Scalability • Speed • Flexibility
Protek Test and Measurement http://designnews.hotims.com/23105-551
PCB PIEZOTRONICS’ SERIES 5400 WHEEL FORCE TRANSDUCER SERIES With onboard signal conditioning, calibration circuitry Designed as one-piece units that mount between the vehicle hub and wheel rim, the Series 5400 Wheel Force Transducers (WFT) are equipped with onboard signal conditioning and calibration circuitry for each channel of data measurement. Water-resistant products, available in various sizes for diverse vehicles, can be fitted with either slip ring or telemetry signal transmission. Offered in aluminum, stainless steel and titanium, the series incorporates temperature compensation and overload stops. PCB Piezotronics Inc. http://designnews.hotims.com/23105-552
Compare your controller to SIMATIC S7 Controllers. www.sea.siemens.com/S7logic
TDYTRAN’S MODEL 2006V2 DYNAMIC PRESSURE SENSOR
SCIT’S UPGRADED AUTOMOTIVE A9 SERIES RELAYS Encompass nine options, accommodates industry standard CIT Relay & Switch™’s A9 Series Relays are RoHS-compliant, accommodate standard-size automotive fuses from 3-40A and are available in 6, 12 and 24V dc coil choices. Rated 40A at 14V dc, contact resistance is less than 50ƙ mm and maximum switching power is 560W. Maximum switching voltage is 75V dc with maximum switching current 40A. Typical applications for the A9 Series include automotive and lamp accessories. Lead time is four to six weeks. ™
CIT Relay & Switch http://designnews.hotims.com/23105-553
Minimizes effects of vibration on output signal Dytran’s Model 2006V2 sensor is acceleration compensated, which minimizes effects of vibration on output signal. The hermetically sealed unit features IEPE wiring configuration, as well as a 2-pin Mil-C-5015 connector and an ¼-18 NPT standard pipe thread mount. It offers sensitivity of 50 mV/psi, and its 316L SS housing and diaphragm are electrically isolated from power ground. Applications include industrial pressure pulsations, industrial acoustic studies and pipeline leak detection.
ELECTRONICS, Continued
TCOLE HERSEE’S MASTER BATTERY DISCONNECT SWITCH Cuts off all battery power from vehicle electrical system Cole Hersee’s Master Battery Disconnect Switch also provides an effective emergency power cutoff, protecting vehicles from tampering, theft and battery drain. The switch also provides service personnel with an extra level of safety, protecting them from hazards, and can be locked-out or tagged-out to satisfy OSHA requirements for energy isolation. Cole Hersee Co. http://designnews.hotims.com/23105-555
Dytran Instruments Inc. http://designnews.hotims.com/23105-554
ACE offers a complete line of Bi-directional, Uni-directional and Bi/Uni-directional models
See our online catalog
new Series introduced · 19Extend life · Preventproduct lid & panel closure damage · Superior noise suppression · Always dependable rotation · Farmington Hills, MI 48335 tel: 800-521-3320 fax: 248-476-2470 e-mail: shocks@acecontrols.com
acecontrols.com
Distributor Inquiries Welcome 54
"EWFSUJTFNFOU
ELECTRONICS, Continued
ENM CO.’S SERIES T47 MERCURYFREE LCD MINIATURE HOUR METER Features five-digit, 3.8-mm LCD ENM Co.’s Series T47, a mercury-free LCD miniature hour meter, is being introduced to replace the company’s mercury hour meter, following a ban on mercury in Europe. The mercury-free version features a fivedigit, 3.8-mm display; operating power of 100-250V ac, 50/60; and internal memory. The minimum battery life of the hour meter, which measures 1.82 x .60 x .38 inch, is five years without external power. ENM Co. http://designnews.hotims.com/23105-556
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SIWAKI’S SMX-F SERIES Modular structure handles liquids with increased specific gravities Iwaki America’s SMX-F Series is a selfpriming compact pump capable of lifting up to 13 ft of fluid in under 90 sec. It is available in seven different flow configurations and produces flows up to 90 GPM and TDH up to 83 ft. Iwaki America Inc. http://designnews.hotims.com/23105-559
FLUID POWER
