September 6, 2012 A Penton Media Publication Tune in to EngineeringTV.com Private Enterprise in Space page 44 NEW ROLE FOR CIRCUIT INTERRUPTERS: PROTECTING EQUIPMENT, page 54 DIY FABRICATION IS HOT, page 62 COPPER ROTORS BOOST MOTOR EFFICIENCY, page 70 RS# 101 High Accuracy Pressure Transducers Hermetically Sealed Gage Transducers PX409 Series All Models $475 Precision Micro-Machined Silicon Transducers and Transmitters PX409 Series Starts at $475 Hermetically Sealed for the Harshest Environments Available with Pin or Twist-Lock Connector Outputs High 0.08% Accuracy Ranges from 0-100 to 0-5000 psis (Sealed Gage) 316L Stainless Steel Wetted Parts Shock and Vibration Tested Visit omega.com/px429-sgv All Stainless Steel Pressure Transducers High Performance Silicon Technology Very High Accuracy Digital Pressure Gauge 316 SS Body, Analog Output and Optional Wireless Transmitter Visit omega.com/px309 Visit omega.com/dpg409 PX309 Series Starts at $175 0.08% Accuracy DPG409 Series Starts at $695 Visit omega.com/px409 omega.com ® Νο ® RS# 102 © COPYRIGHT 2012 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED VOLUME 84 ISSUE 13 SEPTEMBER 6, 2012 MANUFACTURING A sheet-metal class shows users how to operate equipment Members learn layout techniques, how to use the hydraulic shear, how to make corner notchers, and how to use the press brake At the conclusion of that class, these members will be authorized to set up and use the equipment on their own projects MANUFACTURING for the masses Key points: • Areas such as machining, laser, electronics, and industrial-painting sit off a large central workspace • The studio has spring boarded several small businesses Resources: Juan Martinez shows off the prototype of his cargo bike, which he built from the ground up with TechShop software and equipment FEATURES The holes in the cards were cut out on TechShop’s Epilog laser cutter The cards are used to program a Jacquard loom truckin’ with SpaceX 44 Space A private firm develops the first commercial launch vehicle and transport capsule, then proves they can carry payloads into space Ford Motor Co and TechShop Studio layout Detroit facility Director Will Brick says as the shops evolve, TechShop personnel are increasingly dialing-in their layout and design to let users work more efficiently A big central room features several large work tables All the different technology areas, such as the laser, electronics, and industrial-painting studios, sit off the central room “This arrangement encourages people to use the central room to work together on projects,” he says “In fact, many entrepreneurial partnerships have been made between people sitting next to each other at one of these tables.” The computers in the central room each feature more than $20,000 worth of engineering-design software from Autodesk Inc., San Raphael, Calif Programs include Inventor, AutoCAD, Maya, and Revit The central room also 62 MACHINE DESIGN.com TechShop member Richard Jeryan is the weaver in the Weaving Shop at The Henry Ford museum, just down the street from the Detroit TechShop Working with TechShop and other organizations, Ford is helping entrepreneurs commercialize their creations For example, Ford’s Patent Incentive Program provides Ford employee-inventors who come up with potentially patentable ideas, a three-month free membership to TechShop Detroit And the company’s Motor City Innovation Exchange will be an open meeting place for inventors to showcase what they create in TechShop It will provide a way for inventors to negotiate, network, and sell their prototypes to manufacturers, suppliers, start-ups, and research institutions in the automotive industry SEPTEMBER 6, 2012 Auto Harvest, www.autoharvest.org Autodesk, www.autodesk.com Cable Arm, www.cablearm.com Ford, http://corporate.ford.com Ford Land, http://fordland.com Kickstarter, www.kickstarter.com OpenROV, www.openrov.com Square, www.squareup.com TechShop, www.techshop.ws MACHINE DESIGN, “DIY Manufacturing,” http:// tinyurl.com/26clol7 MACHINE DESIGN, “Rapid Prototyping ‘On the Cheap,’” http://tinyurl.com/ylkdoof MACHINE DESIGN, Fab