August 9, 2012 A Penton Media Publication Tune in to EngineeringTV.com 200 mph and BATTERY POWERED page 20 FOCUS on ENERGY WILL NATURAL GAS POWER OUR CARS AND TRUCKS?, page 40 HOW TO MAKE PNEUMATICS MORE ENERGY EFFICIENT, page 44 ULTRACAPACITORS HOP UP MICROHYBRIDS, page 48 [ MOTOR TRUTH #13 ] Are you into belts and chains? If not, then you need SEW’s patented TorqLOC® Its keyless hollow shaft and taper bushings eliminate inefficient belts, chains, and sprockets thus reducing maintenance and energy costs while enhancing system safety Mounting Its spacious air gap provides easy mounting Its tightening bolts provide easy dismounting No more tight tolerances! No more keys! Need retrofit? No problem TorqLOC even mounts onto an existing shaft that has a keyway Visit sewmotortruth.com/truth13 for other ways to reduce energy sewmotortruth.com/truth13 RS# 101 Dismounting !" ,":%,"$ A!% $ Compact Thermal Imagers OSXL-I3 (FLIR-i3) !"# $% & '( ) *%' +% ,% "$% "%+ -.*/0% 1 23#"3 © 2012 Tyco Electronics Corporation, a TE Connectivity Ltd company All Rights Reserved TE Connectivity, TE Connectivity (logo) and Tyco Electronics are trademarks of TE Connectivity Ltd companies RS# 117 THAT’S WHY THE LEADING INDUSTRIAL COMPANIES COUNT ON TE CONNECTIVITY Productivity Efficiency Reliability It all depends on better connectivity TE Connectivity is there, every step of the way—leveraging innovations across markets to deliver the broadest portfolio of solutions to connect power, data and signal in the toughest working environments Whether it’s more automated processes, intelligent buildings, smarter transportation or cleaner energy, we’re helping solve industries’ greatest connectivity challenges And making every connection count EveryConnectionCounts.com REPORTER’S NOTEBOOK India beefs up its automotive testing When one thinks about countries noted for their automobiles, thoughts usually turn to Germany, Italy, France, and, of course, the U. S India as an automotive manufacturer seldom comes to mind But a joint project by the government of India, a number of state governments, and the Indian Automotive Industry may change all that Their combined effort has led to the establishment of centers that are part of the National Automotive Testing and R&D Infrastructure Project (NATRiP) That project is targeting basic automotive R&D, component testing, and validation procedures to ensure compliance with national and international automotive stanA technician at a NATRiP automotive test center in India sets the parameters for a driver’s dards The goal of the project is chair mounted on a Moog DOF multi-axis shaker table The table can simulate the to move India into a prominent vibrations, frequencies, and impacts of a vehicle on the road, compressing 20 hours of position in the global automodriving into a single hour of table time tive market NATRiP facilities also aim to Resources: boost automotive-part manufacturing and exports In addition, the hydraulics Moog Industrial from India OEMs, along with Tier and component are paired with environmenGroup, www.moog.com suppliers, can use the testing facilities to help make tal chambers that let test RS# 406 automotive products that meet specifications in the engineers dial in different cliNATRiP, www.natrip.in/ world market mates For One of the suppliers example, of test equipment in the the chambers can create temperature centers is the Industrial swings from -45 to 80°C over a 2-hr Group of Moog Inc., period, while maintaining humidElma, N. Y It is providing ity levels from 10 to 90% This isn’t servohydraulic test equipquite the range needed to produce ment, including simularain in the chamber, but it can create tion tables (also known fog The chambers also let engineers as multiaxis shaker tables check component resistance to or MASTs), tire-coupled sunlight The artificial sun within the simulators, universal test chamber can generate 1,350 W/m2 benches, and hydraulic According to Terence Miranda, power units This test equipment can simulate on-road program manager for NATRiP, the centers can replicate load conditions in the laboratory for small compo1,000 customer-equivalent miles for every hour under nents or full-sized vehicles test Manually driven tests usually only