September 22, 2011 A Penton Media Publication Tune in to EngineeringTV.com High-tech Zeppelins page 42 CONVERTING GLASS BOTTLES TO PET, page 23 WHEN SOLAR ARRAYS CATCH FIRE, page 50 HOW TO SELECT PNEUMATIC CYLINDERS, page 56 AIR CUSHIONS THAT SELF-ADJUST, page 64 Stop Your Fretting BaldorDodge® Grip Tight® Adapter ball bearings are the solution for damage-free shafting, reduced vibration and greater inventory cost savings Our unique push/ pull adapter system provides fully-concentric 360° shaft contact for quick installation or removal • Unmatched Quality Off-the-shelf and shaft ready, Grip Tight Adapter ball bearings are proven to reduce labor/maintenance costs and stop your fretting once and for all • Lower Total Cost of Ownership dodge-pt.com • Quickest Delivery Available baldor.com 479-646-4711 ©2011 Baldor Electric Company RS# 101 • Superior Reliability Ultra Lights 8000 psid 125" Dia Lee Chek 0.75 Grams With today's high cost of fuel, it's never been more important to shed aircraft weight Fortunately, The Lee Company had plenty of runway with this challenge – by making it our priority 60 years ago As a result, our Ultra Light products are now even smaller and lighter – some weighing less than the page you're reading And of course, they're just as reliable as ever Lee Plugs®, restrictors, valves and screens are unsurpassed in offering breadth of choice and peace of mind No one offers more experience designing, manufacturing and ensuring zero-defect, as-promised quality Which helps explain why we're on board every commercial and military aircraft that leaves the ground today Call today for the latest edition of our Technical Hydraulic Handbook, and discover hundreds of ways to put your next design on a low fuel diet The Lee Company Pettipaug Road Westbrook, CT 06498 USA 860-399-6281 www.theleeco.com Westbrook • London • Paris • Frankfurt RS# 102 • Milan • Stockholm VOLUME 83 ISSUE 16 SEPTEMBER 22, 2011 pneumatics technology guide cylinder cushions adapt on the fly FEATURES Self-adjusting cushion self-adjusting air cushions let machines run smoother and faster Authored by: Michael Guelker Product Manager, Pneumatic Actuators Festo USA Hauppauge, N Y Edited by Kenneth J Korane ken.korane@penton.com Key points: 42 Adjustable air cushion Adjustable air cushions control piston speed by throttling exhaust air (red) through a needle valve • High machine speeds can lead to damaging vibration and impact loads • Conventional pneumatic-cylinder cushions prevent end-of-stroke impacts, but require painstaking adjustment • New self-adjusting air cushions adapt to changing loads and operating conditions Bye-bye blimps Willkommen Zeppelins Goodyear Tire & Rubber Co is upgrading its fleet of blimps, turning them in for larger, more-advanced Zeppelins Resources: Festo USA, www.festo.com/cms/en-us_ us/index.htm RS# 622 ion via our Request free informat Web site at Reader Service esign.com/rsc www.machined 64 mACHINe Design.com Self-adjusting air cushions exhaust compressed air through slots in the cushion spud A common goal throughout the industrial world is to boost productivity while reducing costs Increasingly, this means cutting machine cycle times For pneumatic devices, this often requires running actuators as fast as possible without introducing excessive shock and vibration to products and equipment To reduce an actuator‘s impact energy, engineers rely on two common types of integrated cushioning — bumpers and air cushions Flexible bumpers are generally made of an elastomer incorporated into the piston or end cap They effectively reduce impact noise; however, they only absorb small amounts of energy, limiting them to slow-speed, small-load, or short-stroke applications Operating with higher loads and speeds demands additional cushioning to avoid damaging the cylinder and machine Engineers generally use air cushions for end-of-stroke damping in these cases Unfortunately, these are not plug-and-play devices Experienced maintenance technicians must adjust the air-cushion valves, and that depends on the cylinder’s operating pressure, speed, and load Subsequent changes to these parameters means the air cushions need to be reset Otherwise, the machine may run slower or face unacceptable impact loads A new type of air cushion automatically adapts to changing conditions, eliminating the headache of manual adjustments It offers the potential to increase productivity and reduce maintenance costs Cushion basics Air cushions are variable-orifice air dashpots As the cylinder cycles, a spud on either side of the piston closes a passage to the main piston chamber This traps air in the cylinder end cap and bleeds it off through a small port conSeptember 22, 2011 trolled by a needle valve The cylinder traps a fixed volume of air each cycle But because air is compressible, the load, velocity, and pressure in the cylinder all affect air-cushion performance For any given set of conditions, there is generally only a small window of needle-valve adjustments that provide acceptable cushioning Closing the needle valve too far results in high initial reaction forces, which slow the load too quickly It can also cause end-of-stroke bounce: the piston oscillates as it decelerates, causing vibration and extending cycle time Open the needle valve too far, however, and the trapped air does not generate sufficient back pressure The load reaches the end of stroke too quickly and the piston hits the end cap And as mentioned above, once the needle valve is properly set, any change in weight, pressure, or velocity affects cushion reaction and means the valve must be readjusted Self-adjusting cushions Recently developed self-adjusting cushions eliminate the need for manual adjustment In principle, they work the same way as conventional cushions, except the cushioning air exhausts through notches in the cushioning piston, not past an adjustable needle valve The geometry of these notches is critical LongitudiSeptember 22, 2011 64 off accidental fires 50 Heading in solar arrays Fighting a PV panel fire is hazardous enough without having to stand in water next to a 600-Vdc power source that can’t be turned off 56 pneumatics technology guide guidelines for SeleCting CylindeRS pneumatic cylinders come in thousands of versions here are some tips for choosing the best one for the job Guidelines for selecting cylinders Pneumatic cylinders come in thousands of versions Here are some tips for choosing the best one for the job Authored by: Sheila Campbell Product Manager - Actuators Norgren Inc Littleton, Colo Edited by Kenneth J Korane ken.korane@penton.com Key points: • Pneumatic cylinders come in many basic versions • All cylinders can be tweaked to better fit an application • Custom designs can perform better and save money when standard cylinders don’t fit the job 64 Cylinder cushions adapt on the fly Resources: Norgren Inc., www.norgren.com RS# 621 Clean, compact, durable, and fast-acting air cylinders are workhorses on packaging machinery 56 Self-adjusting air cushions let machines run smoother and faster mACHINe Design.com ion via our Request free informat Web site at Reader Service esign.com/rsc www.machined September 22, 2011 56 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 22, 2011 mACHINe Design.com 65 Directional Control • Solenoid valves • Manifolds Air Preparation • • • • • Filters Regulators Lubricators Filter/regulator combos Relief valves Check around! You’ll see we’ve got great prices on ALL the components you need to complete a pneumatic control system Stainless Steel Pneumatic Cylinders CHECK OUT OUR PRICES ON VALVES and FRL • Non-repairable cylinders • Position switches • Compact round body cylinders AutomationDirect Product Description NITRA MSC McMaster-Carr Grainger Directional Solenoid Valve 5-port, 4-way, 2-position, 1/4” NPT, 24 VDC, single solenoid $26.75 AVS-5312-24D $84.81 $62.48 $93.80 3JCN6 Combination Filter/Regulator 1/4” NPT, gauge, mounting bracket $29.00 $115.47 $74.80 $108.70 AFR-3233 84470475 42007401 6124K513 7390K17 4ZK92 All prices are U.S published prices Many other part numbers are available from all vendors Items are closest equivalents; some minor differences may exist Automationdirect prices are from March 2011 Price List MSC prices are from www.mscdirect.com 2/22/11 McMaster-Carr prices are from www.mcmaster.com 2/22/11 Grainger prices are from www.grainger.com 2/22/11 Prices subject to change without notice Tubing and Hose • Polyurethane or Nylon 12 tubing in popular colors • Bonded polyurethane straight or coiled tubing • Polyurethane straight and coiled hose with fittings CHECK OUT OUR PRICES ON CYLINDERS AutomationDirect Part Description NITRA MSC McMaster-Carr Grainger Stainless Steel Air Cylinder inch bore, inch stroke, double acting, pivot/double end mount $53.25 $99.37 $73.93 $70.97 Stainless Steel Air Cylinder 3/4 inch bore, inch stroke, single acting spring return, nose mount $11.25 $19.18 $15.35 $15.02 Stainless Steel Air Cylinder 1-1/16 inch bore, inch stroke, double acting, pivot/double end mount $24.50 A17060DP $48.20 36696847 $31.83 6498K658 $32.31 6W130 A32040DD A12010SN 36697563 36696458 6498K478 6498K141 6D881 6W070 All prices are U.S published prices Many other part numbers are available from all vendors Automationdirect prices are from March 2011 Price List MSC prices are from www.mscdirect.com 2/22/11 McMaster-Carr prices are from www.mcmaster.com 2/22/11 Grainger prices are from www.grainger.com 2/22/11 Prices subject to change without notice www.automationdirect.com/pneumatic-parts Fittings • Bulkhead, straight, tee, elbow, Y, cross and triple branch unions Flow Control www.automationdirect.com • Manual hand valves, Go online or call to get complete information, request your free catalog, or place an order stop, check, meter-in, meter-out and inline RS# 103 1-800-633-0405 DEPARTMENTS ON THE COVER An LZ N07-101 Zepplin EDITORIAL Food for thought: The distance between a field and your plate 10 EDITORIAL STAFF 12 LETTERS 18 SCANNING FOR IDEAS Hybrid sweeper-scrubber goes green Gas springs provide just the right force 22 32 38 40 REPORTER’S NOTEBOOK LOOKING BACK ADVANCED MANUFACTURING BERKE ON SAFETY Beware of unsafe guards 68 PNEUMATIC PRODUCTS 72 SOFTWARE PRODUCTS 74 PRODUCT SPOTLIGHT Bearings & guides 76 88 90 93 94 94 PRODUCTS BUSINESS INDEX DATA FILES AD INDEX BUSINESS STAFF BACKTALK 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 0024-9114/11 $1.25 + 60) Subscription Policy: MACHINE DESIGN is circulated to research, development, and design engineers primarily engaged in the design and manufacture of machinery, 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LGH al, og eric ech a l g e i e t B G s , a , n L m k T lm c nom F, U ech ie, P ik, ppil H6 diSe ck, A ogi , U m a , B e n T c n r o a P r g Te M SS ust ech , St VWH f, M mp ake i, L Inc cno , \ ol , t n d e B P e E rt s ms , PK HS, a In rde Ellio FD6 , W it Ch IG, aria sign s, T edat K allin P Fö sti, 0H ging sv A , S n, M De tem a-R a er ev ak, s ssi d B PE Ga RQ ka mo IM sig en y e a p S R L c e i experience a C h ffe, De the k I, Ha n, S, ov adifference LV and S, of P r e L one tarthem Y ed DBe L D P n s p M D a A Oy 8Q me ch, Bie and k, n , ofk, B A a a C m , a e , l & R system solutions! p d pa o m , LP xtr s A Uh k ar G P ,S r s K a S e a e n , p t , a V t r , Il lutio 9OD ier, E nchi Sys Build Tet roup teco ine, , Ila Oys ivis , o WUR err fra FT x G F, U ach , YK ns, , Un [ e S e n a V P i n , c $ ia, La me ach Cerm Aetn , MB ia M ctec lutio sim LHU ( F s , l a c PD Has ipol k, O n, M ing, ini, PKB umb n Pa c So o Vl 3HUU fran r l rte Pa str D n S d er, V ac isio ell a o n L L C sta vil, o a P v n b T A a tem tec V o La M , Ine ies, eeg man ac, +DVV poll, e, F T e, Sys Ray akr ac, G tma olog , Th uh Dim WDU l, Vi cm Mac i S s, B er, V avi k, O n, , M l n n F S \ l y a g , h , r i e C r c T e a o c n c e n i b , a , n e b l hin Visio , Al note S T oba Kro mon çHN sme m P c Vis o La M c a s au t, Pa , ES s Gl tta, Thi %OD , Ko yste yte akr , G e b r I , a c e n nta hine tama KHS ckSy i Ber harp -RVH stro ral S ry, R n, M gna c, Si e a A , io s a e c e ll as , Ha ipak ie, P rate on- S SDF ppec , Gen chin Vis , Alb not S T s YR a ed str F s Ma res au , Pa , ES ck A d c l , i , u o n r M du low H 1R ck a enb at HS Pa r t t g , n n n a n F i m e rb ina I ik, 1B MA 0& , T-P & Co kag y, A chin asta ak, K trie, , 1B ll hn &B O eal ics Pac log as , H dip us nik E a d M B ec l, B GH o S a g di , Lo ican chn , T2 nic r Me a In tech sti, rt ppi 6L e e f, M ck er k Te lma cca rbe allin rder r Ga tro rd to H a l m S WHP o i , U me Kö p ,A B Fö sta , g As c t m a o , W r , o e y io 6\V g, L P L c c e n n gin it Ch , Pak ani, ns In Tec atro De , PE s, O ima vopa J D HF cka osv IG ari ig ms, Red da, ADS tion er, D , No FND S M a te sia- , Re ak, olu nni MC H3D os s n e P Ch y s nn lap c S mo , T ig P o, K a , H i I l a a H U h m , h e W P r , oc Bie ,P MI Uhlm , YK ann rp, T , Sid U([ cAst Che , ec hm me UULH pe ch, ont t S , e m, rs a c n , r a Bu n-S ste 3H Ap Ko C c p co chi e Tet P u d l o , , , y e n i o D i a Scan QR code for more information u ex, Gr VL ack ch ics ds a S inDAutomation ,O Ut a M arte nes Perfection V k u , n P F c c a Hall / Booth South 5111 o H 104e www.br-automation.com i + , T- nfra Log Pa fe, U erm etn , MB mb heeg , Kr AF, RS# M D lu n, \VW eal La k, T M ,A B em ief tta More than 200 packaging companies trust in B&R controls What’s new online machinedesign.com Product and supplier database MACHINE DESIGN’s OEM Supplier Directory is the place to find manufacturers and suppliers of products and services for the OEM The Directory includes more than 2,500 types of components and systems — everything from engineering software to dc motors, needle bearings, nuts and bolts, and hydraulic cylinders Information is grouped by technology: CAD/CAM, electrical/electronic, fastening/ joining, fluid power, manufacturing processes, materials, and mechanical It’s intended to help design engineers make educated, informed purchasing and specification decisions Find it at http://directory.machinedesign.com Micro vehicle is tough as nails At AUVSI Unmanned Systems 2011, QinetiQ debuted their latest micro unmanned ground vehicle (MUGV) for military and first-responder robotic missions The Dragon Runner 10 weighs less than 10 lb — light enough to throw through windows, into rooms, and off rooftops The DR 10 is built to withstand harsh environments and gather data through a multitude of interchangeable day and night sensors, radios, cameras, and robotic arms Learn more at www engineeringtv.com/video/ Dragon-Runner-10-Easier-toThro New bearings catalog EDITOR’S WEB PICKS A new catalog from igus covers plastic bushings, spherical bearings, and linear bearings and guides It helps users select products by industry, application, or criteria such as load, temperature, friction, and wear It also includes drawings and a number of new products Get it at www.igus.com/quickorder RS# 105 MACHINE Design.com SEPTEMBER 22, 2011 Enclosures en español tion, electrical conductivity, thermal management, EMC/EMI shielding, and packaging for cushioning and protection View it at www.fabrico com/markets-applications-batteries htm