Machine Design May 5 2011

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May 5, 2011
A Penton Media Publication
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The new technologies in Creo
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RS# 101
8//.508.0253 ] phillipsplastics.com {vrvrtf)
_ 20!!. All rights reserved. Phillips and the Phillips logo are registered trademarks oF Phillips Plastics Corporation
{Rrvrtf)
1here's a reason 8o percent oF Phillips
medical business is repeat business.
vell actually there are :oo reasons.
At Phillips, we have :oo oF the most
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RS# 102
FA7URS
CAD/CAM TECHNOLOGY GUIDE
CAD
Technology
Guide
Bicycle manufacturer Trek Bicycle Corp., Waterloo, Wis.,
relied on service bureaus to create physical 3D models of
bicycle components. The company also prototyped tooling
mockupsandaccessoriessuchasshoesandhelmets. It some-
times took a bureau several days and a lot of paperwork to
create a model. Now the company has moved prototyping
in-house and generates parts in just hours via a Connex50
3Dprinter fromObjet Geometries Ltd., Billerica, Mass.
The machine is clean and office friendly, says Manager
of Treks Prototype Development Group Mike Zeigle. And
it produces parts that rival those made with SLA in terms
of quality and finish. But the biggest advantage is that the
machine unlike other technologies canprint parts and
assemblies made of multiple materials, with different me-
chanical or physical properties, all in a single build.
Parts produced on the Connex have fine details and a
smooth and durable surface. The machine can print so-
called living hinges, soft-touch parts, and overmolds.
Printedparts closely emulate the look, feel, andfunctionof a
wide variety of end products.
Most recently, the machine played a key role in the com-
panys launch of its new Speed Concept 9 Series bike a
time-trial bike used in the Tour de France and Iron Man
Hawaii. The frame design features aerodynamic cross sec-
tions that lower wind resistance and improve speed. Almost
every part of the newdesign was prototyped on the Connex
and then shipped fromTrek in Wisconsin to a California
Most parts of Treks newSpeedConcept
9 Series bike were prototypedonthe
Connex50 3Dprinter fromObjet.
wind-tunnel-testing facility, where sample frames were
tested at wind speeds of 30 mph or more.
The designers had several ideas for the aerodynamic
features and wanted to see the impact on wind resistance,
says Zeigle. We printed multiple parts on the Connex that
the designers couldsnapontothe bike frame andthentest in
the wind tunnel. The teameven 3D-
printed durable accessories such as
water bottles and bento boxes to make
testing conditions more realistic.
That we could print multiple iter-
ations quickly let us experiment more
while still making the deadline, says Zeigle.
The operator of Treks Connex printer, Lupe Ollarzabal,
says that having the machine in-house has boostedthe com-
panys productivity. The Connex let us get a newproduct to
market quicker and get a better product to market on time,
he says. The machine, thereby, provides a win-win for us
and our customers.
Treks designers now find themselves prototyping a
lot more frequently. Most of the prototypes we create are
things we never would have prototyped before, says Zeigle.
When we outsourced or had to rely on our in-house mill-
ing operation, it was just too costly and time consuming
to do a lot of prototyping. The Connex has also helped us
significantly reduce tooling mistakes that can add weeks or
months to a product launch.
3Dprinter heIps buiIda better Trek bicycIe
Objet, www.objet.com
RS# 621
Trek, www.trekbikes.com
RS# 622
MAY 5, 2011 MACHINE Design.com 60
AUTOMOTIVE
Terra Hawk; a high-speed coupe, the Street Hawk; and
a slightly less-expensive, less-capable entry-level ver-
sion, the Steel Hawk. The vehicles will hit the market
late this year, with the company planning on building a
dozen over the first 12 months. After that, they intend
to manufacture 15 to 18 per year, with the least expen-
sive, the Steel Hawk, going for $750,000, and the rest
starting at $1 million. It should take about 18 months
What do you get when you cross a Corvette with the
original military Hummer? A heck of a hybrid. But it
still wouldnt have the outrageous performance and
capabilities of the Super Terrain Vehicles (STV) being
designed and built by Shadow Hawk, Broomfield, Colo.
The company has plans for six versions of its STV: the
Desert Hawk, an off-roader; two for the military, the
Armor Hawk and Battle Hawk; an RV version, the
ShadowHawk raises the bar for high-performance cars.
to build each one, and buyers will be able to customize
nearly every aspect of the car.