it Now, http://tinyurl.com/yke88kl For more on rapid prototyping, scan this code or go to: http:// machinedesign.com/ article/rapid-prototypingfor-the-masses-0609 hosts a hotline to the U. S Trademark and Patent Office through which TechShop users can file a U. S patent or find out the status of one The central room also features the now-iconic coffee maker and popcorn popper The 17,000-sq-ft Detroit facility is clean, spacious, and airy Many windows face both outside and internally to each of the technology areas, helping make the TechShop a pleasant place to work The machine shop, one such area, houses a lathe, a vertical-milling machine, and a Tormach four-axis CNC mill that can be fitted with various accessories such as a motorized rotary table or a mechanism which fits on the table top to let users cut intricate forms, tapers, and cylindrical objects “People use the mill all sorts of ways,” says Brick “For example, one designer came in to make aftermarket car parts, which he modeled in Inventor He took a Tormach machine-tool class and then machined his first prototype We helped him make a fixture so he could produce four or five parts at once He now has a small business.” Another technology area, the wood shop, features a three-phase table saw, a big wood lathe, a router table, and a pair of CNC wood-router Shop Bots, one with a large × 8-ft work surface and one with a smaller work surface “The machines have the same spindle, same controls, and same interface,” says Brick “They just provide two different options for different project sizes.” One of the machines is getting upgraded with a more-efficient vacuum pull-down SEPTEMBER 6, 2012 62 shock: Sensing ground 54 Safety faults in industrial applications Senior Editor leslie.gordon@penton.com Twitter @ LeslieGordon • TechShop gives users access to high-end manufacturing equipment and software DIY fabrication studios let just about anyone make just about anything Do you have a hankering to make something, but lack access to a laser cutter or machine tool? You might want to check out a local TechShop Founded in October 2006, TechShop Inc is a membership-based (about $100/month), do-it-yourself (DIY) workshop and fabrication studio that provides access to more than $1 million worth of high-quality machines, tools, and software, as well as classes and workshops on the technologies TechShop is open to people of all ages and skill levels It is based in Menlo Park, Calif., with locations in San Francisco, San Jose, Raleigh, N. C., and Detroit Locations in Arizona, Pittsburgh, and D. C are being planned Authored by: Leslie Gordon Originally designed to protect people, ground-fault sensing now helps extend equipment life ELECTRICAL/ELECTRONIC Industry Manufacturing for the masses 62 DIY fabrication studios let just about could take a shine to COPPERROTOR MOTORS Authored by: anyone make just about anything Trista Baldwin Contributing Editor Edited by Leland Teschler leland.teschler@penton.com Key points: • Rotors made from copper conduct electrical current better than aluminum, thus run cooler with more efficiency • The process of die casting copper has become economical thanks to recent advances in modeling the casting process Resources: could take a shine 70 Industry to copper-rotor motors International Copper Association, www.copperalliance.org For more on copper rotors, scan this code or go to: http://machinedesign.com/ article/copper-shines-inmotor-rotors-0818 Better manufacturing techniques may let rotors cast from copper become a mainstay of superefficient motor technology The stringent efficiency levels now spelled out in NEMA Premium tables have fostered interest in motor architectures that can deliver high efficiency One of those architectures uses a squirrel-cage rotor cast from copper rather than the traditional aluminum Copper cuts down on the I2R losses by up to 40% and overall motor loss by 20%, though it increases the weight of the rotor a bit The motivation for a copper-rotor design stems not only from efficiency considerations but also from a desire to minimize the size of the motor But