Pumps and compressors The new Thomas Global Catalog has updated specs and performance data on hundreds of articulated piston, diaphragm, rotary, and linear oilless air compressors/ vacuum pumps; and peristaltic, linear, and diaphragm liquid pumps Selection guides help users quickly find the right product by technology and model View or download a copy at www.gd-thomas.com Pentair Technical Products, Hoffman has a new Web site (http://hoffmanonline.com/espanol) offering a wide range of Spanishlanguage literature on engineered enclosures It includes a specifier’s guide, product catalog, a white paper on global standards, renewable- Guide to inspection energy brochure, and an interactive software selection tool to calculate cooling Delcam has an online guide relatrequirements based on thermal ing new developments in its inspecload and enclosure size tion software The site includes a series of videos on capabilities, enVideo demystifies hancements to GD&T functions, and battery insulation Fabrico’s new video looks at materi- how to speed analysis, efficiently reuse measured data, and handle als issues with lithium-ion, nickelcadmium, and other advanced bat- point-cloud data View the site at teries It delves into electrical insula- www.delcam.tv/pi2011/lz 15 500+ 250 MILLION SERVICE CENTERS STOCKING DISTRIBUTORS OF INVENTORY COAST TO COAST Millions and Millions of Reasons One Connection Together, we can deliver more uptime, more product innovations and a greater bottom line value Connect with Parker for premier customer service and superior product performance We are your choice for pioneering products like Robust Port Stud™, Compact Spiral™ and Trap Seal® Parker also helps reduce equipment and machinery downtime by increasing the speed and accuracy of acquiring replacements with our exclusive PTS For more information on our 250 million + reasons to choose Parker, scan the QR code with your smart phone or visit www.parker.com/oneconnection ENGINEERING YOUR SUCCESS www.parker.com 800 C-Parker RS# 106 EDITORIAL Food for thought: The distance between a field and your plate The Pack Expo trade show is about to kick off and is notable because it caters to the packaging industry The packaging industry, in turn, largely revolves around the packaging of food So it might be appropriate to examine the recent trend toward hand-wringing over “food miles.” The idea is that the longer food travels before it hits your plate, the more energy dissipated and greenhouse gases generated At least according to popular mythology The truth of the matter is that most energy and greenhouse gases associated with food go into its production, not its transportation And that goes equally for food bought at the local farmers’ market as well as for that picked from grocery-store shelves The issue of food miles has been thoroughly investigated by two environmental engineers at Carnegie Mellon University in the U S and by the Dept for Environment, Food and Rural Affairs in the U K CMU researchers Christopher Weber and H Scott Matthews found that the food-production phase contributed 83% of the average U S household’s annual carbon footprint for food consumption Transportation as a whole accounted for only 11% of greenhouse-gas emissions associated with food And final delivery from producer to retail contributes only 4% of that 11% It also emerges that transport by ship, rail, and air freight over long distances is efficient compared with trucking food a comparatively short distance to its final destination The trucking phase is responsible for 71% of the total greenhouse gases generated while transporting food Wholesaling and retailing operations accounted for just 5% of overall emissions CMU researchers as well found that globalization has increased the distance food travels by around 25% since 1997 But this has boosted greenhouse-gas emissions associated with transport by a mere 5%, simply because ocean shipping is far less energy intensive than overland trucking In the U K., DEFRA examined the “food miles” question partly to see whether a “buy-local” movement in that country made any sense DEFRA uncovered percentages similar to those of the CMU research, and also discovered that “buying local” could lead to more greenhouse-gas emissions rather than less The reason is that a lot of produce in the U K must be grown in greenhouses rather than in open fields The energy debt of a greenhouse is a dealkiller, greenhouse gas-wise The situation isn’t much better for produce grown in U K fields that must be put in cold storage until it is eventually consumed U K residents generate fewer greenhouse gases shipping fresh apples in from New Zealand than putting British apples in a cooler And when it comes to milk, U K dairy farmers use twice as much energy to produce a metric ton of milk solids than New Zealand farmers, says DEFRA The lesson from all this is that food should be grown where it is most economically virtuous to so And the packaging industry needn’t worry about “buy-local” movements cutting into the need for its products — Leland Teschler, Editor Congratulations to Don Schimizzi, J Harboy, Rich Werth, Sasa Pudar, and Bradley Miller They each won a $100 American Express gift card as top scorers for August in our World’s Smartest Design Engineer contest Challenge yourself now at www.smartestdesignengineer.com and see if you can top the scoreboard next month! RS# 107 SEPTEMBER 22, 2011 PRODUCTS Side-exit check valve The new 093 Lee Chek is an ultraminiature side-exit check valve The 0.093-in.-diameter valve is based on the same technology as the 0.187-in.-diameter side-exit Lee Chek The 0.14gm valve offers a 90% reduction in weight over the 187 Model and is 50% shorter for a reduction in installation boss size and weight Unmatched Precision Unmatched Affordability The all-stainless-steel valve features a hard metal-to-metal seat and is available in a forward-flow configuration The Lee Co., Pettipaug Rd., Box 424, Westbrook, CT 06498, (860) 399-6281, www.theleeco.com RS# 480 The planetary gear reducer that sets a new industry standard for performance at an exceptional price point Shimpo’s ABLE Speed Reducers Retaining-ring, wavespring catalog Contact us today about your servo motor application, and let us help you build a better, more cost effective piece of equipment for your customer Make it a Shimpo! The new Parts and Engineering Catalog combines the existing Spirolox Series of retaining rings and wave springs with a newly released Series that includes Hoopster retaining rings, constant-section-rings, metric-wave springs, and small Series wave springs The catalog, which features 130 pages of part tables, engineering guides, design information, and expanded part offerings, comes in both paper and PDF formats Smalley Steel Ring Co., 555 Oakwood Rd., Lake Zurich, IL 60047, (847) 719-5900, www.smalley.com RS# 481 RS# 169 84 MACHINE Design.com SEPTEMBER 22, 2011 Supplies feature 10-year capacitor life The 50-W ZWS50BAF and 75-W ZWS75BAF join the ZWS line of compact ac-dc power supplies The supplies combine high efficiency — at low load conditions — with a wide operating temperature range, small size, and up to 10-year electrolytic capacitor life The supplies accept a 85 to 264-Vac ac input range, have a low profile of 1.0 to 1.3 in., and measure 2.0 × 5.2 × 5.9-in long The devices feature a universal ac input with PFC; operate from a 120 to 370-Vdc input; are designed to withstand 3-kVac, input-to-output; and are available with output voltages of 3.3, 5, 12, 15, and 24 V or 48 Vdc, all of which have a ±10% adjustment range for nonstandard