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October 18, 2012 A Penton Media Publication Tune in to EngineeringTV.com Special issue on MOTION CONTROL A Robot Revolution page 20 OFF TILT: WHERE INDUSTRIAL MEMS GYROSCOPES EXCEL, page 34 SIMULATION HELPS CALCULATE TRAJECTORIES, page 40 PROTOTYPING WITH SPRINGS, page 44 CLOUDBASED HELP FOR MOTION SYSTEM DESIGNERS, page 50 [ MOTOR TRUTH #7 ] Can I save energy by using a VFD (inverter)? YES NO MAYBE The truth is that it depends on your application If you have a high-cycling application, a VFD can reduce the starting current on each cycle If you have a hoisting application, a VFD can provide energy regeneration If you have an oversized motor on a small load, a VFD with flux control can maximize the motor efficiency Otherwise, a VFD is a load and actually consumes energy - especially if you use a high carrier frequency Visit sewmotortruth.com/truth7 to get the whole story on VFDs and energy-efficient drivetrains sewmotortruth.com/truth7 864-439-7537 RS# 101 www.theleeco.com Go ahead, push us to your limits RS# 102 We love a good challenge If you need a fluid handling component for whatever reason, no matter how extreme, talk to The Lee Company We’ve been solving complex fluid control problems in all kinds of industries for more than 60 years Our extensive family of precision fluid control products offers unsurpassed reliability in just about every configuration you could imagine, including: • Miniature Solenoid Valves • Fixed and Variable Volume Pumps • Atomizing and Dispense Nozzles We’re not just talking about off-the-shelf solutions, either A Lee engineer will be happy to discuss your application, and develop a custom design if needed From managing nanoliter droplets to creating fully integrated fluidic systems, we’re unsurpassed in breadth and experience to deliver the precise, reliable performance you require Whatever problem you face, make the solution easy Contact The Lee Company today Innovation in Miniature • Micro Dispensing Valves • Integrated Fluidic Manifolds • Custom Engineered Designs See us at MD&M Minneapolis, Booth #636 The Lee Company Pettipaug Road | Westbrook, CT 06498-0424 Tel: 860-399-6281 | 800-533-7584 | www.theleeco.com Westbrook • London • Par is • Fr ankfur t • Milan • Stockholm VOLUME 84 ISSUE 16 OCTOBER 18, 2012 CAE CAE Building a BETTER SPACECRAFT FEATURES CAE software tests hypersonic-reentryvehicle designs The European Space Agency launch of Thales Alenia Space’s Intermediate eXperimental Vehicle aboard the Vega small launch vehicle is planned for 2013 Authored by: Kyle Indermuehle Aerospace Lead Simulia Providence, R I robot for the rest of us 20 AA relatively low-cost factory-floor robot that can be trained or programmed by a factory-floor worker Edited by Leslie Gordon leslie.gordon@penton.com Key points: • Process-automation software can link design and simulation models to automate the execution of hundreds or even thousands of simulations • The software can help designers improve designs by improving them in terms of performance or cost variables through statistical methods Resources: Simulia, www.simulia.com For more on simulation software, scan this code or go to: http://machinedesign.com/ article/software-automates-the-executionof-thousands-of-simulations-0609 40 MACHINE DESIGN.com As CAE software becomes increasingly sophisticated, engineers can now refine designs to their nearly final form This lets engineers test physical prototypes later in the product-development cycle The use of CAE software is critical in the space industry, where it’s difficult to create test settings that simulate real-world conditions Vacuum chambers and wind tunnels help, but they cannot account for all conditions at the same time That’s why spacecraft producer Thales Alenia Space Italia (TAS-I) in Italy used CAE software in the design, testing, and building of its hypersonic reentry vehicles for the European Space Agency Head of aeromechanics and propulsion at TAS-I, Cosimo Chiarelli helped design and test the vehicles He explains that the physics of atmospheric reentry are complex, so vehicle analysis required a multidisciplinary optimization (MDO) approach to account for all the variables Variables include aspects of the spacecraft structure such as geometry (length and shape), as well as the di- mensions and material attributes of the shell and thermal-protection system Other variables include the trajectory (comprising the vehicle’s speed, altitude, and angle of attack), the thermal conditions for the vehicle’s windward, leeward, and nose zones, and the thermal loads the vehicle encounters The final design accounts for all variables, with a focus on the 150 sec that make up the most-critical portion of reentry To improve designs, engineers conducted separate simulations for each of the physics disciplines They used a collection of software packages and divided the analysis into seven major