Engine and chassis
At the heart of all the Hawks, except the Steel Hawk,
is a 6.6-liter diesel V8, a pumped-up derivative of a mass-
produced engine. A diesel was chosen based on its abil-
ity to crank out lots of power at usable rpms. The engine
Authoredby:
Stephen J. Mraz
Senlor Ldltor
stephen.mrazQpenton.com
Resources:
HawkVehicIes,http://
shadowhawkvehicles.com
The Shadow
Hawk company
pIans tobuiIdsix
simiIar-Iooking
vehicIes, each
combining
performance
andcapabiIities
suitedtoa
specific niche.
There wiII be an
RVversion, an
off-roader, and
two miIitary-
themedversions.
Buyers can
customize each
tomeet their
ownneeds.
WANT MORE?
Focus onthis code image
usingyour smartphone and
free software fromwww.
neoreader.comandyouwill be
connectedto relatedcontent
onmachinedesign.com
http://tinyurl.com/6epc7g2
Its a Hummer,
an armored Corvette,
no its a
Super Terrain Vehicle!
MAY 5, 2011 MACHINE Design.com 44 MAY 5, 2011 MACHINE Design.com 45
VOLUME 83
ISSUE 8
MAY 5, 2011
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Its a Hummer, an armored
Corvette, no its a Super
Terrain Vehicle!
A new company plans on building
Super Terrain Vehicles, a whole new
concept in high-performance cars.
Waste heat: Best green
power source?
To better boost your green
credentials, try to make use of heat
thrown off by industrial equipment.
Helical gears help
manufacturers go green
High-efficiency gears are
environmentally friendly and save
money.
CAD Technology Guide
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DPAR7MN7S
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ON THE COVER
Super Terrain Vehicles from
Shadow Hawk.
EDITORIAL
Bad advice online
EDITORIAL STAFF
LETTERS
SCANNING FOR IDEAS
Opposed-piston, opposed-cylinder engine bumps
up the power density
Smallest three-channel reflective encoder
REPORTERS NOTEBOOK
LOOKING BACK
FROM THE SAFETY FILES
The price of slow safety correction:
Crushed fingers
VANTAGE POINT
Meeting the efficiency challenge Karl Tragl
INVENTORS CORNER
A new twist on a fully independent suspension
OEM SERVICES
Quick parts from a new source
FE UPDATE
Multiphysics software helps build a better blood
monitor
PRODUCT SPOTLIGHT
Gears & mechanical drives
PRODUCTS
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TheTruthAboutCompressedAirl
FactsaboutBIowers
Energy conscious plants might think a
blower to be a better choice due to its slightly
lower electrical consumption compared
to a compressor. In reality, a blower is an
expensive capital expenditure that requires
frequent downtime and costly maintenance
of lters, belts and bearings. Here are some
important facts:
Filters must be replaced every one
to three months.
Belts must be replaced every three to
six months.
Typical bearing replacement is at least once
a year at a cost near $1000.
G Blower bearings wear out quickly due
to the high speeds (17-20,000 RPM)
required to generate eective airows.
G Poorly designed seals that allow dirt and
moisture inltration and environments
above 125F decrease the one year
bearing life.
G Many bearings can not be replaced in the
eld, resulting in downtime to send the
assembly back to the manufacturer.
Blowers take up a lot of space and often
produce sound levels that exceed OSHA
noise level exposure requirements. Air
volume and velocity are often di cult to
control since mechanical adjustments are
required.
To discuss an application, contact:
EXAIR Corporation
11510 Goldcoast Drive
Cincinnati, Ohio 45249-1621
(800) 903-9247
Fax: (513) 671-3363
email: techelp@exair.com
www.exair.com/45/423b.htm
ComparetheseBIowoffs
Tere are a variety of ways to blow the water from the bottles shown in the photo below, but
which method is best? To decide, we ran a comparison test on the same application using
four dierent blowo methods: drilled pipe, at air nozzles, Super Air Knife (each using
compressed air as a power source), and a blower supplied air knife (using an electric motor
as a power source). Each system consisted of two twelve inch long air knives. Te following
comparison proves that the EXAIR Super Air Knife is the best choice for your blowo,
cooling or drying application.
Te goal for each of the blowo choices was to use the least amount of air possible to get the
job done (lowest energy and noise level). Te compressed air pressure required was 60 PSIG
which provided adequate velocity to blow the water o. Te blower used had a ten horsepower
motor and was a centrifugal type blower at 18,000 RPM. Te table at the bottom of the page
summarizes the overall performance. Since your actual part may have an odd conguration,
holes or sharp edges, we took sound level measurements in free air (no impinging surface).