system requirements The operating temperature range is –10 to 70°C, allowing 100% load operation in a 50°C environment TDK-Lambda Americas Inc., 3055 Del Sol Blvd., San Diego, CA 92154, (800) 526-2324, www.us.tdk-lambda com/lp/products/zws-series.htm RS# 482 Don’t slip up with ball screw actuators Tritex Linear and Rotary Actuators Choose the all-in-one actuator solution with roller screw technology Tritex™ is the compact, low maintenance motion solution with an integrated controller, amplifier, motor and advanced roller screw actuator, all in one efficient, sealed package Eliminate complexity and get the most performance in the smallest footprint Compare and learn more at www.exlarcorp.com Controller Amplifier Motor Actuator Exlar’s patented roller screw actuators outperform ball screw actuators in life, load, speed and acceleration RS# 170 SEPTEMBER 22, 2011 MACHINE Design.com 85 For those tough nuts to crack! “Kapton”™Insulating Tubing Tired of waiting? Engineered solutions Self-Extinquishing Flame Retardant -269°C to +400°C Does Not Melt 7,000 VPM More info? Call, Fax or E-Mail for Catalog …FAST 2102 5132 (1.8" x 95" x 60") (3.2" x 1.9" x 90") • High Flow • High Pressure 1032 5.5" x 3.5" x 2.7") • High Vacuum • High Efficiency • Low Cost To receive literature & details fast - www.pptube.com Phone: 847-537-4250 • Fax: 847-537-5777 • E-Mail: sales@pptube.com The Original - Since 1934 CUSTOM ENGINEERING CUSTOM SOLUTIONS EXCEPTIONAL VALUE 877-244-4330 Paper Tube Company Made in the USA ™ ® DuPont Co RS# 171 1033 S Noel Ave., Wheeling, IL 60090 RS# 172 Constant Force Counterbalance Support arms move farther, smoother, and last longer Whether it’s a surgical system arm, computer monitor arm or another automation application, AMETEK Hunter Spring constant force spring reels offer clear advantages over gas struts and counterweights They’re compact, allowing smaller packaging size And amazingly durable, with a fatigue life from thousands to more than a million cycles, depending on load and spring size Rated at up to 200 lbs., with 4' to 6' linear extensions and a smooth range of motion that begins at first touch: no heavy starting inertia or uneven resistance at the end of their range Lighten your load with constant force counterbalance springs from AMETEK Hunter Spring www.ametekhunterspring.com RS# 173 da Vinci® S™ Surgical System Instrument Arm image ©2007 Intuitive Surgical, Inc Used with permission PRODUCTS Light curtains The F3SJ-E safety light curtains provide reliable hand-intrusion detection for use in stand-alone devices and machines Quickmount brackets and reduced wiring, combined with easyto-view alignment indicators let OEMs and end users easily mount the curtains F3SJ-E models satisfy straightforward hand-guarding applications, while the F3SJ-A advanced-type safety-light curtains offer series connectivity, finger or hand/ limb/body protection, and advanced blanking and muting functions Sensors with protective heights of up to 2.5 m are available for applications that involve large-sized workpieces Omron Scientific Technologies, 6550 Dumbarton Circle, Fremont, CA 94555, (510) 608-3400, www.sti.com RS# 483 Pushbuttons The Series 84 PCB pushbuttons offer multicolor “halo” illumination capabilities for HMI systems and control panels The range of 22.5-mm, PCB-mounted pushbuttons and indicators are quick and easy to program to change color, pulse, flash, and illuminate at the edge for a variety of dynamic effects The devices use 10 different SMD LEDs to produce customer-specific illumination combinations Users select eight outer ring LEDs to produce a “halo” and an additional bicolor LED for the center Along with additional electronics, the switches can be used with touchscreens and displays to emphasize primary or additional controls to show initiation sequences with a dynamic LED countdown; increase or decrease output – each time the button is pressed another LED lights up around the ring; provide visual warning signals through the use of multiple colors or animated illumination sequences;, and show various cycle stages of application by changing illumination The device mounts on a PCB using a flange with snap-on connector Users can choose flat or raised, plastic or aluminium lenses EAO Corp., 98 Washington St, Milford, CT 06460, (203) 877-4577, www.eao.com RS# 484 Staple Set Brush by Sealeze • Conveyor and Material handling • Packaging Lines • Food Processing • Water and wastewater processing Custom staple set brushes in a variety of sizes and configurations For more than 25 years, Sealeze has manufactured the widest variety of custom strip brush products Now, we introduce custom staple set brushes in a variety of sizes and configurations designed to meet your application needs Our experienced Sales Representatives, in-house engineering staff and design services are available to help you find the right brush solution for your application 800.787.7325 e-mail: industrial@sealeze.com www.sealeze.com RS# 174 SEPTEMBER 22, 2011 MACHINE Design.com 87 BUSINESS INDEX Ace Controls Inc 20 Air Canada 23 Altech 96 BigBelly Solar 22 Bishop-Wisecarver Corp 74, 95 Bosch Rexroth Corp., Pneumatics 68 British Airways 23 Carnegie Mellon University Cecchetti Wine Co 23 Chicago Athenaeum Ð Museum of Architecture and Design 34 Cimatron Group 38 Clean Energy Research Institute 25 Clippard Instrument Laboratory 68 Comsol Inc 36, 72 Continental Airlines 23 Delcam Dept for Environment, Food and Rural Affairs Deublin 96 Digi-Key Corp 34, 96 DuPont 42 From private spaceflight to deep sea submersibles, Ultra Motion linear actuators are trusted in some of the most demanding applications We specialize in high performance linear motion systems engineered for custom solutions Top image courtesy of Armadillo Aerospace, an Ultra Motion customer Eastman Chemical Co 34 European Centre Ð Architecture Art Design and Urban Studies 34 FAG Bearing, Schaeffler Group 74 Fabrico 6, 30, 34 Festo 69 Festo USA 64 Fetzer 23 Goodyear Tire & Rubber Co., The 42 Hallam Inc 30 Huaneng Power International Inc 25 igus Inc 6, 75 Indiana University School of Medicine 25 Linear Actuators and Controllers ultramotion.com sales@ultramotion.com 631-298-9179 888-321-9178 KHS Plasmax GmbH 23 Kaydon Corp., Bearings Div 75 Koppers Co 32 LEDIL 34 Lawrence Livermore National Laboratory 25 Lockheed Martin 42 Mack Molding Co 22 RS# 175 SEPTEMBER 22, 2011 Marbon Chemical Div of BorgWarner Corp Maxim maxon precision motors Inc Mechanical Simulation Corp Mercedes-Benz Molex Mrs GriffinÕs Barbecue Sauce National Fire Protection Association National Institute of Standards and Technology NewAge Industries Nilfisk-Advance Norgren Inc Northwire 32 34 96 72 32 34 23 50 34 69 18 56 96 Parker Hannifin, Filtration and Separation Div 70 Pelican Products 34 Pentair Technical Products, Hoffman Pew Research Center 94 Pisco USA 70 Princeton University 29 Purdue University 24, 29 QinetiQ R+W America 96 SKF USA Inc Saint-Gobain Solar Seal Master Siemens PLM Software Simrit Smalley Steel Ring Society of Hispanic Professional Engineers Stahlin Non-Metallic Enclosures Sutter Home 74 75 96 72 96 96 36 50 23 TAFA Metallisation Inc 32 Textron Lycoming 42 Thomas Thomas Div., Gardner Denver 69 Underwriters Laboratories 52 This index includes all significant references to parent companies mentioned in feature editorial material within this issue of MACHINE DESIGN It doesnÕt cite companies listed solely in the Products and Lit Section Page numbers listed refer to the pages where the articles begin 7SPZIQSXMSRGSRXVSPTVSFPIQW [MXLQYPXMTPIGLSMGIERW[IVW 61'ERH61' 1SXMSR'SRXVSPPIVW SVYTXS E\IW 