computational tasks and 40 subtasks, many with their own input and output file types Engineers used Isight process automation software from Simulia, Providence, R. I., to organize the tasks, manage the execution of TAS-I’s dif- OCTOBER 18, 2012 The MDO workflow for the reentry vehicle in Isight comprised several analysis tasks such as grid generation and trajectory computations It used a variety of commercial and proprietary codes and input and output file types Engineers used the software to tie together separate simulations and automate the analysis OCTOBER 18, 2012  40 aim with MEMS gyros 34 Taking Superaccurate MEMS gyroscopes ferent codes, and aide in the understanding of results from all of the tasks “The software helped us create flexible simulation workflows and automate the exploration of solutions for the large design matrix,” says Chiarelli.” To conduct a feasibility study of their new MDO approach, engineers chose a theoretical hypersonic reentry vehicle and applied simplified assumptions Further streamlining the process, they decided to optimize globally for all variables combined, rather than locally for each individual variable To minimize costs, engineers applied the process-automation software’s adaptive simulated annealing algorithm, a statistical technique that searches the envelope of design solutions Isight performed 200 iteration cycles in only a day, assembling several designs that satisfied requirements simplify the motion-sensing tasks of industrial robotics a better spacecraft 40 Building CAE software tests hypersonic- MECHANICAL Working reentry-vehicle designs Here are some tips when using springs for prototyping and design with STOCK SPRINGS 44 Here are some tips when using springs Working with stock springs Mechanical equipment and related hardware routinely include springs in their designs And in a perfect world, knowing the load and travel, an engineer can adjust the mating parts so that the design can use a stock spring However, that is usually not the case, and springs are frequently an afterthought Often this is because springs are well-engineered and for prototyping and design design gets 50 Motion help from the cloud proven components Springs operating within their design parameters will last a long time And they come in thousands of different sizes and versions Most common are compression and extension springs, made from various materials, with or without a finish Stock springs are often used for applications requiring less than 500 springs per year Generally, however, it is not only better but more cost effective to contact spring manufacturers with specific requirements From there, the manufacturer may recommend a new design and make a customized spring for little or no cost premium One cannot emphasize enough the importance of discussing design requirements with a spring manufacturer Stock springs are great for prototyping, but their use in production often compromises other aspects of a design This article is meant to help size springs for prototyping, prior to seek-  Authored by: Norman Ellis Ellis & Associates Laguna Hills, Calif Edited by Kenneth J Korane ken.korane@penton.com Key points: Free and simple cloud-based analytic tools help designers quickly analyze motion-system performance in both the time and frequency domains • Stock springs are generally intended for prototyping, and their use in production can compromise designs • Experts recommend discussing specific design requirements with a spring manufacturer Stock springs are useful for prototyping, but altering mating parts to accommodate a stock spring can compromise other aspects of the final design 44 MACHINE DESIGN.com Resources: Spring Manufacturers Institute, www smihq.org The SMI is a good source for information on spring design and capabilities, as well as for locating spring manufacturers OCTOBER 18, 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 MACHINE DESIGN.com OCTOBER 18, 2012 MACHINE DESIGN.com 41             We’ve got the pneumatic parts you need, and they ship the same day.* New air pilot valves are a basic component of many pneumatic systems; our AVS-5 series can be used individually, or multiple valves can be assembled on manifolds available in up to stations Manual control valves are designed for non-electrical operator control applications These basic valves are available in toggle hand lever, push-pull, and rotary hand lever styles, as well as foot pedal valves Air Pilot Valves - start at: $14.00 • • • Body ported five-port (four-way) spool valves 1/8” to 1/2” NPT port sizes Single or double pilot operation Manual Control Valves - start at: $14.00 • • • Toggle hand lever and push-pull styles with body ported five-port spool valves, in 1/8” and 1/4” NPT port sizes 4-port rotary valve stye in 1/4” and 1/2” NPT port sizes Foot pedal valves with guard are 5-port spool valves with 1/4” NPT ports, momentary or latching models Solenoid Valve