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March 7, 2013 A Penton Media Publication Tune in to EngineeringTV.com FUTURE TECHNOLOGY ISSUE What does the FUTURE HOLD? page 46 CARBON FIBER COMES TO 3D PRINTING, page 52 DRONES THAT CAN MOVE MOUNTAINS, page 58 ELECTRIC VEHICLES — THE REAL ACTION IS IN BIKES, page 73 ROBOTS GO OPEN SOURCE, page 80 They save you a bundle Talk about a bundle of advantages! 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operator Shown here is a concept model of its futuristic SfinX excavator FEATURES 38 Motion Focus control at America’s • Ensuring quality largest steel mill • Machine vision boosts productivity on bottling line The idea of using robots for arduous tasks like mining probably dates from the dawn of the industrial age, and it’s long been a mainstay of science fiction Isaac Asimov, for one, wrote of autonomous asteroid-mining robots in the 1940s The concept is now reality, with robotic haul trucks hard at work at several mines around the world Many experts expect their numbers to grow substantially in the coming years, potentially changing the face of the mining industry Equipment manufacturers began discussing autonomous mining in the 1970s But commercializing it took numerous technology breakthroughs, along with developments that slashed hardware costs Among these are GPS for navigation, high-speed wireless communication networks, and so-called “perception” technologies: laser, ultrasonic, radar, and other sensors that can detect nearby stationary and moving objects There have also been advances in hardened electronics, processing speeds, and control algorithms And the acceptance of innovations such as electrohydraulics — where electrical signals command powerful actuators — play a key role in “drive-by-wire” steering, braking, and work functions Even with all this, autonomous mining is only in its infancy and, today, it centers around massive “ultraclass” dump truck trucks that carry several hundred tons of ore They run predictable routes in open-pit mines, loading in one place and delivering the material to another Autonomy’s benefits Fueling commercialization of these driverless trucks are the potential benefits they bring For example, they make production more efficient by letting mine operations run consistently around the clock There are no operators who need coffee and lunch breaks, and grow fatigued near the end of a shift The vehicles eliminate the productivity lost during shift changes from one crew to another, when conventional trucks sit idle Another benefit is consistent performance Trucks can be programmed to 58 MACHINE DESIGN.com Authored by: Kenneth J Korane Managing Editor ken.korane@penton.com Key points: • Autonomous mining boosts productivity, cuts operating costs, and enhances safety • Driverless haul trucks are currently working at several mines around the world Resources: Autonomous Solutions, http://autonomoussolutions.com Caterpillar, https://mining.cat.com/ command-for-hauling Flanders Electric, www.flandersinc.com Hitachi Construction Machinery, www.hitachi-c-m.com Komatsu, www.komatsuamerica.com/mining Leica Geosystems Mining, www.leica-geosystems.com/en/MiningSolutions_96237.htm Rio Tinto, www.riotinto.com/ ourapproach/17203_mine_of_the_future.asp Drones come down to Earth Haul trucks that drive themselves offer a glimpse at the future of mining Volvo Construction Equipment, www.volvoce.com MARCH 7, 2013 58 project to 46 ADARPA-fundedperfect prosthetics A effort pushes the state of the art in biomedical engineering FUTURE TECHNOLOGY 52 The future of additive manufacturing Companies, government agencies, and even tinkerers are using additive manufacturing to make production parts Your first e-vehicle could be an e-bike A speedy pace of innovation could make electric motorcycles and scooters more viable for consumers than electric four wheelers Authored by: Leland Teschler Editor leland.teschler@penton.com The Lit Motors C-1 will be a motorcycle built with automotive unibody construction when it goes into production, hopefully next year Key points: • Electric motorcycles are much easier to produce than electric four wheelers, a fact that has attracted numerous entrepreneurs • The tough part: Kinetic-energy recovery during braking because the front wheel loads much more than the rear Resources: 80 The future of robotics: Crowd-sourced code Open-source software is giving rise to emerging breeds of quasicommercial, prosthetic, and industrial robots Chip Yates Bonneville World’s Fastest Electric Motorcycle Video, http://youtu be/W_UlRWRfU88 Current Motor, www.currentmotor.com EngineeringTV.com Current Motor interview, http://www.engineeringtv.com/ video/Electric-Scooter-Cloud-Communic;OnlyEngineering-TV-Videos Lit Motors, www.litmotors.com Lit Motors C-1 on YouTube, www youtube.com/ watch?v=VkvvsRBSroA Swigz.com Pro Racing (Chip Yates) For another feature on electric motorcycles, scan this code or go to http://eetweb.com/applications/swigz_ racing_bike_121410/ You can thank the Japanese for fostering the birth of the modern electric motorcycle, but not in the way you might think “The big four motorcycle companies — Honda, Kawasaki, Suzuki, and Yamaha — are all very conservative Rather than come up with their own e-bikes, they sat back and watched events unfold That let a bunch of guys in their garages on low budgets use creativity to demonstrate e-bikes that were at parity with gas bikes,” says retired electric motorcycle racer Chip Yates Yates is in a position to know what he’s talking about In the first-ever organized race between an all-electric motorcycle and beefy, twin-cylinder, 1,150-cc gas bikes, Yates collected third-place honors on a bike carrying 102 lithium-ion polymer pouch cells and a dc permanent-magnet motor He and his team also set the world-speed record for electric motorcycles in 2011, hitting 190.6 mph during a one-mile, standing-start run in the California desert The accomplishments of Yates and his crew personify the role garage entrepreneurs have had in advancing e-bike technology E-bikes are now a hotbed of development dominated by independent inventors and small start-ups One reason is that for someone set on producing an electric-powered vehicle, it’s far more manageable to bring a motorcycle to market than anything with four wheels “In some ways bikes are a natural platform for innovation because they are easy to get your head around,” says Yates “An e-bike is relatively inexpensive to build It is a much simpler undertaking than a car You can spend more of your time on new technology rather than on building a giant platform.” In Yates’ case, some of that innovation went into coming up with a patentMARCH 7, 2013 MACHINE DESIGN.com Your first e-vehicle could be an e-bike Because they use smaller battery packs and lesspower-hungry motors, e-bikes could become practical for most people before an EV on four wheels 73 73 Access our Reader Service Web site to quickly find and request information on the products and services found in the pages of MACHINE DESIGN www.machinedesign.com/rsc MACHINE DESIGN.com MARCH 7, 2013 Get the PRO in &20081,&$7,216 We make it easier to communicate Communicating to ASCII devices can be a hassle with some control systems, but the Productivity3000 controller’s user-friendly design makes that job easier Follow along in this example to set up communications with a bar code 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