X SIERRA INSTRUMENT’S STEEL-MASS MODEL 640S Now available with selfcleaning purge port field Sierra’s Steel-Mass Model 640S Immersible Thermal Mass Flow Meter is constructed of heavyduty 316 stainless-steel wetted materials designed for demanding industrial gas mass flow measurement applications. It is hazardous area-approved by CSA and CRN (Canada), FM (U.S.), ATEX, CE and PED (EU), IEC Ex (Australia) and Chinese Pattern Approval (China). Meter accuracy is ±1 percent of reading plus ±0.5 percent of full scale with repeatability of ±0.2 percent of full scale. Sierra Instruments Inc. http://designnews.hotims.com/23105-557
TASHCROFT TYPE 1259
SBESWICK’S PRDHF, PRDHF8 HIGH-FLOW PRESSURE REGULATORS Sets industry standards for light weight, small size The PRDHF-ANB-C allows for higher flow through the regulator when compared to the PRD pressure regulator. The PRDHFANB-C-DEF high flow regulator sets an industry standard for miniaturization, as well as light weight. For gas and pneumatic pressure regulation applications, it’s particularly useful when space and weight are critical. The PRDHFANB-C-DEF weighs approximately 35 gm in brass and stainless steel and about 18.2 gm in aluminum. Beswick Engineering Co. Inc. http://designnews.hotims.com/23105-560
4BGFUZ Siemens is the safe and responsible choice. Accommodating both standard automation and safety, SIMATIC S7 Controllers eliminate the need for two controllers, saving significant cost while reducing complexity. S7 Controllers provide:
• Certified Compliance • Easy Integration • Common Platform • No Extra Engineering
PROCESS GAUGE Features a solid front safety case The Type 1259 process gauge is offered with an as-welded Bourdon tube to ensure longer life than competitive gauges. Meeting ASME B40.1, it has been engineered to meet marketplace requirements and features a solid front safety case; adjustable, selflocking micrometer pointer; and ranges to 20,000 psi. A date-coded socket ensures pedigree. Ashcroft Inc. http://designnews.hotims.com/23105-558
CLIPPARD’S STAINLESS-STEEL PNEUMATIC CYLINDERS Available in 12 bore sizes, strokes up to 40 inch Clippard’s pneumatic cylinders feature polished ID 304 stainless-steel tubes for low break-away. They are available in 12 bore sizes with strokes up to 40 inch. Clippard also manufacturers brass and corrosionresistant models, as well as the Minimatic® compact Air Force One® cylinder. Clippard Instrument Lab. Inc. http://designnews.hotims.com/23105-561
Compare your controller to SIMATIC S7 Controllers. www.sea.siemens.com/S7safety
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H A R D WA R E / S O F T WA R E
TOTHER WORLD COMPUTING’S VOYAGER PRODUCT LINE Hard Drive Docking Bundles, FireWire® 800/400 compatible OWC’s Voyager product line includes a docking mechanism that allows users to insert any standard 2.5or 3.5-inch SATA I/II hard drive with up to 2.0TB capacity. It also allows connection to a Mac or PC via a quad-interface options, including FireWire® 800, FireWire® 400, USB 2.0 or eSATA. Other World Computing http://designnews.hotims.com/23105-563
TNEWER TECHNOLOGY’S NEW VOYAGER Q Adds new life to old, swapped out drives Newer Technology’s Voyager Q Hard Drive Docking Solution turns any 2.5 or 3.5 inch Serial ATA (SATA) I/II up to 2.0TB hard drive into a fully bootable and hot-swappable external drive solution. It also features four interfaces: FireWire® 800, FireWire® 400, USB 2.0 and eSATA for maximum data transfer performance and connection flexibility. Voyager Q is a plug-and-play, easy-to-use external hard drive solution that works with both Macs and PCs. It also features a weighted based and non-skid rubber feet for stable operation, two-color status LED, quiet operation and a compact design — 3.94 x 5.93 x 3.17 inch. It weighs 1.32 lb and comes with a one-year warranty. Newer Technology Inc. http://designnews.hotims.com/23105-564
SVIA’S VIA NSR7800 2U RACKMOUNT SERVER Ideal base for e-mail, file, Web server applications With eight, 3.5-inch hard drive bays in a 2U form factor rackmount chassis, the VIA NSR7800 offers system integrators the perfect balance of power efficiency, performance and capacity. Powered by an energy-efficient 1.5GHz VIA C7 processor, the VIA NSR7800 is an ideal base for a variety of rackmount server applications including e-mail, file and Web server products. VIA Technologies Inc. http://designnews.hotims.com/23105-565