Cables & Air Valve Connectors See everything at: - start at: $4.75 www.automationdirect.com/pneumatic-parts • • • Also Available 8, 10 and 18mm (pin spacing) DIN 43650 form cables; 9.4 and 11mm DIN style cables 24, 110 and 230 VAC/DC models available PVC jacketed cables in 1, or meter lengths Brass Threaded Fittings - start at: $4.00 (5-pack) • • • • Tubing and Hose 10 different styles, including Tee and elbow Male and female connectors in 1/8” to 1/2” NPT sizes Work with water, oil, air and other gases Maximum pressure 800 psi Quick-disconnect Air Couplings - start at: $5.00 Pneumatic Air Cylinders Fittings and Air Couplings • • • Plugs and couplers for 1/4” and 3/8” inch hose sizes Male and female NPT threaded Compatible with three of the most popular connection styles www.automationdirect.com Pneumatic Solenoid Valves and Manifolds Air Preparation Go online or call to get complete information, request your free catalog, or place an order 1-800-633-0405 RS# 103 ON THE COVER Baxter, a robot from Rethink Robotics DEPARTMENTS EDITORIAL Antidote to innovation … Six Sigma 10 EDITORIAL STAFF 12 LETTERS 16 SCANNING FOR IDEAS Going big with ultrasmall ball screw Rotary motion with speed and precision 20 REPORTER’S NOTEBOOK 24 LOOKING BACK 31 COMMENTARY So much for the idea of putting a hex on your boss — Stephen J Mraz 33 INDUSTRIAL DESIGN Making “cheap” products look expensive 63 ORR ON ENGINEERING What’s New? 64 SOFTWARE PRODUCTS 66 PRODUCT SPOTLIGHT Hydraulic & pneumatic cylinders 68 74 76 77 78 78 79 PRODUCTS DATA FILES BUSINESS INDEX AD INDEX CLASSIFIEDS BUSINESS STAFF BACKTALK MACHINE DESIGN.com For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at reprints@pentonreprints.com or visit pentonreprints.com Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert Microfilm copies available from National Archive Publishing Company (NAPC), 300 N Zeeb Rd., P.O Box 998, Ann Arbor, MI 48106-0998, Ph: 734-302-6500 or 800-420-NAPC (6272), extension 6578 Permission to photocopy is granted for users registered with the Copyright Clearance Center (CCC) Inc to photocopy any article, with the exception of those for which separate ownership is indicated on the first page of the article, provided that the base fee of $1.25 per copy of the article, plus $.60 per page is paid to CCC, 222 Rosewood Dr., Danvers, MA 01923 (Code No 0024-9114/12 $1.25 + 60) 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 Media, Inc All rights reserved MACHINE DESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January, February, June, July, and December by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212 Paid subscriptions include issues 1-18 Issue No 19 (OEM Handbook and Supplier Directory) is available at additional cost Rates: U.S.: one year, $139; two years, $199; Canada/Mexico: one year, $159; two years, $239; All other countries: one year, $199; two years, $299 Cost for back issues are U.S $10.00 per copy plus tax, Canada $15.00 per issue plus tax, and Int’l $20.00 per issue Product Locator, $50.00 plus tax Prepaid subscription: Penton Media (MACHINE DESIGN), P.O Box 2100, Skokie IL 60076-7800 Periodicals Postage Paid at Shawnee Mission, Kans., and at additional mailing offices Can GST #R126431964 Canadian Post Publications Mail Agreement No.40612608 Canada return address: Pitney Bowes, P.O Box 25542, London, Ont., N6C 6B2 Digital 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 OCTOBER 18, 2012 POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O Box 2100, Skokie, IL 60076-7800 Secure your operations with proactive maintenance Imagine the conditions in the North Sea They take their toll on all types of equipment Bearings are no exception At one of the major production platforms, failing motor bearings used to cause gas compressors to break down as often as every third month Each time, that meant 25% lost production for several days Jim Marnoch and his team provided SKF ProActive Reliability Maintenance services After thorough analysis of the vibration signatures and the damaged bearings, they found a long term solution SKF NoWear bearings along with a new sealing arrangement made all the difference, allowing the compressors to run times longer than before At today’s high oil prices, for every breakdown that can be avoided, the platform operator saves tens of million dollars On top of that, these improvements also reduce health, safety and environmental risks It’s another great example of knowledge engineering at work Find out more at www.skf.com/poke The Power of Knowledge Engineering Gas Export Compressor SKF ProActive Reliability Maintenance ® NOWEAR is a registered trademark of the SKF Group Jim Marnoch, SKF RS# 104 What’s new online machinedesign.com Free Webcasts: Designing Effective Safeguarding for Machines Thursday, October 18, 2:00 p m ET Attend this Webinar to learn how to design effective machine safeguarding Experts from Schmersal will discuss types of