average apEach MAST consists of a six-degree-of-freedom taproximately 50 mph, and so it would take 20 hr of drivble that can replicate the vibrations, frequencies, and ing time to replicate 1,000 miles of wear and tear impacts of a vehicle traveling on a highway AutomoAll equipment uses the same controllers and software tive simulators can easily recreate 10-g shock loads for safety, reproducibility, and simpler maintenance MD The goal of the National Automotive Testing and R&D Infrastructure Project is to move India into a prominent position in the global automotive market 24 MACHINE DESIGN.com AUGUST 9, 2012 INDUSTRIAL AUTOMATION NORTH AMERICA at IMTS 2012 027,21'5,9(6 $8720$7,21&21)(5(1&( Penton Media’s Design Engineering Group and the National Fluid Power Association will present two in-depth conference tracks — 1) Motion Control in Automation, and 2) Hydraulics and Pneumatics in Automation — for engineers and individuals tasked with improving performance, productivity, life, efficiency, and environmental footprint of manufacturing equipment and industrial automation systems 027,21&21752/,1$8720$7,2175$& RECENT ADVANCES IN PREDICTIVE TECHNOLOGIES FOR NEXTGENERATION MACHINES AND MANUFACTURING SYSTEMS Unscheduled downtime is a productivity killer that can cost a company tens of thousands of dollars in damaged goods and lost output Here’s a look into the latest research involving condition monitoring and predictive maintenance, along with advice on how to economically upgrade controls and equipment Speaker: Research Center on Intelligent Maintenance Systems, University of Cincinnati TRENDS IN HIGHSPEED BEARINGS Spindles on machine tools, and machines in general, are running faster That can lead to issues like vibration, chatter, and other unwanted dynamic characteristics that adversely affect cutting speed and quality, as well as the precision and repeatability of movements New bearing designs, lubricants, and sophisticated software counteract these problems and let engineers further push the machine-design envelope Speaker: Schaeffler Group SECURITY IN INDUSTRIAL AUTOMATION Computer viruses like Stuxnet, Duqu, and now Flame are making news for infecting and wreaking havoc on industrial computers and controllers This session offers timely advice on steps to take to protect your equipment from viruses, hackers, industrial espionage, and even the well-intentioned but misguided worker on the plant floor Speaker: Rockwell Automation HOW SMART ENGINEERING & MODULAR HARDWARE CONCEPTS CONTRIBUTE TO EFFECTIVE MACHINE AUTOMATION SOLUTIONS We will explore the latest market trend of OEMs transitioning from a one-sizefits-all approach to custom solutions Plus, learn effective ways to overcome the challenges of completing more engineering projects with fewer resources and how a mechatronic engineering approach, efficient software tools, and modular hardware provide effective solutions for your equipment Speaker: B&R Industrial Automation TECHNIQUES FOR BOOSTING MACHINE EFFICIENCY The motors and drives, gears and drive trains, controls, cooling, and auxiliary functions, as well as proper power management, all play a role in machine efficiency Several techniques can be employed to reduce the amount of energy a machine consumes Speaker: Heidenhain Corporation THINK LIKE A MACHINIST Many designers and engineers learn solid modeling in universities or technical schools and then start designing machines and components without considering whether the 3D CAD component is actually manufacturable The result: The machinist is often confronted with parts that are unnecessarily difficult or impossible to make This discussion will offer some practical tips on how engineers and CAD/CAM users can design easier-to-manufacture components that cost less, offer faster turnaround, and consistently higher quality Speaker: Aztalan Engineering MECHANICAL AND STRUCTURAL CONSIDERATIONS FOR PRECISION MOTION CONTROL In high-speed and high-precision motion systems, controls engineers who ignore the mechanical components and machine structure so at their own risk We examine mechanical factors engineers should consider, such as inertia, natural frequency, vibration, thermal deformation and other factors that lead to a loss of