DriIIedPipe
Tis common blowo is very inexpensive
and easy to make. For this test, we
used (2) drilled pipes, each with (25)
1/16" diameter holes on 1/2" centers.
As shown in the test results below, the
drilled pipe performed poorly. Te initial
cost of the drilled pipe is overshadowed
by its high energy use. Te holes are
easily blocked and the noise level is
excessive - both of which violate OSHA
requirements. Velocity across the entire
length was very inconsistent with spikes
of air and numerous dead spots.
FIatAirNozzIes
As shown below, this inexpensive air
nozzle was the worst performer. It is
available in plastic, aluminum and
stainless steel from several manufacturers.
Te at air nozzle provides some
entrainment, but suers from many
of the same problems as the drilled
pipe. Operating cost and noise level are
both high. Some manufacturers oer
at air nozzles where the holes can be
blocked - an OSHA violation. Velocity
was inconsistent with spikes of air.
BIowerAirKnife
Te blower proved to be an expensive,
noisy option. As noted below, the
purchase price is high. Operating
cost was considerably lower than the
drilled pipe and at air nozzle, but
was comparable to EXAIRs Super
Air Knife. Te large blower with its
two 3" (8cm) diameter hoses requires
signicant mounting space compared
to the others. Noise level was high
at 90 dBA. Tere was no option for
cycling it on and o to conserve energy
like the other blowos. Costly bearing
and lter maintenance along with
downtime were also negative factors.
EXAIRSuperAirKnife
Te Super Air Knife did an exceptional
job of removing the moisture on one
pass due to the uniformity of the laminar
airow. Te sound level was extremely
low. For this application, energy use was
slightly higher than the blower but can be
less than the blower if cycling on and o
is possible. Safe operation is not an issue
since the Super Air Knife can not be dead-
ended. Maintenance costs are low since
there are no moving parts to wear out.
The Super Air Knife is the low cost way to blowoff, dry, clean and cool.
If you think compressed air is too expensive and noisy - read this. The facts will surprise you!
Blowof Comparison
Comp. Air
Horsepower
Required
Sound
Level
dBA
Purchase
Price
Annual
Electrical
Cost*
Approx. Annual
Maintenance
Cost
First
Year
Cost Type of blowof PSIG BAR SCFM SLPM
Drilled Pipes 60 4.1 174 4,924 35 91 $50 $4,508 $920 $5,478
Flat Air Nozzles 60 4.1 257 7,273 51 102 $168 $6,569 $1,450 $8,187
Blower Air Knife 3 0.2 N/A N/A 10 90 $5,500 $1,288 $1,500 $8,288
Super Air Knife 60 4.1 55 1,557 11 69 $494 $1,417 $300 $2,211
*Based on national average electricity cost of 8.3 cents per kWh. Annual cost refects 40 hours per week, 52 weeks per year.
RS# 104
Whats new online machinedesign.com
Social media and
linear motion
NookIndustries recently
launched an interactive blog
site (http://Blog.nookindustries.
com) devoted to linear-motion
control. It lets engineers quickly
access comprehensive and timely
technical product data, news,
tutorials, how-to videos, 3D CAD
models, as well as user comments,
catalogs, and other information.
Motion-control
solution center
7homsons online Solution Center
provides technical answers to
a broad range of questions on
the selection, application, and
installation of motion components
and systems including linear
actuators, clutches and brakes,
bearings and guides, ball and
leadscrews, and gearheads. Users
can search for specific answers,
browse by technology, or submit
questions for prompt response
from the companys technical
support team. Learn more at www.
thomsonlinear.com.
SHUTTLE
EngineeringTV talks to executives of SNCSpace
Systems about the Dream Chaser, a follow-up to
the shuttle program. The reusable spacecraft will
take off vertically, carry up to seven passengers and
cargo into low-earth orbit, and land horizontally
on a standard runway. Its unique
hybrid engines use recycled
rubber as the primary fuel. Learn
more at www.engineeringtv.com.
Energy Efficiency & Technology education day
The Energy Efficiency Technology Conference and Expo, May 26 in Santa
Clara, Calif., features technical presentations for engineers involved with
energy-efficient products and processes. Chris Scruton from the CaIifornia
nergyCommission will discuss the ramifications of a state initiative that all
new residential buildings be zero net energy by 2020. Sessions will cover LED
lighting, EVs, energy harvesting, smart-grid applications, energy-efficient power
supplies, and related topics. Theres also a product exhibition and networking
opportunities throughout the day. Learn more at http://eetweb.com/sponsor/
energy-efficiency-technology.