hazards, various options for separating guards and devices, different levels of circuit design, and how to engineer a complete safety system Making 3D Printed Parts “Real” Thursday, October 25, 2:00 p m ET Rapid prototyping — now called additive manufacturing — has had a profound impact on the product design/development process across many industries This presentation from GreatBatch Medical and Objet will explore recent advances and benefits of AM, including: • Materials that range from rigid to flexible, high temperature, and clear • Time and cost savings using Polyjet technology • Example applications • A Q&A on equipment and capabilities Learn more and register for these events at http://machinedesign.com/training Environmentally safe cryogenic machining EDITOR’S WEB PICKS The chief technical officer of MAG IAS explains the benefits of using cryogenic machining on composites and ultrahard metals, and how environmentally safe cooling fluids eliminate waste-disposal problems manufacturers face with traditional coolants View it at www.engineeringtv com/video/Cryogenic-Machining-UsingEnvir;International-Manufacturing-Tec RS# 105 MACHINE DESIGN.com OCTOBER 18, 2012 Actuators and drives App Bosch Rexroth’s GoTo Products apps for iPhone and iPad provide quick access to information on more than 3,500 linear motion, hydraulic, pneumatic, electric drive, and control products Content includes technical data, dimension and specification tables, and product visuals, as well as video clips explaining key features of various motion and control technologies The iPhone version takes advantage of GPS and autodial features to simplify ordering from the nearest distributor Learn more at www boschrexroth-us.com/gotoapp Simulation Hall of Fame Do you consider your simulations prize-worthy? The Ansys Hall of Fame competition showcases eye-popping simulation images and striking videos that illustrate real-world multiphysics applications using the company’s software Winners will be selected based on the project and resulting benefits, with Apple iPads as the top three prizes Deadline is November 23 Learn more and view previous winners at www.ansys.com Elastomers and thermoplastics for vehicles Minnesota Rubber and Plastics has a new brochure on molded components and assemblies for motor-vehicle applications Charts list a wide range of products, compare the performance of amorphous and semicrystalline polymers in relation to cost, and provide selection criteria for high-temperature thermoplastics Get a copy at www mnrubber.com &"%!,&)" * &- %( 32, /2%3130 0/%& *0%/-( +-+)&) !+-(+ #)*(+,!#'+%( +)-'*-  $2&3, /30/-( /,3 *'3 $2&3, '2-(3 )*(+,-*,$*'($)%,!-+#-,'# 21301*#-444) 44443'4)"! " + )*(+,-*,$*'($)%,!-+#-+-*%+),%*-,'# .1/-444 ! )44443'4 +")"  ) 64 MACHINE DESIGN.com RS# 153 OCTOBER 18, 2012 NestlibOnline is online nesting software for optimizing material use It helps users fit 2D shapes on large sheets Users can easily get nested layouts by loading 2D DXF parts and specifying sheet sizes The software provides nested layouts and nest summary in PDF format To download nested layouts in DXF format, users must opt for a paid subscription Visit www nestlibonline.com Geometric Americas Inc., 50 Kirts Blvd., Suite A, Troy, MI 48084, (248) 404-3500, www geometricglobal.com RS #429 Free CAD plug-in for custom parts Print3D software, a free plug-in, works with Pro/Engineer, SolidWorks, and Inventor to provide real-time feedback and quotes for custom manufactured parts directly in the CAD program The software makes it unnecessary to export STL files or upload files to external Web sites Non-CAD users can also benefit by downloading the stand-alone plug-in To download Print3D, visit http://tinyurl com/cft5lov Quickparts.com Inc., 301 Perimeter Center N, Suite 500, Atlanta, GA 30346, (877) 521-8683, www.quickparts.com RS #430 r formation via ou Request free in Web site at Reader Service c design.com/rs ww w.machine maxon EC 22 HD Highly robust RS# 154 maxon drives in deep drilling technology When it really matters Our drive systems also go to great depths inside the earth They are used, for instance, in drill heads and help to open up hard-to-reach deposits The maxon product range is built on an extensive modular system, encompassing: brushless and brushed DC motors with the ironless maxon winding, planetary, spur and special gearheads, feedback devices and control electronics maxon motor is the world’s leading supplier of high-precision drives and systems of up to 500 watts power output Rely on the quality of the highly specialized solutions which we develop with and for you www.maxonmotorusa.com RS# 156 RS# 155 SPOTLIGHT HYDRAULIC & PNEUMATIC CYLINDERS Tie-rod cylinders The MH Series of metric hydraulic tie-rod cylinders feature pistons that offer a unique combination of cast-iron rings and polyurethane Ucup seals for excellent load holding The piston rod and rod bearings are constructed with