TAVX’S COMPONENT MODELING, SIMULATION SOFTWARE Multiple parameter graphing options AVX Corp.’s new component modeling and simulation software, the Designated AVX Component Simulator, enables designers to view all basic characteristics and parameters for Accu-P, Accu-L, Thin Film Low Pass Filters, Couplers, 3dB Splitters, Hi-CV SMT, LICC, LGA and IDC products. The simulation software features multiple parameter graphing options including Smith Charts, S-parameter, ESR, impedance, current, inductance and capacitance values. AVX Corp. http://designnews.hotims.com/23105-566
.PUJPO Siemens is the right choice to keep your operation moving forward. The reality of machine control is that both motion control and automation must work in tandem. SIMATIC S7 Controllers approach automation and motion as a single control task, providing:
• Libraries • Wizards • Flexibility • Simplicity
NEXT VIEW’S LATEST VERSION OF NEXT VIEW LIVE™ Expanded support, integration Next View Software’s release of the latest version of Next View Live™ includes enhanced cross-platform integration capabilities. The innovative platform now has expanded support and integration of third-party supply chain applications including WMS, TMS and industry portals. Next View Software Inc. http://designnews.hotims.com/23105-567
Compare your controller to SIMATIC S7 Controllers. www.sea.siemens.com/S7motion
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M AT E R I A L S / FA S T E N I N G
TGKS LASER SCANNING Helps 3M™ correct face shield design The need for safety, security and the protection of people working in facilities around the world is increasing every day. 3M™’s Occupational Health and Environmental Safety (OH&ES) Div. was tasked with developing a new face shield for welders. About halfway through the design and prototyping phase, 3M™ realized it needed to improve the aesthetics of the design and needed new CAD data to revise the model. GKS Inspection Services http://designnews.hotims.com/23105-568
S ALL METRIC’S CORROSIONRESISTANT PULL-DOWN LATCHES Designed for boxes, transportation equipment A new series of Corrosion-Resistant Pull-Down Latches from All Metric Small Parts (aMsp) is designed for various types of boxes and transportation equipment. Because springs are used, a tightening force is applied when the latch is closed. Since the latch is stainless steel, it has excellent corrosion resistance. The holes for a padlock are on the side, preserving the appearance, even when there is no lock. 3-D CAD models are available for download on the aMsp website. All Metric Small Parts (aMsp), a division of Designatronics Inc. http://designnews.hotims.com/23105-569
M AT E R I A L S / FA S T E N I N G , C o n t i n u e d
TSOUTHCO®’S R4-EM ELECTRONIC ROTARY LATCH With push-to-close operation This easy to install, easy to maintain solution delivers the convenience of electronic access control with the security of a proven, robust, all-metal rotary latch design in a compact, integrated package. Easy push-to-close operation and electronic actuation simplify access across a wide variety of applications. Southco® http://designnews.hotims.com/23105-571
expand Reell’s diverse catalog products and opens up opportunities for Reell to further expand into the marine, medical and food industry markets. Reell Precision Mfg. Inc. http://designnews.hotims.com/23105-572
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MOTION CONTROL
TCARLO GAVAZZI’S RSHL SMART SOFTSTARTER
SSAINT-GOBAIN’S MELDIN® 7000 THERMOSET POLYIMIDE MATERIALS Meet many standard specifications for polyimide The Meldin® 7000 series of materials exhibit extremely high geometric stability at elevated temperatures. Exhibiting more toughness as compared to the Meldin® 2000 series, the Meldin® 7000 grades can be molded into finished or semi-finished parts using direct forming, an automated pressing operation capable of producing complex features with tight tolerances. Meldin® 7000 grades meet many standard specifications for polyimide, such as MIL-6-46198, ASTM D 6456-99 and SAE Aerospace Material Specification AMS 3644E. Saint-Gobain Performance Plastics http://designnews.hotims.com/23105-570