7]RGLVSRM^IHGSRXVSPSJ TSWMXMSRERHTVIWWYVI JSVGI 2I[[M^EVHWJSVUYMGOIEW] WIXYTERHXYRMRK )XLIV2IX-4ERH 463*-&97GSRRIGXMZMX] %\MW 1YPXME\MW ❑ 1E\MQYQ]MIPH❑ 0S[IVPMJIG]GPIGSWX❑ )EWISJYWI4MGOXLVII ;LIXLIV]SY«VIVIXVSJMXXMRKERSPHQEGLMRISVFYMPHMRKERI[SRI (IPXEQSXMSRGSRXVSPPIVWKMZI]SYTVIGMWIGPSWIHPSSTGSRXVSPJSV GVMXMGEPMRHYWXVMEPETTPMGEXMSRW[LIVITVIGMWMSRQE\MQM^IWTVSHYGX ZEPYI3YVJMIPHTVSZIR61'8SSPWWSJX[EVIQEOIWMXIEW]XS STXMQM^IL]HVEYPMGERHIPIGXVMGWIVZSSTIVEXMSRWJSVPSRKIV QEGLMRIPMJIERHMRXIVJEGMRKXS4'WERH40'WMWEWRET 7S]SYWIIMX«WIEW]XSGLSSWIXLIVMKLX FS\IZIV]XMQI.YWXGEPP SV GLSSWI]SYVGSRXVSPPIVEXHIPXEQSXMSRGSQ RS# 176 RS# 178 BETTER FASTENER SEALING WITHOUT CHEMISTRY 360° Metal-toMetal Contact GRAPHALLOY BEARINGS CAN TAKE THE HEAT ® �US ® C UL Recognized Component Pre-assembled embedded O-ring seals in asymmetrical groove – Patent No 3,175,454 Seal and fasten in one step with a reusable, selfsealing fastener No liquid adhesive/sealants … no worries about waste disposal or respiratory safety HANDLE HIGH TEMPERATURE AND HARSH OPERATING CONDITIONS WITH EASE GRAPHALLOY® bushings, bearings and components: • Survive when others fail • Run hot, cold, wet or dry • Excel at -450°F to 1000°F • Corrosion resistant • Self-lubricating • Non-galling • Low maintenance • Ovens, dryers, pumps, valves, turbines, mixers, conveyors Seals liquids & gases to 20,000psi internal/external Self-sealing screw, bolt, nut & rivet versions Temperature range from -160°F to +500°F (-106°C to +260°C) GRAPHITE METALLIZING CORPORATION Yonkers, NY 10703 U.S.A ISO 9001:2008 H06a View Video WHEN JUST FASTENING ISN’T ENOUGH® 800.498.9034 www.apmselfsealingfasteners.com TEL 914.968.8400 • WWW.GRAPHALLOY.COM/MD RS# 177 Tested to UL Standard 50, Types 1-13 Optional threadlocking Self-sealing washers seal to 100psi Metric and inch Made in U.S.A RS# 179 DATA FILE LITERATURE ADVERTISING ader Service Access our Re kly find and ic Website to qu ation on the request inform ices found rv se d an products MACHINE DESIGN of s ge pa e th in c design.com/rs w w w.machine To advertise in the DATA FILE sections call 216.696.7000 or e-mail laurel.hirkala@penton.com Tubus Bumpers Ace Controls, Inc offers TUBUS Bumpers that outperform rubber, urethane, and coiled steel shock absorption materials These cost effective bumpers are perfectly suited for harsh environments, with excellent resistance to Oil, Grease, Chemicals, Salt-water, Ultra-violet Light, and Microorganisms Contact ACE Controls for your free catalog: ACE Controls Inc RS# 251 RS# 250 Farmington Hills, MI (800) 521-3320 (248) 476-0213 Fax (248) 476-2470 Email: shocks@acecontrols.com www.acecontrols.com Seal it Right Right From Apple Apple RubberÕs Silicone Housing Seals Beat Gaskets Flat Apple Rubber’s Capabilities Brochure gives a comprehensive overview of their complete capabilities As a leading designer and manufacturer of seals and elastomeric products, Apple Rubber has the experience, products, and capabilities to deliver the exact sealing solution for your applications – from design through manufacturing to certification Silicone housing (face) seals from Apple Rubber are a superior alternative to flat gaskets and other gasketing methods This brochure highlights Apple Rubber’s durometer, shape, and color options; advanced liquid injection molding (LIM) design processes, and in-house tooling capabilities for fast prototypes – direct from their USA plant Axis Driver + Controller Measures Just 2.25Ó Square The product is a miniature axis stepper motor controller and driver measuring 2.25” x 2.25” x 0.6” The controller-driver is capable of driving each motor at Amp of current at 1/16th micro-step resolution The controller performs fully profiled moves and accepts high level commands from RS232, RS485 or USB On boards program storage allows stand alone operation Connections for limit / home switches for each channel , and dual encoders for position monitoring and correction are supported All Motion www.allmotion.com (408) 460-1345 RS# 252 New tutorials and podcasts on Learn Web site “What is a PLC” plus many more topics on industrial control products including new videos and podcasts on AutomationDirect’s free self-service learning site Visit http://learn.automationdirect.com to watch these and other tutorials on a range of industry topics Apple Rubber Products Apple Rubber Products RS# 254 RS# 253 RS# 255 Versal phase micro step driver - MD5-HF28 NEW Manual Brake System for Compact Linear Guides Autonics proudly introduces MD5-HF28 AC universal type phase micro step driver – realizing high accuracy (max 250 divisions), high speed and high torque control MD5-HF28 maximizes user’s convenience with diverse resolution setting types (max 250 divisions) and front ALARM LED and 100-220VAC universal power supply * Diverse alarm function (over temperature, over current) available with self diagnosis * Auto current down, self test, user’s run/ stop current setting, zero point excitation output provided * Photo coupler input insulation to minimize external noise Bishop-Wisecarver now offers a new carriage brake system for its popular UtiliTrak linear guide product line This new option is a simple two-component assembly solution for manually securing a carriage to a rail in confined spaces Easily retrofitted to existing applications or factory preassembled on new systems Available in sizes, the hard anodized aluminum body provides excellent corrosion and abrasion resistance, good braking action and long life A second brake assembly can be installed for added braking strength 888.580.8272; www.bwc.com Boker’s complimentary 2011 Washer Catalog features over 25,000 nonstandard flat washer sizes available with no tooling charges Outside diameters of 0.080” to 5.140”, a wide variety of inside diameters and thicknesses and over 2,000 material options provide endless possibilities Materials include low-carbon sheet steel, various spring steels, stainless steel, aluminum, brass, copper, nickel silver and non-metallics ISO 9001:2008 Registered Boker’s, Inc (888) 927-4377, FAX: (800) 321-3462 Email: sales@bokers.com URL: www.bokers.com/mdd Autonics USA, Inc RS# 256 RS# 258 RS# 257 Free design guide to servo-hydraulic motion control www.deltamotion.com Popular, practical 64-page guide with 16 topics by Peter Nachtwey: s #LOSED LOOP #ONTROL s 3IZING #YLINDERS AND 6ALVES s 3ELECTING !CCUMULATORS s 4RANSDUCERS AND 2ESOLUTION s 4UNING FOR /PTIMAL 0ERFORMANCE RS# 260 RS# 259 Gems Fluid Sensors & Controls Master Catalog Galil’s “Pocket PLC” Has Lots of I/O This 340-page Master Catalog details the broad portfolio of Gems liquid level, flow, and pressure sensors, miniature solenoid valves, and pre-assembled fluidic systems designed for OEMs across a wide range of industries Provides full specifications, dimensions and part numbers 800-378-1600 www.GemsSensors.com RIO Pocket PLC is smart, compact, low-cost, and packed with I/O 32 digital and 16 analog I/O in 3.9 x 4.3 x 1.3” package Ethernet/RS232, RISC processor, PID process loops, counters, timers, data logging, email alerts Network multiple RIOs $295 qty 1/$195 qty 100 Call Galil at 800-377-6329 or http://www.galilmc.com/ pocketplc for specs and free tutorials Galil Motion Control Gems Sensors & Controls RS# 262 90 MACHINE Design.com RS# 263 SEPTEMBER 22, 2011 RS# 261 New Spring Brochure New brochure, “The spring for the 21st century,” describes Helical’s special expertise in designing and producing single piece, maintenance free, “machined” springs for a broad range of applications It also features examples of integrated attachments plus data comparing wire-wound and machined springs