precision, and explain how to compensate for or totally eliminate the problems Speaker: Bosch Rexroth NEXT GENERATION CNCS CNCs and motion controllers are the brains of many manufacturing systems Here’s a look at recent advances in “intelligent” machine controls, artificial intelligence, adaptive control, and low-cost controllers with advanced functions Speaker: Siemens V To register for the MDA conference and IMTS, please visit industrialautomation-na.com For more information please contact: Adrian Piazza at 216-931-9426 or adrian.piazza@penton.com Our New Standard in Geared AC Motors REPORTER’S NOTEBOOK • Times More Torque • High Strength, Long Life • Quiet Operations • Same Price As Conventional Models Custom couplings and springs let rover explore Mars Resources” Helical Products Co Inc., heli-cal.com RS# 407 V Series geared AC motors offer distinct advantages over conventional geared AC motors and now they are offered at the same price as our conventional models Quick & Stable Lead Time The arm on front of Curiosity, Visit www.orientalmotor.com Technical Support Tel: 800-468-3982 7:30am- 7:00pm, CST (M-F) Stepping Motors • Servo Motors • AC Motors • Brushless Motors • Linear & Rotary Actuators • Cooling Fans RS# 118 The NASA rover Curiosity recently NASA’s latest Martian rover, will reached Mars and if all went well, the carry a custom coupling wheeled robot is relying on several custom components from the engineers at Helical Products Co Inc., Santa Maria, Calif For example, the subsystem mounted on the rover’s front-mounted arm that will dig up and retrieve soil samples makes use of a flexible coupling from Helical The coupling lets soil samples be vibrated and sifted, so only powder is transferred inside Curiosity for further processing and analysis The coupling is compliant in all directions (axial, angular, and parallel), so it can compensate for misalignments to the vibratory drive The coupling also reduces bearing loads on the drive while reliably transmitting the torque needed to sift the samples After five months of intensive design work, Helical manufactured the couplings out of 15-5PH stainless steel heat treated to H1025 This will give the device the strength, fatigue resistance, and ability to maintain these characteristics despite the frigid Martian temperatures (–160°F) Engineers at Helical also had to add NASA-specified connectors to both ends of the coupling The rover also incorporates custom-machined springs from Helical They are critical components in a locking mechanism that ensure the rocker-bridge joints in the rover’s six-wheeled suspension stay locked in place once unfolded and deployed on the surface of Mars The lightweight titanium springs had to meet strict requirements for compression and lateral translation spring rates And like the couplings the company made for the rover, the springs needed to have NASAapproved connectors MD AUGUST 9, 2012 New chips offer efficiency with accuracy? Not exactly… Resources: Rice University, Prototypes of a new bit.ly/JNjFdN computer chip recently unveiled at the ACM International Conference on Computing Frontiers are 15 times more efficient than equivalent chips made using current production technology, promising major power reductions and extended battery life for portable devices But these efficiency gains didn’t come without a price: the chips make occasional errors Though the concept Inexact computer chips like this prototype are 15 is deceptively simple, times more efficient in terms of speed, size, and a research team with energy consumption than today’s microchips members from Rice Photo: Avinash Lingamneni/Rice University/CSEM University in Houston, Nanyang Technologies University in Singapore, the Center for Electronics and Microtechnology in Switzerland, and the University of California, Berkeley, has been working on the project since 2003 The goal was to get “inexact” chips that use less power by making a few mistakes in calculations By managing the likelihood of errors and limiting which calculations create errors, researchers found they can cut energy demands while boosting performance One approach eliminates rarely used portions of digital circuitry The first pruned chips were twice as fast, half the size, and