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REELL’S STAINLESS-STEEL POSITIONING HINGE Allows expansion into marine, medical, food industry markets Reell Precision Mfg., a world leader in custom hinges and hinge design of small package torque hinge solutions, has released the Reell PHCS Stainless-Steel Hinge, the first in a series of 316 Stainless-Steel Friction Hinges. These hinges
With overload protection The RSHL Smart Softstarter controls and protects three-phase induction motors rated up to 5 hp at 220V ac, 10 hp at 480V ac and 15 hp at 600V ac. Soft starting and stopping can be achieved with nine customizable (time and shape) voltage ramping profiles. A current-limiting starting option is also available. The built-in, manually adjustable, electronic overload can be set for either a Class 10 or Class 20 trip characteristic and for manual or automatic reset. Carlo Gavazzi Automation SpA http://designnews.hotims.com/23105-573
THELICAL’S NEW WEBSITE
MOTION CONTROL, Continued
SQBC’S BBXCAM-CNNEW NEEDLE BEARING CAM Reduced friction, quiet operation QBC’s Needle Bearing Cams feature hardened and ground outer race and low-carbon alloy steel hardened studs and inner races. These cam followers are both hex-head or slotted-head type and are available in nominal I.D.’s ranging from ½ to 4 inch. The cam followers may only be lubricated through the head end and have a clamping torque based on dry threads. Quotes and online orders are available at the new QBC eStore. This design gives the company’s cam followers reduced friction, quiet operating ability and increased durability. Quality Bearings & Components http://designnews.hotims.com/23105-574
Offers better user experience Helical Products Co. Inc.’s new website focuses on delivering a vastly improved user experience and key technical information. A new “Flexure Facts” database is easily searchable to find all of the various uses flexible couplings can be applied to, from aerospace to medical applications. The HELI-CAL® Flexure is a flexible helix (curved) beam machined from one piece of material into a specific configuration that incorporates special design requirements, performance features or characteristics.
3-D models. The Cylinder Configurator, accessible through Peninsular’s website, makes ordering cylinders easier by having users answer questions from drop-down menus, thus eliminating the need for confusing cylinder catalogs and complex engineering data. Peninsular Cylinder Co. http://designnews.hotims.com/23105-576
Helical Products Co. Inc. http://designnews.hotims.com/23105-575
SSTEINMEYER’S NEW VOICE COIL DRIVEN STAGE
PENINSULAR’S HYDRAULIC CYLINDER CONFIGURATOR Generates ready-to-use drawings The Peninsular Metric model IHP Hydraulic Cylinder Configurator is now providing 2-D dimensional drawings and
Compact table weighs 1 kg The application is a proprietary bio-medical device used for cell manipulation and testing. With an overall footprint of just 80 x 50 x 145 mm, the compact table weighs just 1 kg. It is available with a choice of two travels, 5 or 7 mm. By incorporating a Renishaw linear scale, the stage has a standard resolution of 0.1 μm (micrometer), repeatability of 1 μm and positioning accuracy of 3 μm. Other specifications are available. Typical speeds of 1 m/s and accelerations of 5 m/s2 are easily achieved. Steinmeyer Inc. http://designnews.hotims.com/23105-577
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CALAMITIES
Tr u e S t o r i e s
MYRON J. BOYAJIAN PRESIDENT ENGINEERING CONSULTANTS
and found to be in good order, with no electrical fault paths to the truck frame. Housekeeping and maintenance was a high priority. Spills were cleaned up regularly. In fact, a maintenance crew replaced a broken fluorescent fixture over the caustic tank only a week before the accident. That time, another driver raised the forks, hit and bent the fixture, breaking the lamps. The crew quickly replaced the fixture and its 8-ft-long, 220V ac lamps. The Smoking Gun
THE CASE OF THE LETHAL LAMP An unfortunate forklift driver becomes part of a lethal circuit IMPROPER INSTALLATION OF EQUIPMENT CAN RESULT
in serious injury or worse, but other evidence may hide an accident’s actual cause.