Helical machined springs are used in industries such as medical, aerospace, military, nuclear, industrial and electrical/electronics Visit: www.heli-cal.com Helical Products Co., Inc RS# 264 NEW REVISED ELECTRIC HEATER CATALOG SELF-LUBRICATING GEAR SOLUTIONS CALCULATED FOR LIFE Hotwatt manufactures electric heaters including cartridge, air process, immersion, strip and finned strip, tubular and finned tubular, band, crankcase, foil, flexible glasrope and ceramic heaters We have been manufacturing resistance heating elements since 1952 and offer a wide variety of heaters for OEM, industrial, medical, commercial and military applications E-mail: sales@hotwatt.com Web Page: www.hotwatt.com HOTWATT, INC RS# 265 The Intech Power-Core™ gears are precision machined and offer solutions to applications in which lubrication, wear, noise, vibration, inertia, shock load, moisture and chemicals present a problem for nylon, Delrin or metal gears Metal Core provides for a secure attachment to the shaft and higher torque transmission Gear design and sizing is backed by durability calculation using proprietary software Intech Corp., 250 Herbert Ave., Closter, NJ 07624 (201) 767-8066; Fax: (201) 767-7797 www.intechpower.com RS# 266 RS# 267 Cross-referenced to metal cam followers for easy replacement Quickly make your product wireless with a minimum amount of time and effort Linx OEM wireless solutions are pre-approved and can be easily customized to your exact needs Only our patent pending iCamFollowers® offer all these advantages: plastic tire eliminates rail wear; no lubrication is required in the bearing or on the rail; reduce noise up to 10dB; absorb shock and vibration; high load capacity; ball bearings permit higher linear speeds; lighter weight reduces inertia; are suitable for use in clean rooms; wash downs; work well in subzero temperatures (-40F) For load ratings and sizes go to www.intechpower.com/icam Intech Corporation, 201-767-8066 Linx Technologies, Inc Wireless Made Simple® 800-736-6677 RS# 270 Roxtec EzEntry™ – the new seal for cabinets and enclosures It is UL/ NEMA and IP rated and allows for pre-terminated cables of various sizes ì Low viscosity ì Dimensionally stable ì Ideal for potting applications RS# 271 RS# 272 Cutting edge product is ideal for digital and analog imaging aplications! r7JTJCMF/*3MJHIUNJDSPTDPQF r&BTZTFUVQBOEJOTUBMMBUJPO r*EFBMGPSUPNNPCKFDUT r*OUFHSBUFE-&%JMMVNJOBUPS r6TF*NBHFSTVQUPuGPSNBU r6QHSBEBCMF r7FSZ$PNQBDU r6TFUPY*OàOJUZ0CKFDUJWF r(SFBUGPSTUBOEBMPOFVTFPSJOZPVS0&. applications &NBJMTBMFT!TBOUBCBSCBSBJNBHJOHDPN XXXTBOUBCBSCBSBJNBHJOHDPN Seal Master Corp., Kent, OH Smalley Steel Ring Company rJOGP!TNBMMFZDPNrXXXTNBMMFZDPNHFUDBUBMPH RS# 277 RS# 280 Rugged, precision, light-weight electroforms can withstand extreme temperatures down to -423°F Diameters range from 0.020” (0.5 mm) to 9”, with walls as thin as 0.002 inch Electroforms can be made an integral unit with a flexible bellows, eliminating weld, solder or bond joints Email info@servometer.com and request a copy of our Precision Electroforms brochure, today! Servometer¨/PMG, LLC $FEBS(SPWF /+r rXXXTFSWPNFUFSDPN RS# 276 Discover SymmcoÕs Parts Conversion Opportunities � � � � Design Support (for Simple to Complex Parts) Gears DonÕt Cast & Assembly Solutions Machine Ð Save Materials Options Your Key To Quality & Savings RS# 278 814-894-2461 � Time & Money with Powder Metallurgy (P/M) TAYLOR DEVICES UNI-SHOK Taylor Devices offers the Uni-Shok industrial shock absorber for high-speed, automated machinery Available in 14 models, Uni-Shok provides up to 5000 in-lbs of capacity Patented, self-adjusting fluidic metering system eliminates adjustment down-time Features stainless steel piston rod, internal coil spring reset, bronze bearings, silicone fluid and threaded body for mounting ease Contact: Taylor Devices Inc., 90 Taylor Dr., N Tonawanda, NY 14120-0748 Phone: 716.694.0800 Fax: 716.695.6015 Web site: www.taylordevices.com Taylor Devices Inc RS# 279 www.symmco.com New Motion Control Website Vinyl & Rubber Extrusions Trim-Lok Inc releases a brand new FREE “Catalog 500” featuring “How to Order” steps for the first time customer, along with an expanded line of complete trims and seals FREE samples may be requested Latest additions include our Flap Seal, Fire Retardanct Trim, adn Hatch Seal Contact us toll fee at 1-888-874-6565, e-mail us at info@ trimlok.com or visit us on-line at www.trimlok.com Precision Electroforms RS# 275 RS# 274 Smalley’s new catalog combines existing Spirolox Retaining Ring and Smalley Wave Spring selections with series recently released from Smalley Now a single catalog includes new: Hoopster Rings, Metric Wave Springs, Constant Section Rings and more Over 10,000 standard parts in carbon and stainless steel; free samples available Specials manufactured with No-Tooling-Costs™ from 200”-120” RS# 273 Solve difficult closure problems with custom-built, fabric-reinforced, fully molded elastomeric Seal Master® inflatable seals With close tolerance capability and resistance to compression, they’re ideal for imaginative production and processing applications too Engineered specialties include fabricreinforced bags, bladders, plugs and other custom rubber products Design assistance offered SANTA BARBARA IMAGING, LLC New Smalley Engineering & Parts Catalog Roxtec Inc, Tulsa, OK www.roxtec.com SEALS, ACTUATORS, GRIPPERS AND BAGS Industrial Microscope Trim-Lok Inc., Buena Park, CA Magnetic Component Engineering RS# 269 Thermally Conductive/ Electrically Insulative Epoxy www.masterbond.com New catalog features high performance magnet materials such as NdFeB and SmCo, molded magnets, ceramic and alnico magnets MCE offers magnet circuit design, custom fabrication, assembly, and advanced coatings Complete traceability is offered Phone:(310)784-3100, Fax:(310)784-3192; mcesales@mceproducts.com; www.mceproducts.com www.linxtechnologies.com RS# 268 EP30AO High- Performance Magnets OEM Wireless Solutions POWER TRANSMISSION STRETCH BELTS Pyramid Inc has manufactured round and flat Pyrathane® belts for over 40 years Pyrathane® belts are used in a wide variety of low and fractional horsepower drive applications such as live-roller conveyor systems, as well as transport devices for paper, currency and small parts Pyrathane® belts are manufactured to our customers’ specifications and are of the highest quality with exceptional abrasion resistance and durability Pyramid Inc 522 N 9th Ave E • Newton, IA 50208 Phone: 641-792-2405 • Fax: 641-792-2478 E-mail: sales@pyramidbelts.com Website: www.pyramidbelts.com Experience the new look and feel of Wittenstein Including alpha gearboxes, custom servo solutions and simulation systems - the world of motion is only a mouse click away Put your web in motion with Wittenstein Visit us today at www.wittenstein-us.com Wittenstein RS# 282 RS# 281 SEPTEMBER 22, 2011 MACHINE Design.com 91 The more you know… the faster you can build your control panels Knowledge is power SmartWire-DT™ from Eaton is the first innovation that effectively reduces the complexity, commissioning and complications involved with wiring control cabinets Eliminate point-to-point wiring and replace it with a simple eight wire cable that connects components in minutes, not hours Learn more at: www.eaton.com/smartwire-dt RS# 180 WE’LL DO THE ADVERTISER INDEX RS# COMPANY PAGE 152 A&A Manufacturing 68 181 ACE Controls, Inc 93 162 Advanced Antivibration Components 73 147 Agathon Machine Tools 63 135 Ametek Inc 40 173 Ametek Inc 86 145 Ansys Inc 61 179 APM Hexseal Corp 89 133 Apple Rubber Products 37 131 Associated Spring/Raymond 