only needed half the energy of their more-accurate, intact cousins Another approach uses a technique called confined voltage scaling It takes advantage of processing speed to cut power demands Tests show inexact chips with an average 0.25% error rate cut energy demands by a factor of 3.5 compared to traditional chips That factor could rise to 15 Obviously, high-error rates would not work well in an engineering environment But processing a photo is another matter There, small errors are ignored by the human eye For example, it was found relative errors up to 0.54% were almost indiscernible while rates up to 7.5% still produced discernible images Initial uses for the pruning technology will most likely be in application-specific processors embedded in hearing aids, cameras, and other electronic devices The inexact hardware is also key to a new educational computer tablet called an I-slate The I-slate is for classrooms in India with no electricity and few teachers The low-power needs of the pruned chips should let the I-slate run on solar panels similar to those in handheld calculators The first I-slates are expected to go on sale next year MD AUGUST 9, 2012 • Compact, High Torque • Wide Speed Range • Continuous Duty • No Maintenance Brushless Motor Advantages REPORTER’S NOTEBOOK Brushless Motors offer all the design flexibility needed for many different types of applications Learn more about the Brushless Motor Advantages from Oriental Motor Quick & Stable Lead Time Visit www.orientalmotor.com Technical Support Tel: 800-468-3982 7:30am- 7:00pm, CST (M-F) Stepping Motors • Servo Motors • AC Motors • Brushless Motors • Linear & Rotary Actuators • Cooling Fans RS# 119 REPORTER’S NOTEBOOK LOOKING BACK 10 YEARS AGO — 2002 to pass fraudulent checks The software will work with the ICE 7000CE Web-enabled card payment terminal from Hypercom Corp., Phoenix Check forgers take note: Photo ID software is on your case — True ID photo-identification software from Identico Systems LLC, Nashua, N. H., may help catch scofflaws trying A driver’s license or other valid photo-ID card is first scanned, encrypted, and stored on the True ID device, along with payment information When the customer next pays with a check or credit card, the device instantly displays their photo on the terminal for verification The ICE 7000CE has a 6-in., 256-color ¼-VGA touch graphics and pen-input screen It uses a 32-bit CPU running at 128 MHz 30 YEARS AGO — 1982 Screen eliminates CRT keyboard: An unusual touch-sensitive CRT screen from Detector Electronics, Minneapolis, supplements — and can supplant — a conventional keyboard Called TouchMagic, the transparent control screen is said to be a simple and straightforward method of interfacing between people and computer memory No special training or keyboard expertise is needed The screen, which fits over conventional CRT screens, has 16 horizontal electrical paths on a convex glass panel positioned opposite 16 vertical paths on a plastic sheet Each position where the 32 paths cross is a switch position 50 YEARS AGO — 1962 Manned moon landing from an orbiting spacecraft is foreseen by two Lockheed Missile & Space Co engineers A space vehicle carrying three or four men would be launched from the Earth and enter moon’s orbit at an altitude of 100 miles A two-man vehicle would detach from the craft, descend to the moon for a week’s stay, the return to the orbiting vehicle for the trip back to Earth This plan is similar to one for Project Apollo, which was recently approved by NASA MD 28 MACHINE DESIGN.com AUGUST 9, 2012 (PPEOFXT ZPVμWFCFFO VQHSBEFE /FXVQHSBEFE4,'&YQMPSFS TFMGBMJHOJOHSPMMFSCFBSJOHT DBOQSPWJEFVQUPUXJDFUIF TFSWJDFMJGFVOEFSEJG¾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’S NOTEBOOK COMPANY NEWS NEW FACILITY Altra Industrial Motion, South Beloit, Ill., is building a 90,000-sq-ft manufacturing facility in Changzhou, China (near Shanghai) The new plant will be home to Altra Industrial Motion Changzhou (AIMC) Altra is multinational de- signer, producer, and marketer of mechanical power-transmission products, as well as the largest selection of industrial couplings ACQUISITION Agilent Technologies, Santa Clara, Calif., will acquire the test and measurement business of