until recently, copper rotors were tough to cast because of copper’s higher melting point (1,083°C compared to 660°C for aluminum), and a tendency to oxidize Now, breakthroughs in copper die casting have made it more economical to mass pro- Visible in this cutaway view of an induction motor is its copper rotor Use of copper rotors can let induction motors run efficiently enough to provide the same amount of horsepower as conventional motors that sit in larger frame sizes New manufacturing techniques make it possible to cast rotors in copper and bring new levels of efficiency to induction motors 70 MACHINE DESIGN.com SEPTEMBER 6, 2012 70 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 SEPTEMBER 6, 2012 MACHINE DESIGN.com 63 Along with our great prices, you get: Rotary Encoders, ;[...]... 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If you think compressed air is too expensive and noisy - read this The facts will surprise... that can rotate; the TS400’s housing is fixed r formation via ou Request free in Web site at in place Both can be directly or ice rv Se er Read remotely mounted sign.com/rsc w.machinede ww RS# 401 16 MACHINE DESIGN.com SEPTEMBER 6, 2012 SM YOU’LL CALL IT the most technologically advanced process for customer-focused solutions in extruded aluminum Sapa innovation turns visions into leading end-use products... Resources: 3D, crucial to fineFisher/Unitech, www.funtech.com tuning the overall The Roof For Two canopy is concept MD currently in beta testing and is expected to go to market in Spring 2 013, www.rooffortwo.com SEPTEMBER 6, 2012 MACHINE DESIGN.com 21 REPORTER’S NOTEBOOK Additive manufacturing in outer space? An additive process developed mainly by NASA Langley Research Center materials engineer Karen Taminger... The challenge is to build an additive machine small enough to take on space flights, yet versatile enough to handle different types of materials while making a single part A proof-of- A NASA technician checks out current EBF3 technology Credit: NASA/Phys.org concept EBF3 machine has been tested in zero gravity and found to work well The next step is to build smaller machines that can be tested on the... personal relationship’ [i.e., I only screw my friends if I am paid well for it].” Ferguson further relates that the salesman got the extra commission — Leland Teschler, Editor 8 RS# 107 MACHINE DESIGN.com SEPTEMBER 6, 2012 4ALK ABOUT A BUNDLE OF ADVANTAGES s%# TECHNOLOGY FROM EBM PAPST GIVES YOU MORE CONTROL OPTIONS FOR ADVANCED APPLICATIONS THAN !# TECHNOLOGY AND ITS HIGH EFlCIENCY ALSO SAVES A WHOLE... 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 SEPTEMBER 6, 2012 DŽŽŐŽŵƉŽŶĞŶƚƐ'ƌŽƵƉŝƐĂǁŽƌůĚůĞĂĚĞƌŝŶƐůŝƉƌŝŶŐƚĞĐŚŶŽůŽŐLJ͕ƐĞƌǀŽŵŽƚŽƌĂŶĚƌĞƐŽůǀĞƌ ĚĞƐŝŐŶĂŶĚĮďĞƌŽƉƟĐƌŽƚĂƌLJũŽŝŶƚƐĨŽƌŚŝŐŚďĂŶĚǁŝĚƚŚĂƉƉůŝĐĂƟŽŶƐ͘ ZĞůŝĂďŝůŝƚLJŝƐďƵŝůƚŝŶƚŽĞĂĐŚƉƌŽĚƵĐƚ͘ džƚĞŶƐŝǀĞůŝĨĞƚĞƐƟŶŐŵĞĂŶƐŽƵƌƉƌŽĚƵĐƚƐĂƌĞĚĞƐŝŐŶĞĚ... the law for financial gain Or as the blog stated “It may be legal, but it’s certainly slimy.” John Lamber CEOs have a fiduciary duty, not to mention a self-interest, to reduce RS# 113 14 MACHINE DESIGN.com SEPTEMBER 6, 2012 costs So why be shocked when they do things like this? Laws should be written to prevent or at least make it difficult to evade the intent of the law Doing otherwise is a sign of incompetent... It should read www nanometrics.ca LETTERS TO THE EDITOR Please include your name, address, and daytime phone number Letters may be edited for brevity and to focus on essential points Mail: Letters, MACHINE DESIGN, 1300 E 9th St., Cleveland, OH 441141503, Fax: 216-621-8469 E-mail, Editorial: mdeditor@penton.com COMPLETE ENGINEERING SOLUTIONS Start here "The navigation and ordering process are easy to... exploration 40 VANTAGE POINT Specialization helps machine builders endure economic uncertainty 42 INVENTOR’S CORNER Surgical dressing restores mastectomy patients’ figures 84 SOFTWARE REVIEW Plug-in imports organic surfaces into CAD 86 PRODUCT SPOTLIGHT Hose & fluid connectors 88 92 93 94 94 95 4 PRODUCTS BUSINESS INDEX AD INDEX CLASSIFIEDS BUSINESS STAFF BACKTALK MACHINE DESIGN.com Editorial content is indexed