35 103 Automationdirect.com .3 129 Avago Technologies U.s Inc 33 140 Avnet 49 166 Barry Controls 79 104 B&R Industrial Automation 101 Baldor Electric Co IFC 150 Bellowstech, LLC 67 141 Bison Gear & Engineering 51 168 Carlyle Johnson Machine Company, LLC 81 123 Celesco Transducer 26 167 Cicoil Corp 80 119 Contrinex Inc 20 178 Delta Computer Systems Inc 89 171 Dynaflo, Inc 86 160 Eagle Stainless & Fabrication, Inc 73 180 Eaton 92 143 Element 14 55 170 Exlar Corporation 85 108 Festo Corporation 183 Forest City Gear 96 127 Galil Motion Control Inc 30 128 Galil Motion Control Inc 31 161 Gortrac, Division of A&A Mfg Co., Inc 73 177 Graphite Metallizing Corp 89 105 Igus, Inc .6 158 J W Winco Inc 71 159 Kaydon Bearings Division 72 110 KB Electronics Inc 10 149 Kepner Products 67 102 Lee Company 153 Lee Spring Co 69 156 Linx Technologies 71 134 Master Bond, Inc 39 148 Maxon Motor USA 63 109 MITRPAK 10 111 Moog Components Group 11 LIFTING & LOWERING 117 Moog Inc 17 164 Nammo Composite Solutions LLC 77 139 Nason Co 48 118 NB Corp 19 116 Nexen Group Inc 16 132 Onvio, LLC 36 106 Parker Hannifin .7 172 Precision Paper Tube Company 86 184 Proto Labs, Inc IBC 176 Quality Bearings & Components 89 112 Quickparts.com Inc 12 157 Raco International, L.p 71 Rino Mechanical Components Inc 32 136 Rittal Corporation 41 142 Rittal Corporation 52-53 124 Rollon 27 126 Rollon 29 114 Roxtec Inc 14 174 Sealeze Corp 87 154 Servometer¨ 70 165 Setco USA 78 169 Shimpo Drives Inc 84 144 Simrit Group 59 113 SKF Industries Inc 13 130 Smalley Steel Ring Company 34 146 Sorbothane Inc 63 107 Spirol International Corporation 151 Steinmeyer, Inc 67 163 Stock Drive Products 73 137 Tadiran 45 138 Taylor Devices Inc 47 120 TDK-Lambda Americas Inc 21 125 Thomas Net 28 182 Trelleborg Sealing Solutions 95 115 Turck Incorporated 15 175 Ultra Motion 88 155 Vecoplan, Llc 71 121 W.L Gore & Associates Inc 24 122 W.L Gore & Associates Inc 25 185 Yaskawa Electric America Inc BC Made in USA New ACE Controls AGS Gas Springs provide counterbalance motion control for lifting and lowering lids, hoods, hatches, machine guards, panels and more Offered in a wide range of body sizes, stroke lengths and forces · · · · Solid, Long Life Construction Push & Pull Type Designs Fixed Force or Adjustable Models Variety of End Fittings & Mounting Brackets Aerospace, Defense, Transportation, RV, Medical, Furniture, Packaging, Printing, Amusement and More 3URGXFW ,QIRUPDWLRQ $YDLODEOH 2QOLQH RS# 181 While every effort has been made to ensure the accuracy of this index, the publisher cannot be held responsible for any errors or omissions SEPTEMBER 22, 2011 )DUPLQJWRQ+LOOV0, WHO ID[ HPDLO VKRFNV#DFHFRQWUROVFRP ZZZDFHFRQWUROVFRP MACHINE Design.com 93 BUSINESS STAFF BACKTALK Phony talk Dennis Jensen, Associate Publisher Larry Berardinis, Business Development Director Virginia Goulding, Online Sales & Marketing Manager Julie Ritchie, Research Manager Jane Maloney Cooper, Marketing Manager Debbie Brady, Audience Development Manager Michelle Modtland, Production Manager, 913-967-7292 Courtney Denison, Production Coordinator, 913-967-1738 Denise Donaldson, Administrative Manager Advertising Sales Mike Hancock International Sales Director, mike.hancock@penton.com Ph: 011-44-1372-824284, Fax: 011-44-1372-824322 Inside Sales: Mary J Brown, mary.brown@penton.com Phone: 866-821-0318, ext 60945 Fax: 800-440-1760 Inside Sales: Leslie Travis , leslie.travis@penton.com Phone: 866-821-0318, ext 60938 Fax: 800-440-1760 Corporate Officers Bob MacArthur, Senior Vice President Nicola Allais MacArthur, CFO Sharon Rowlands, CEO United Kingdom, Scandinavia, France, Spain, Portugal : Tanya McClelland, tanya.mcclelland@husonmedia.com Ph: 011-44-1932-564999, Fax: 011-44-1932-564998 AZ, CA, ID, OR, NV, UT, WA, British Columbia: Belgium, Netherlands, Luxemburg: Jim Theriault, Rodric Leerling, rodric.leerling@ jim.theriault@penton.com, husonmedia.com, Ph:011-31-229-841882 , Ph: 408-857-0322, Fax: 925-736-8705 Mobile 31-683-232625, AL, AR, GA, KS, LA, NM, MS, MO, OK, TX: Germany, Austria, and Switzerland: Franny Singleton, Christian Hoelscher, franny.singleton@penton.com, christian.hoelscher@husonmedia.com Ph: 678-947-8563, Fax: 913-514-6884 Ph: 011-49-89-95002778, CO, IA, S IN, KY, MN, MT, NE, ND, Fax: 011-49-89-95002779 S OH, SD, TN, WI, WV, WY: Dennis Jensen, Italy: Cesare Casiraghi, dennis.jensen@penton.com, Casiraghi Pubblicitá Estera, Ph: 952-368-0018, Fax: 913-514-6627 Ph: 011-390-31-261407, Fax: 011-390-31-261380 IL: Melinda Hurley, melinda.hurley@penton.com, Ph: 847-784-9825, Fax: 847-784-9826 N IN, N OH, MI, NY, PA, Ontario: Bill Rodman, bill.rodman@penton.com, Ph: 216-931-9636, Fax: 216-621-8469 DE, DC, MD, NJ, NC, SC, VA: Brandy Bissell, brandy.bissell@penton.com, Ph: 919-773-1875, Fax: 913-514-6357 CT, ME, NH, MA, RI, VT, Quebec: Liz Stott, liz.stott@penton.com, Ph: 857-636-9737, Fax: 913-514-6914 India, New Delhi: Shivaji Bhattacharjee, Information & Education, Ph: 011-91-11-6867005, Telex: 953-31-72278, Fax: 011-91-11-6526055 Korea: Young Sang Jo, Business Com., Inc., Ph: 011-82-2-739-7840, Fax: 011-82-2-732-3662 Tokyo, Japan: Yoshinori Ikeda, Pacific Business, Inc., Ph: 011-81-03-3661-6138, Fax: 011-81-03-3661-6139 1300 E 9th St Cleveland, OH 44114-1503, Ph: 216-696-7000 — Fax: 216-696-0177 94 MACHINE Design.com SEPTEMBER 22, 2011 A survey by Pew Research Center’s Internet & American Life Project has shown that approximately 13% of people stage fake calls on their cell phones to avoid speaking to people around them For those 18 to 29-yearsold, that number jumps up to 30%, while dipping down to 6% for those between 50 and 64 In the 30 to 49 age range, 11% are regular fakers Smartphone owners bring the average up a bit with one in five of admitting to making phony calls The survey of 2,277 Americans revealed that a whopping 83% owned some kind of mobile phone Additional findings include: • Forty-two percent indicated that they use their mobile phones for entertainment • Mobile phones can also be a lifesaver, with 40% saying they’d found it useful in an emergency • Most use their mobiles to send text messages • The younger you are, the more likely it is you’ll own one, with 94% of 18 to 29-year olds using cells • Seventy-three percent use their phones to send text messages or take photographs • Forty-four percent surf the Web on them • Twenty-nine percent admitted turning off their phone for some peace and quiet The survey also showed that manufacturers have a bit of R&D work to do, as 16% had difficulty reading something on their phone because the screen was too small and 10% found entering a lot of text on their phone frustrating MD Cycling for MS When your company mission is “Motion Without Limits,” what better way to accomplish this than to sponsor one of your employees in the Oregon Bike MS fund raiser Bishop-Wisecarver Corp., San Francisco, sponsored employee and cyclist Chris Crawford in the two-day event, which benefits more than 7,200 people with multiple sclerosis that the National MS Society, Oregon Chapter serves each year “I have friends and loved ones affected by MS, and so many of our employees As a company based on motion without limits, it’s only befitting of us to get involved,” said Pamela Kan, president of Bishop-Wisecarver, adding she has been a personal sponsor of Crawford for years “I am very honored to have helped Chris support this cause He is a true inspiration.” Bishop-Wisecarver is a leader in guided motion technology and the manufacturer of the original DualVee guide wheel Crawford rides in support of his sister, Bonnie Iglesias, who has been fighting MS