Centellax, Santa Rosa, Calif Centellax designs and manufactures biterror ratio testers and signal generators used for testing high-speed digital-communication systems and components Agilent offers measurement product for chemical analysis, life sciences, electronics, and communications AWARDS 3V Fasteners Co Inc., Corona, Calif., a subsidiary of PennEngineering Co., received the prestigious “2011 Platinum Supplier Award” by Spirit AeroSystems Inc., Wichita, Kans The award recognizes overall customer satisfaction and excellent performance 3V Fasteners, one of only 13 companies – and the only fastener manufacturer – selected from Spirit’s entire worldwide supplier base to win the award Spirit designs and manufactures aerostructures for commercial aircraft 3V Fasteners manufactures precision aerospace fasteners AGREEMENT Dunkermotor, Elgin, Ill., a manufacturer of intelligent servomotors, has expanded its distribution agreement with Axis New England, Danvers, Mass., to include Dunkermotor’s complete line of rotary motor products Axis provides manufacturing solutions in the motion-control and machine-automation fields PARTNERNETWORK PROGRAM New suppliers and machine builders have joined the Rockwell Automation PartnerNetwork Program New Automation Encompass members in the Americas region are 3M Cogent, a wholly owned subsidiary of 3M Co within 3M’s Security Systems Div.; General Cable, a developer, designer, manufacturer, marketer, and distributor of copper, aluminum, and fiberoptic wire and cable products for the energy, electrical infrastructure, and communications markets; RF IDeas Inc., a provider of card readers A new Asia Pacific member is InHand Networks, a machine-to30 MACHINE DESIGN.com RS# 121 AUGUST 9, 2012 Technology You Can Trust Avago Technologies Optocouplers A Superior Technology for High Voltage Protection! IEC 60747-5-5 Certified Optocouplers are the only isolation devices that meet or exceed the IEC 60747-5-5 International Safety Standard for insulation and isolation Stringent evaluation tests show Avago’s optocouplers deliver outstanding performance on essential safety and deliver exceptional High Voltage protection for your equipment Alternative isolation technologies such as ADI’s magnetic or TI’s capacitive isolators not deliver anywhere near the high voltage insulation protection or noise isolation capabilities that optocouplers deliver For more details on this subject, read our white paper at: www.avagoresponsecenter.com/672 RS# 122 REPORTER’S NOTEBOOK COMPANY NEWS machine technology company Control Station Inc., a manufacturer of Loop-Pro software, has expanded its membership New members of the Rockwell Automation OEM Program (formerly the Machine Builder Program) include Aagard Group LLC, Alexandria Minn., which designs, engineers, and manufactures automated packaging machinery; and Tennessee Rand, a provider of engineering, machining, and robots a developer and manufacturer of wireless products including radiofrequency modules, is shipping the product lines it acquired from Radiotronix earlier this year RADIOTRONIX PRODUCTS ANNIVERSARY Linx Technologies, Merlin, Oreg., TÜV Rheinland, Boxborough, Mass., is celebrating 140 years of independent certification, testing, and assessment services to businesses worldwide The company began as an entrepreneurial endeavor to inspect boilers in the districts of Elberfeld and Barmen in Germany COMSOL CONFERENCE BOSTON 2012 OCTOBER - NAME CHANGE Thermadyne Holdings Corp., St Louis, has changed its name to Victor Technologies Group Inc and the name of its wholly owned subsidiary Thermadyne Industries Inc to Victor Technologies International Inc Victor Technologies provides cutting, welding, and gascontrol equipment RETIREMENT Punita Pandit, cofounder of Animatics, has retired after 24 years Punita started Animatics upon graduating from San Jose State Univ and was instrumental in establishing operations and processes of the company including finance, distribution, manufacturing, and marketing Moog acquired Animatics in 2011, at which time the company became Moog Animatics PERSONNEL Wilbrecht LEDCO Inc., St Paul, a subsidiary of Microprecision Electronics SA, has appointed Robin Lindorfer as Switches and Foil Resistors Product Manager ENGINEERING SCHOLARSHIP PROGRAM Exlar Corp., Chanhassen, Minn., awarded $1,000 scholarships to four high-school graduates planning to pursue engineering degrees In its second year, the Exlar Scholarship Program is awarded to students planning to pursue engineering degrees Exlar designs and manufactures linear and rotary-motion products MD )2)6+= RS# 123 RS# 124 !