E
D
I
T
O
R
S

W
P
I
C
k
S
UPCOMING WEB
EVENTS
Free Webinars and
videos on PLCs and other
automation products
Attend live or view
prerecorded Webinars on
the latest control products
from AutomationDirect.
NEW PRODUCTS
AutomationDirect continues to
add many new product lines for
2011. Join us to see all of the new
products and how they can save
you time and money. A question-
and-answer session follows at the
end of the 30-min live show.
May11,2011,2:007
DirectSoft Advanced
Programming
In this 40-min show, you will
learn advanced programming
techniques and instructions for
the DirectLogic PLC programming
software, DirectSoft. See working
demos with program examples,
and learn where to get your FREE
version of DirectSoft5 to start
programming. A live question-
and-answer session closes the
session.
1une8,2011,2:007
Visit www.automationtalk.com
to register and view Webinars,
or watch previously recorded
presentations. Or visit http://learn.
automationdirect.com to view
dozens of short video tutorials on
PLCs, HMI, motor controls, and
more.
Linear-motion
configurator
HaydonkerkMotionSoIutions,
a manufacturer of stepper-
motor linear actuators, precision
leadscrew assemblies, and linear
rail and guide systems, has a new
Web site (www.haydonkerk.com)
with an online configuration tool.
It lets engineers customize parts
by specifying parameters such as
stroke length, screw lead, motor
step angle, and operating voltage.
Users can then download 2D
drawings or 3D models and order
parts.
Direct PCB designs
SunstoneCircuits now offers free
CAD conversion when ordering
printed-circuit boards. Design
engineers can order prototype
boards using their original design
files. This eliminates the need for
Gerber files, reportedly saving
time, ensuring more-consistent
conversion, better controlling
revisions, and speeding delivery.
Learn more at www.Sunstone.com.
RUBBERFUELED SPACE
RS# 105
EDITORIAL
adadvice online
Sign onto a social network or online forum and, in theory,
you should be able to find a network of people who might
give you useful advice. Thats probably true for getting
a tattoo or baking a ham. But its tough to get advice online about technical
issues from practitioners who are really experts. Particularly in science and
engineering, knowledgeable people generally have better things to do than
hang out on forums dispensing pearls of wisdom.
On this score, it is interesting to see what happened when research journals
tried to use online forums to improve the peer-review process. The thought was
that commentary from the community was preferable to that coming from
a small enclave of peer reviewers. The goal was to get around the possibility of
having potentially important research papers blocked from dissemination by a
few experts who might have axes to grind or hidden agendas.
There was another reason for getting away from limited peer reviews: The
evidence is that peer reviewers tend to miss most errors in research papers. Bet-
ter, it was thought, to mimic what happens with open-source software when a
community of online experts ferrets out problems.
But peer-review journals that tried this model have rapidly abandoned it. The
drawbacks quickly become evident in an episode related by David H. Feedman,
a science journalist who, in his book aptly titled Wrong, examines why expert
opinion is often incorrect. In 2006, the scientific periodical Nature tried col-
lecting online comments about papers considered for publication. Few authors
were interested. Of 1,369 eligible papers, authors of 71 agreed to have their work
posted. Thirty-three of those papers received no comments at all. Comments
totaled 92, and more than half of them were on just eight papers.
Journal editors who examined the comments didnt think much of them.
They also found it difficult to get established researchers to make observations.
The remarks that did come in were so general as to be useless (a typical post:
Nice work). A former Nature editor told Freedman, Scientists are sufficiently
busy that they arent motivated to troll through the Web to write commentaries
on whatever catches their fancy.
Substitute the word engineers for scientists and the point is still true.
It looks as though the same could be said for most online forums that fo-
cus on technical content. To cite one example, a magazine called The Scientist
started a forum in 2008 with idea of providing a place where a community could
identify breakthrough research and commercialization opportunities before
they receive widespread attention. It hasnt worked out that way. As Freedman
relates, only about 1% of visitors post a comment, and those who do tend to
focus on career issues rather than technical ideas.
Of course, both researchers and engineers have good reasons to play things
close to the vest when it comes to putting information online. Engineers can
probably relate to one researchers explanation of why she didnt post anything
of substance: Shes busy. And besides, when she has a good idea she wants to save
it for publication, not just throw it onto a forum.