hard-chromeplated/polished high-strength steel and bronze Medium carbon-steel tie-rods with rolled threads extend cylinder life The units are designed to ISO 6020/2 160 bar standards for the global metric market Pneumatic stopper cylinders Stopper cylinders are available in seven rodend styles with strokes of 20 and 30 mm and in 32, 40, and 50-mm bores Shock absorbers are standard on lever/roller-style models; direction of rollers is adjustable All styles feature magnetic pistons so magnetic sensors can be mounted on cylinder surfaces when input signals are required for controllers The device’s extruded aluminum body has counterbored through holes for rigid mounting in limited space Units can be double acting or single acting with spring extended rod The double-acting models are available with a built-in failsafe extended rod Fabco-Air Inc., 3716 N. E 49th Ave., Gainesville, FL 32609, (352) 373-3578, www.fabco-air.com RS# 447 Dual-rod-guided air cylinders The cylinders are available in bore diameters of 25, 32, 40, 50, 63, 80, 100, 125, 160, and 200 mm with working pressures up to 210 bar ISO MP1, MP3, MP5, MT1, MT2, MT4, ME5 and ME6 mounting configurations are available Doublerod versions of the MT1, MT2, MT4, ME5 and ME6 are also available Male or female threaded-rod options are standard, and standard porting is BSPP for leak-free connections Milwaukee Cylinder, 5877 S Pennsylvania Ave , Cudahy, WI 53110, (414) 769-9700, www.milwaukeecylinder.com RS# 446 r formation via ou Request free in Web site at ice rv Se er ad Re c design.com/rs ww w.machine 66 MACHINE DESIGN.com OCTOBER 18, 2012 The E-Series dual-rod-guided air cylinders joins the NITRA pneumatic line for applications requiring precise alignment or that have large side loads Interchangeable with other brands, the double-acting cylinders feature a high-quality extruded aluminum housing and switch-mounting tracks, dual chromeplated stainless-steel guide rods, and bronze bushings With a maximum operating pressure of 142 psi, the cylinders are available in eight bore sizes from 12 to 63 mm, and depending on bore size, stroke lengths from 10 to 250 mm AutomationDirect, 3505 Hutchinson Rd., Cumming, GA 30040, (770) 889-2858, www.automationdirect.com RS# 448 Powerful, clean, efficient OFFERS QUALITY MOTOR SOLUTIONS! Since 1917, Ohio Electric has produced a full range of standard and custom DC motors Shown below are two types of the many choices of motor products available from Ohio Electric: High performance drum motors r:WHJLZH]PUN r9L]LYZPISL r4HPU[LUHUJLMYLL r   TLJOHUPJHSLMÊJPLUJ` r/PNOHJJLSLYH[PVUHUKKLJLSLYH[PVU r/PNOU\TILYVMWYLJPZPVUZ[HY[ZZ[VWZ r[...]... more forward thinkers like the folks mentioned here Buy American Be American Bill White RS# 113 14 MACHINE DESIGN.com OCTOBER 18, 2012 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... screws, scan this an option The screws can meet ISO code or go to: http:// tolerances from P0 to P5 machinedesign.com/ RS# 401 article/how-rolled-andground-ball-screwsstack-up-0708 r formation via ou Request free in Web site at Reader Service c design.com/rs ww w .machine 16 MACHINE DESIGN.com OCTOBER 18, 2012 N OW I T H I N K I N 3 D AND MY DESIGNS JUST KEEP GET TING BET TER With our Dimension® 3D Printer,... sorting: Checking parts for weight or shape, evaluate them against a criteria, and perform different actions depending on results • Operating machines: Watching machinery and performing sequences of actions based on input or alarms For example, it could insert a part into a machine, push a button, then remove the part • Packing and unpacking: Picking up an object, bag, box, or tray and arranging them in an... up,” explains Brooks “You don’t have to do it in order Baxter OCTOBER 18, 2012 Continued on page 26 MACHINE DESIGN.com 21 REPORTER’S NOTEBOOK The politics of engineers Engineers tend to view themselves as much less liberal and slightly more conservative than the general public, according to a recent survey of over 1,200 readers of MACHINE DESIGN and Electronic Design magazines The same survey also found... lengths, it’s economical and versatile enough for many applications, field-programmable, and the perfect replacement for old-style potentiometers Learn more at our website ametekapt.com 18 MACHINE DESIGN.com OCTOBER 18, 2012 RS# 116 These new generation CD® Couplings feature zero backlash precision and high torsional stiffness They answer today’s demanding servo motor applications with high reverse loads... safety and to carry out tasks, Baxter has 360° sonar and machine vision with one main “face” camera and access to four others The wrists, for instance, carry a camera so Baxter can closely monitor what its end effectors are doing Each wrist also carries a range finder Baxter operates in temperatures from 32 to 104°F and is rated OCTOBER 18, 2012 IP50, which means it is protected against dust but not... 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