#3.18 1!,%6.1* TM is an advanced Manufacturing Execution System (M.E.S.) technology for result-oriented /%1&.1,!-#%,%!241%,%-3!-$"%-#(,!1*)-'.&)-$4231)!+2(./< 12 (%!$./3).-.&3(%3%#(-.+.'8"8'+."!+ Fortune 500 companies has increased the Overall Equipment Effectiveness (OEE) of their manufacturing facilities by up to 20% within the first 12 months of deployment Visit them at booth E-4481 or www.forcam-usa.com INDUSTRIAL AUTOMATION NORTH AMERICA at IMTS 2012 International Trade Show for Factory, Process and Building Automation Systems and Solutions at September 10 - :#.1,)#* +!#%()#!'.++)-.)2 V To register for IANA and IMTS, please visit www.industrialautomation-na.com Organized by: Partner: www.ia-na.com For more information, please contact Aryan Zandieh at (312) 924-1688 or azandieh@hfusa.com R SENSOR SENSE Ultrasonic anemometers Anemometers simply measure wind speed Many designs use the wind to spin a fan or other mechanical device The speed at which the fan turns is then calibrated to the speed of the wind In contrast, ultrasonic or, as they’re sometimes called, sonic anemometers measure wind speed using sound Sound waves travel at a constant velocity through any medium For air, that speed is approximately 1,100 fps However, the velocity of any wind may add to or subtract from the velocity of sound For example, if the wind blows in the direction of travel of a sound wave, the velocity of the wind adds to the sound’s velocity Conversely, wind blowing against the direction of the sound reduces the sound’s velocity Ultrasonic anemometer operation Length of arrows shows relative speed of sound Longer arrow = faster sound N (Vs + Vw) Vs = Velocity of sound in still air Vw = NS or EW velocity of wind (Vs + Vw ) – (Vs – Vw ) 2V = w = Vw Calculations are made for both NS and EW pairs E W (Vs – Vw ) Wind WS = Wind speed VNS = Vw for NS pair VEW = Vw for EW pair WS = VNS + VEW Ultrasonic transceivers S Wind velocity is measured in both the North-South (NS) and EastWest (EW) directions Those values are then used to calculate overall wind speed ([WUHPHO\UREXVW6HQVRUV IRUDQJOHLQFOLQDWLRQ SRVLWLRQPHDVXUHPHQW 326,7$3(〲 7DSH([WHQVLRQ 3RVLWLRQ6HQVRUV x 0HDVXUHPHQWUDQJH LQ x $QDORJP$66, &$1RSHQ- x 3URWHFWLRQFODVV,3 ,3 326,&+521〲 3&)3 0DJQHWRVWULFWLYH 3RVLWLRQ6HQVRUV x 0HDVXUHPHQWUDQJH LQ x $QDORJP$66, &$1RSHQ- x 3URWHFWLRQFODVV,3 ,3 326,&+521〲 0DJQHWRVWULFWLYH 3RVLWLRQ6HQVRUV 0HDVXUHPHQWUDQJH LQ x $QDORJP$66, &$1RSHQ- x 3URWHFWLRQFODVV,3 ,3 326,527〲 0DJQHWLF$QJOH6HQVRUV Edited by Robert Repas AUGUST 9, 2012 3&67 35$69 x DQJOHVHQVRU x $QDORJLQFUHPHQWDO 66,&$1RSHQ- x :LWK LQVKDIW x 3URWHFWLRQFODVV,3 ,3 326,7,/7〲 ,QFOLQRPHWHUV The design of an ultrasonic anemometer starts with two pairs of ultrasonic transceivers One pair is aligned in a North-South direction (the NS pair), while the other pair is aligned in an East-West direction (the EW pair) Each pair measures the amount of time needed to send a sound pulse from one transceiver to the other in both directions As the distance between transceivers is fixed, the velocity of the sound can be calculated from the elapsed time In one direction the wind velocity adds to the sound velocity and subtracts from it in the opposite direction Subtracting the velocity in one direction from the velocity in the other direction and dividing by two gives the velocity of the wind along each axis Summing the wind velocities for each axis determines the overall wind velocity However, as the NS and EW axes are perpendicular to the other, one must use right-angle addition from the Pythagorean theorem: square each velocity, add them together, then take the square root of the sum Ultrasonic anemometers have an additional benefit not found in other types of anemometers They can also display wind direction by calculating the arctangent value of the NS and EW velocities MD :% 37$037'0 x D[HV x ,Q0(06WHFKQRORJ\ x $QDORJRXWSXW &$1RSHQ- x 3URWHFWLRQFODVV,3 ,3 326,7,/7〲 37$037'0 ,QFOLQRPHWHUV x D[HV x $QDORJRXWSXW &$1RSHQ- x3URWHFWLRQFODVV,3 RS# 126 $606HQVRUV,QF ZZZDVPVHQVRUVFRP LQIR#DVPVHQVRUVFRP 7HO$6086$ COMMENTARY Two sides of a green-energy failure Creative Solutions for Your Applications! ,QJHDUER[HVHOHFWULFPRWRUVPDWHULDOVKDQGOLQJ V\VWHPVZLQGWXUELQHVUDLOYHKLFOHWUDFWLRQ PRWRUVSXPSVRUDJULFXOWXUDOPDFKLQHU\ 1.