Leland Teschler, Editor
You wont get bad online advice at the WORLDS
SMARTEST DESIGN ENGINEER. Incorrect answers in the first
three levels of any category show you the correct answer,
thus enhancing your learning experience! If you
havent been to the challenge for awhile get
back in the game today!!
RS# 106
With our centrifugal modules, weve scored the winner once again. The modular design means that you no longer
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That makes the replacement of AC with ultra-efcient GreenTech EC technology as simple as can be.
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RS# 107
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EDITORIAL STAFF
LeIand.7eschIer,Editor,
leland.teschler@penton.com
kenneth1.korane,Managing Editor,
ken.korane@penton.com
SNI0RDI70RS
LesIieCordon,
Stephen1.Mraz
AU70M07IV&
NWSFA7URS
Stephen1.Mraz,
stephen.mraz@penton.com
CAD/CAM
LesIieCordon,
leslie.gordon@penton.com
LC7RICAL,LC7R0NICS
Robert1.Repas,1r.,
robert.repas@penton.com
FAS7NINC,10ININC
1essicaShapiro,
jessica.shapiro@penton.com
FLUIDP0WR
kenneth1.korane,
MANUFAC7URINC
LesIieCordon,
kenneth1.korane,
MA7RIALS
1essicaShapiro,
MCHANICAL
kenneth1.korane,
1essicaShapiro,
C0N7RIU7INCDI70R
Victoriaurt,vburt@gmail.com
DI70RIALPR0DUC7I0N
DeniseCreco,
Editorial Production Manager
RandaIIL.Rubenking,Art Director
1300 E. 9th St. Cleveland, OH 44114-1503
RS# 109
RS# 108
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Help hcsl 1eremy luchini design lhe frsl hardccre baby buggy using
SclidWcrks
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Watch. 5hare. Vote. Lets6o0esgn.tv

PP0IECT 5: H0T P0D AY U66Y
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RS# 110
Copyright 2011 Rockwell Automation, Inc. All Rights Reserved. AD RS2209-R1/2P
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LETTERS
components with appropriate
grills and protection to prevent
the problem in the first place. I
dont think Im the only one with
this problem. When I mentioned
it to the car-dealer service guy, he
started to tell me about all of his
own mouse problems. So, auto
companies, get with it.
Phil Quenzi
Maybe get a cat, a certified mouser,
for the garage?
Great mileage but . . .
I thought i t parti cul arl y i nter-
esting that many winners of the
Progressive Insurance X-Prize of
$10,000,000 were recognized for
designs that are neither practical
nor affordable (Aerodynamics
When mice invade
Af ter spendi ng more than 40
years designing mobile equip-
ment, I would like to suggest that
the auto companies devote just
a tiny bit of the engineering time
they spend on cupholders mak-
ing their cars mouseproof. Every
car I have owned has eventually
ended up with mice nests in the
ai r cl eaner, cabi n fi l ter, under
the dash, or some other place.
They often chew holes in the air
cl eaner whi ch i s not good for
the engine. In other instances, I
am inundated with mouse-nest
parts and droppings when the
heater fan switches on. Mice also
get caught in the blower fan and
have to be fished out. I have also
spent many hours trying to dis-
cover how they get in and then
blocking their access.
In most cases, it is not easy to
plug the holes once the car is built.
But it should be simple to design
Mice and ants
and the price
of free trade
MACHINE DESIGN readers came up
with several novel complaints
and questions regarding mice
and ants. Meanwhile, other read-
ers want to scrap free trade and
set our economy free.
RS# 111
>>
Find out how LabVIEW can make you better at ni.com/labview/better 800 453 6202
2011 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.
Other product and company names listed are trademarks or trade names of their respective companies. 01197
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on time, on spec, and on budget
LabVIEW makes me better because I can deliver multiple
Name
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Betancourt, Certied
LabVIEW Architect
Job Title
Automated Test and
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Area of Expertise
Manufacturing Test
LabVIEW Helped Me
Reduce test time by
more than 10X
Latest Project
Building a vision-based
inspection system for
washing machine drums
RS# 112
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FAX 918 254 2544
EMAIL info@us.roxtec.com, www.roxtec.com
Cable entries made easy
Easy to install
Adapts to cable dimensions
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Seals multiple pre-terminated
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Protects against water, dust
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Multidiameter by Roxtec No more cutting off connectors Sealed to UL/NEMA and IP ratings
LETTERS
generation, everything else is a
shell game.