for years As part of Bishop-Wisecarver’s corporate involvement, the brother and sister team were asked to share their story on camera Crawford and his sister have raised $250,000 since their first bike ride in 2000, and he credits this success to the personal stories they share publicly with their supporters After the bike ride this year, he wrote a letter of his personal experiences to all of his supporters The letter is published online on Bishop-Wisecarver’s company blog To watch video coverage of the event and interviews with Crawford, check out the BishopWisecarver YouTube channel For live news and updates, follow Bishop-Wisecarver online at www twitter.com/bwcnews MD Turcon® M12 – Unrivaled Performance in Hydraulic Sealing New high-performance PTFE seal material Turcon® M12 – provides superior solutions to many challenging applications Trelleborg Sealing Solutions Americas 2531 Bremer Road Fort Wayne, IN 46803 Phone: 260-749-9631 Fax: 260-749-4844 www.tss.trelleborg.com/us facebook.com/trelleborgsealingsolutions youtube.com/trelleborgseals twitter.com/trelleborgseals RS# 182 SEPTEMBER 22, 2011 MACHINE Design.com 95 BACKTALK THANKS TO THE FOLLOWING GAME SPONSORS: READER SERVICES “Actually, it’s not magic at all… these guys just like to dress up!” “At Forest City Gear, you see, we produce the highest quality, engineered solutions to our customers’ requirements and we it using the best gearmaking machines and test equipment we can afford If there’s any magic in us at all, it’s found in the people who make those gears, splines and assemblies at our company, every day, then deliver them to you on time and at the best price possible.” “Our company motto is Excellence Without Exception and we try to live by that code, on every part on every job To less would make us bad wizards and, worse, it would disappoint our worldwide customer base, some of whom are you folks reading this ad, right now That’s a witch’s brew and you’ll never find such a concoction at our company…ever.” “That’s one spell you can count on!” -Fred Young, CEO and Chief Wizard, Forest City Gear Scan this code on your smart phone and see Fred walking through the plant (He’s really the guy who likes to dress up!) www.bit.ly/ForestCityWizard Or visit www.forestcitygear.com for the rest of our story! 11715 Main Street Roscoe, IL 61073 815-623-2168 RS# 183 96 MACHINE Design.com SEPTEMBER 22, 2011 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 44114-1503, Fax: 216-621-8469 E-mail, Editorial: mdeditor@penton.com Online forums: To comment on articles, editorials, and other engineering topics, go to http:// community.machinedesign.com/ forums/157/ShowForum.aspx and log in Questions about articles: Denise Greco, 216-931-9402, denise.greco@penton.com, Fax questions about releases & literature to 913-514-6694 Subscriptions: For a subscription qualification form, see our Web page at submag.com/sub/mn Subscription problems or questions: Contact a customer service representative at 866-505-7173 or e-mail: machinedesign@halldata.com Order a paid subscription: 847-763-9670 Circulation: machinedesign@halldata.com Editorial reprints: Contact Joel Kirk, 216-931-9324, joel.kirk@penton.com or visit pentonreprints.com List rentals: Marie Briganti, 877-796-6947, mbriganti@meritdirect.com Real parts Really fast Simply upload your 3D CAD model, and choose the best option for your needs CNC Machining in 1–3 days Best for 1–10 parts Priced from $95 Choose from 30 different materials including ABS, Nylon, PC, Delrin, PEEK, ULTEM, aluminum and brass Injection Molding in 1–15 days Best for 10–10,000+ parts 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IP55 wash-down rated Engine speed adjusts to deliver all the power needed to formation via ou Request free in Web site at support various machine operating modes The hybrid machines use 50% less fuel Reader Service c design.com/rs and emit fewer CO2 emissions ww w .machine The all-electric version, dubbed 3Power, uses the same electric drives and delivers 5.4 hr of run time on a single charge, which... for industrial buildings such as connected to related content warehouses, factories, and shipping facilities, and in outside areas such on machinedesign.com as park grounds and parking lots http://tinyurl.com/4yrjq9t RS# 401 18 MACHINE Design.com SEPTEMBER 22, 2011 NB’s Ultra Precise Slide Guides Easily Pass Your ‘Multiple Choices’ Test You have so many choices within each guide class – the NB standards,... efficient Available in several sizes Fewer knockouts Complete light-weight kits Seals multiple pre-terminated cables in one opening Protects against water, dust and vibration RS# 114 MACHINE Design.com SEPTEMBER 22, 2011 800 520 4769, 918 254 9872 918 254 2544 EMAIL info@us.roxtec.com, www.roxtec.com PHONE www.roxtec.com/ezentry 14 Sealed to UL/NEMA and IP ratings FAX MODULAR POWER IS NO LONGER A...Keep Your Machine Running! Festo’s VTUB pneumatic manifold is not only reliable, but is also very easy to maintain Simply mount valves with one single screw Designed for corrosion resistance, your machine will be running longer and faster with the VTUB RS# 108 Global manufacturer of process control and... 346-3377 • Outside FL 800 221-6570 www.kbelectronics.com • e-mail: info@kbelectronics.com from $55! * “A Complete Line of Motor Drives” 1300 E 9th St Cleveland, OH 44114-1503 RS# 110 10 MACHINE Design.com SEPTEMBER 22, 2011 We have the motion solutions.™ DŽŽŐŽŵƉŽŶĞŶƚƐ'ƌŽƵƉŚĂƐŝŶŶŽǀĂƟǀĞƐŽůƵƟŽŶƐĨŽƌLJŽƵƌŵŽƟŽŶŶĞĞĚƐ tĞĂƌĞĂǁŽƌůĚ ůĞĂĚĞƌŝŶƐůŝƉƌŝŶŐƚĞĐŚŶŽůŽŐLJ ƐĞƌǀŽŵŽƚŽƌĂŶĚƌĞƐŽůǀĞƌĚĞƐŝŐŶĂŶĚĮďĞƌŽƉƟĐƌŽƚĂƌLJũŽŝŶƚƐ... 300 mm) Contrinex Inc Old Saybrook, CT 06475 Toll free: (866) 289-2899 Fax: (860) 388-3574 E-mail: info_us@contrinex.com www.contrinex.com Visit our Design Site at www.contrinex.com 20 MACHINE Design.com SEPTEMBER 22, 2011 RS# 119 The Series 4050 features a rugged 40 x 50 x 15 mm PBTP housing suitable for rough environments RS# 120 REPORTER’S NOTEBOOK Molded panel lets solar-powered trash compactor... recepwatch?v=eDFX1I0e3kg The trash bin in the comtacle can sit anywhere because it needn’t pactor is rotomolded of lowTrash compactor… continued on page 27 density polyethylene resin 22 MACHINE Design.com SEPTEMBER 22, 2011 Barbecue sauce and wine give up on glass Clear plastic bottles are nothing new in food and beverage packaging, but they are now being used in markets where products were traditionally... recently converted its 12-oz ring-neck and 32-oz decanter-style glass bottles to PET packages from Amcor and uses its existing filling lines Mrs Griffin’s president and CEO SEPTEMBER 22, 2011 PET… continued on page 27 MACHINE Design.com 23 REPORTER’S NOTEBOOK When it matters Implantable O2 generator harvests power from ultrasonics Purdue University researchers have devised miniature transducers that... carry a large, uninterrupted label panel around its circumference MD GREAT TECHNOLOGY IS ONLY GREAT IF IT CAN BE DELIVERED www.linearmotiondelivered.com Design Now, Deliver Now RS# 124 SEPTEMBER 22, 2011 MACHINE Design.com 27 ThomasNet.com’s new semantic search technology will transform your product and supplier discovery process Our revolutionary product finder understands syntax patterns—so unlike... removed use it through a Web site based at Purdue MD IT’S NOT NEXT GENERATION TECHNOLOGY IF THE DELIVERY SKIPS A FEW GENERATIONS www.linearmotiondelivered.com Design Now, Deliver Now RS# 126 SEPTEMBER 22, 2011 MACHINE Design.com 29 REPORTER’S NOTEBOOK Adhesives let shooters improve aim with tracers RS# 127 People outside of the military generally had not had the opportunity to shoot tracer bullets until engineers