(EHDULQJVFDQEHIRXQGZKHUHYHUURWDU\ PRWLRQWDNHVSODFH :HGHYHORSDQGPDQXIDFWXUHSUHPLXPTXDOLW\ EHDULQJVIRUDOODSSOLFDWLRQVLQFOXGLQJ\RXUV &RQWDFWXVWRGD\IRUPRUHLQIRUPDWLRQ 1.($8675,$*PE+ ,P6WDGWJXW& $6WH\U$XVWULD 7HO )D[ (PDLO LQIR#QNHDW ZZZQNHDW 0DLQ'LVWULEXWRULQ86$ Ritbearing 3UDWHU'ULYH &RYLQJWRQ*$ ZZZULWEHDULQJFRP LQIR#ULWEHDULQJFRP &DOOXVWRGD\WROOIUHH Kenneth J Korane Managing Editor This issue of Machine Design has a focus on energy, with a look at developments related to efficiency, storage, alternative fuels, and the like Last year in a similar edition, we reported on some of the research funded by the Dept of Energy’s Advanced Research Projects Agency – Energy (ARPA-E) Included was a story about Beacon Power and the grid-scale-flywheel energy-storage system it was developing with a $2.2 million ARPA-E grant (“Reinventing the Flywheel,” Aug 11, 2011) A big problem with renewable energy like solar and wind is that it is intermittent and often unreliable The massive flywheels Beacon hoped to develop were to serve as giant mechanical batteries, letting utilities store large amounts of electricity and deliver it when renewable sources are unavailable They would have gone a long way towards bringing green energy into the mainstream Unfortunately, Beacon has since gone bankrupt Worse, it also received $43 million in loan guarantees from the Dept of Energy’s Loan Program Office (LPO), the same program that backed Solyndra, the failed solar firm that got $535 million in federal aid Does that mean ARPA-E is a bust? I’d like to think not Its mission, according to the DOE’s Web site, is to focus on basic “out of the box” transformational energy research that industry, by itself, won’t support due to the risk — but where success would provide dramatic benefits for the nation ARPA-E’s focus is exclusively on high-risk, high-payoff concepts — technologies promising genuine transformation in the ways we generate, store, and use energy, such as biochemical-energy capture, novel battery chemistries, and revolutionary thermal-energy storage techniques Failure of projects like Beacon’s is to be expected, according to Microsoft Chairman Bill Gates Speaking at an ARPA-E conference early this year, he pointed out that funding basic research naturally has a high failure rate, noting that potentially 90% of ARPA-E projects are headed for the dustbin But the high failure rate is why we “literally need thousands of these companies to try this,” to deliver needed energy breakthroughs, said Gates He said the U. S government’s investment in energy research was woefully underfunded and, as part of the American Energy Innovation Council, called for a government investment of $16 billion per year into basic research to deliver energy innovation LPO, on the other hand, looks like corporate welfare It seeks to finance the growth of the commercial “clean-energy” industry in areas such as biomass, hydrogen, solar, wind, carbon sequestration, and alternative-fuel vehicles Its stated mission includes financing the growth of large-scale clean-energy technologies to reduce greenhouse gases and create “green” jobs, as well as reduce our dependency on foreign oil and enhance American competitiveness in the global economy LPO guarantees loans for clean-energy projects, agreeing to repay the debt if the borrower defaults It also provides direct loans to eligible automobile manufacturers and their suppliers for equipment and facilities to produce advancedtechnology vehicles and components LPO has doled out about $35 billion, while ARPA-E was appropriated about $275 million for fiscal year 2012 It appears we have our priorities backwards MD RS# 127 AUGUST 9, 2012 RS# 128 FLEXIBILITY DESIGN CHAIN SOLUTIONS FROM AVNET You think about innovation, we think about the rest Our team of engineers has the right mix of technical skills and application experience to give you the support you need – throughout the design chain Extensive technical support, FPGA design, and world-class training That’s what the No in design support can to help you focus on what you best and successfully compete in the global market Our solutions bend to meet your needs What can we for you? www.avnetexpress.com Accelerating Your Success!