Plant personnel admitted the fixture had also been broken during the fatal accident. The electrician who replaced the fixture prior to this accident admitted, “I might have missed” making a secure ground connection. Whoa! Suddenly, in a perverse way, the broken light fixture lit up the dark corners of this puzzle. The accident sequence seemed clear. The raised mast smashed the ungrounded light fixture and energized the truck with 220V. Without lowering the forks, the driver began dunking the hides into the tank. The driver must have touched both the metal pallet and tank, completing the fault circuit with fatal results. Had the fixture been properly grounded, a circuit breaker would have tripped and removed power. Despite my conclusions, the attorney insisted the truck was at fault. Monetary damages could not be recovered from the employer, hence the need to find fault within the forklift. My insistence that the truck did not have any electrical faults put an end to my participation in this case.
The Scene of the Crime
At a tanning plant, cow hides were dunked into a caustic solution to remove hair. A driver lifted a metal pallet of hides over the tank. As he dunked the hides, he called out in pain, fell to the ground and expired. An autopsy confirmed he died from an electric-current-induced cardiac arrest. The driver’s family’s attorney suspected an electrical fault in the forklift and retained me to determine the accident’s cause.
This illustration depicts how the forklift accident likely occurred.
The Investigation
I reviewed the forklift service records, operator and maintenance/repair manuals, and witness statements. I was puzzled because the truck met UL Standard 583. With its isolated 36V dc electrical system, the truck frame was not part of any control or power circuit. Barring catastrophic component or wiring failure, or misuse or tampering, it seemed unlikely the truck hurt the driver. I considered the possibility that the conductive caustic solution in some way splashed onto or into the forklift control system, resulting in an electrically “live” truck. This didn’t add up as the driver’s body would still have to become part of an electrical circuit. Cardiac arrest can occur with only a few milliamps of current, so low voltage could cause injury with a sufficiently low resistance path into the driver’s body, say, if the conductive caustic solution splashed on the driver. The forklift was tested immediately after the accident 62
D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
Calamities is picked up regularly in our Sherlock Ohms blog. Go to www.designnews.com/Sherlock to comment on this article and read more cases.
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
GADGET FREAK ONLINE Check Out Gadget Freak Case #139: Autonomous Blimp Has a Mind of Its Own
THE GADGET FREAK® FILES CASE #140
Nick Wagner’s infraLED Zeppelin charts its own course: http//designnews.hotims.com/23105-510.
Security Robot Roams, Shrieks at Intruders
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.
ADVERTISEMENT “DOMO ARIGATO MR. ROBOTO” Amt
ere’s a robot that will roam your home or office seeking intruders. The Searching Security Robot was designed by Ian Smith and his fellow students in a mechatronics’ course at Colorado State University. It sits on motor-powered wheels and its eyes consist of an ultrasonic range finder to keep it from bumping into walls. Once it’s set up, the robot will roam a building seeking moving objects. It has four infrared sensors that detect motion in 360 degrees. When a moving object is detected, the robot sounds its alarm. Check out the Security Robot in action at
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www.designnews.com/GadgetFreak.
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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. And don’t forget to supply us with a video file of your gadget in action. 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.
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D E S I G N N E W S M AY 2 0 0 9 [ w w w. d e s i g n n e w s . c o m ]
Part Description
Allied Part #
1
24 x 2 LCD Display
670-1141
1
Geared Stepper Motor
316-0060
4
Relays
788-1033
1
Keypad
948-7874
4
Power Transistors
503-0330
5
PIC16F88 Microcontroller
383-0496
7
0.1 μF Capacitors
507-0820
15
1,000 Resistors
296-4741
5
330 Resistors
296-4764
4
Breadboards
237-0015
Additional parts required: For a complete list of parts, go to www.designnews.com/GadgetFreak.
To get Gadget Freak delivered directly to your inbox, along with more Gadget Freaks, sign up here: www.designnews. com/GadgetFreak. For parts’ information, call (800) 433-5700 or go to www.alliedelec.com/gadgetfreak SPONSORED BY » Photo: Kevin Maloney