™ 800 332 8638 | www.avnetexpress.com | @avnetdesignwire [...]... on machines — usually for an entire The energy-efficient OVEM vacuum generator has an integrated filter and sensors that monitor the status of the vacuum system 44 MACHINE DESIGN.com AUGUST 9, 2012 44 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 2 MACHINE DESIGN.com AUGUST 9, 2012. .. subscription rates: U.S.: one year, $69; two years, $99; Canada/Mexico: one year, $79; two years, $119; All other countries: one year, $99; two years, $149 4 MACHINE DESIGN.com AUGUST 9, 2012 POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O Box 2100, Skokie, IL 60076-7800 Intelligent fans for smart savings Most axial fans of the “compact class” use the old shaded-pole motor... Subscription Policy: MACHINE DESIGN is circulated to research, development, and design engineers primarily engaged in the design and manufacture of machinery, electrical/electronic equipment, and mechanical equipment To obtain a complimentary subscription see our Web page at submag.com/sub/ mn For change of address fill out a new qualification form at submag.com/sub/mn Printed in U.S.A., Copyright © 2012 Penton... issues should not simply be the responsibility of production-floor personnel Machine and system designers and financial managers of industrial and manufacturing corporations have a stake in this as well With pneumatic systems, there are basically three different ways to approach energy savings: leak detection, design, and advanced machine diagnostics Here’s a closer look at each Leak detection a cap in... prevent machines from running at peak capacity A study by the Fraunhofer Institute in Germany looked at compressed-air systems in the European Union and concluded that 42% of the total potential savings in optimizing pneumatic systems comes from simply implementing a solid leak-detection program The objective should be to completely check the pneumatic system from the compressor (supply side) to each machine. .. " % $@ C " % " % $ 1 6 B0C $ Visit omega.com/os-vir50 Visit omega.com/pr-24 Visit omega.com/os151-usb ® Νο ® RS# 102 © COPYRIGHT 2012 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED VOLUME 84 ISSUE 11 AUGUST 9, 2012 ENERGY EFFICIENCY Chrysler had already adapted several of its vehicles, including the Ram truck, to bifuel technology, letting them run on natural gas or gasoline... built into embracing them Technologies we favor are likely to have few costs Less favored technologies are all bad In this ideal world, decisions are easy — Leland Teschler, Editor 8 RS# 107 MACHINE DESIGN.com AUGUST 9, 2012 The widest product range in the shortest lead time Scan this QR code* to learn more about Numatics Express * Requires QR code reader Configure and order hundreds of FRLs — plus thousands... Korane MECHANICAL Lindsey Frick Kenneth J Korane EDITORIAL PRODUCTION Denise Greco Editorial Production Manager Randall L Rubenking Art Director 1300 E 9th St Cleveland, OH 44114-1503 10 MACHINE DESIGN.com RS# 110 AUGUST 9, 2012 Lubriplate® The Essential OEM Lubricant Range WHEN IT COMES TO SPECIFYING LUBRICANTS FOR ORIGINAL EQUIPMENT Lubriplate® CAN MEET YOUR REQUIREMENTS 5 142 Years of Lubrication Expertise... stations, like this one Authored by: Dick Medvick Contributing Editor Cleveland, Ohio Edited by Stephen J Mraz stephen.mraz@penton.com For more on natural-gas vehicles, scan this code or go to: http:// machinedesign.com/ article/uneven-prospectsfor-natural-gasvehicles-0810 gas That might seem like a lot of natural gas, but last year the U. S Potential Gas Committee reported that the U. S has at least... 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 2 MACHINE DESIGN.com AUGUST 9, 2012 MACHINE DESIGN.com 41 Bryant Watertight Wiring Devices ) ) ) ) Watertight devices need to work, so we offer the best - and at our everyday low direct prices Rugged Bryant brand components are rated