Joe Bonasses
A head-scratcher
of a problem
I work in a physiology laboratory
and we would like to accurately
measure the force generated by
the leg of an immobilised ant,
dorsal side down. Any sugges-
tions of the proper piezosensi-
tive transducer and its amplifica-
tion unit?
George Theophil
Getting out from
under free trade
Readi ng your edi t or i al ( The
Dark Si de of Free Trade, Nov.
4) reminded me of an excellent
article on the perils of running
trade deficits written eight years
windows and little to no airflow?
Joseph Kilian
Venture your
own capital, please
A venture capitalist complaining
about delays in receiving gov-
ernment grants (Why Many New
Factori es Star t up Of f -shore,
March 2)? Am I reading this cor-
rectly? Dont venture capitalists
use their own money, or at least
that of peopl e who gi ve them
funds to invest?
Instead of spending taxpayer
dol l ars on corporate wel f are
programs like this, the entire tax
structure shoul d be changed.
American companies that man-
ufacture overseas shoul d not
be tax exempt, and unti l thi s
changes, the bleeding will never
stop. Domestic manufacturing
is the only true source of wealth
and Weight Key for Automotive
X-prize Winners, Jan. 13). I love
the new technology, ideas, and
approaches but they coul d ve
been more practical and afford-
able. I make a very good salary
(better than 90% of the worlds
population). For example, I can-
not begin to afford a $110,000 car
unless it will last 50 years.
As for the design, what kind
of fuel mileage do these new de-
signs get while providing comfort
for the drivers and passengers? I
l i ve through 50F Mi nnesota
winters that get even colder with
wind chills. How do I stay warm?
How do I get through half a foot
of snow, slush, ice, and water with
hard, high-mileage tires? How do I
keep the windows safely defrosted
of human breath? And then in the
scorching summers, how do I stay
cool when Im buttoned up in a
highly fuel-efficient car with no
RS# 113
WHEN THE GOAL
IS RELIABILITY,
THE NAME IS MOOG.
WHAT MOVES YOUR WORLD
moog.com/industrial
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RS# 114
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LETTERS
I started di sagreei ng half-way
through the first sentence of the
column (A Mandate to Revitalize
Manufacturing, Jan. 13). What
Ameri ca needs i s for the gov-
ernment to stop deciding what
America needs and let capitalism
do its job. The governments job
is to level the playing field. For
example, if a country has lower
(or no) minimum wage, a tariff
should be added to level the
field. If their environmental laws
are lax, a tariff should be added
to bring the costs up to our own.
I fail to see how a bunch of bu-
reaucrats are going to direct our
economy in any meaningful, pos-
itive way. Isnt that what the Sovi-
ets tried from 1917 through the
1980s? Howd that work out?
David Leahy
Weve legislated a decent stan-
dard of living for ourselves that
includes minimum wage laws,
envi r onment al pr ot ect i ons,
and social security. And thats
a good thing. However, we let
products come into our country
from places that do not adhere
to si mi l ar standards. The si m-
plest answer would be to hold
the companies in other countries
that bri ng the goods i nto our
country WalMart, GM, Hyun-
dai, GE, or whomever to the
same standards we demand of
domestic manufacturers, and ex-
act the same penalties for violat-
ing those standards.
We cannot, nor should we, im-
pose our standards on anyone
else in the world. However, we
can hold those who choose to do
business in our country respon-
sible for upholding them.
Kevin Boron
ago by Warren Buffett. (Search
the Web for Squanderville ver-
sus Thri f tvi l l e. ) He cal l ed for
the implementation of what he
called Import Certificates (ICs).
Simply put, to import a product,
you need to buy an IC, which is
created when a company exports
a product. If there is a trade sur-
plus, the ICs are worthless. But
when there is a trade deficit, ICs
woul d have a trade val ue. Hi s
i deas are as rel evant today as
they where in 2003.
We need manufacturing in the
U. S. because as the referenced
editorial points out, it is the only
real source of wealth (other than
farming and other extraction in-
dustries). Also, there is a social
aspect to the loss of manufactur-
ing jobs in the U. S. not every-
one is cut out to be an informa-
tion worker.
Mark Hagen
RS#115
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RS# 116
SCANNING FOR IDEAS
Edited by Stephen J. Mraz
Opposed-piston, opposed-cylinder
engine bumps up the power density
An engine being developed at comotors, Allen Park,
Mich. (www.ecomotors.com), is based on an opposed-
piston opposed-cylinder (OPOC) concept updated
with the latest computer modeling and thermody-
namic analysis. It has a modular design, with two
cylinders and four pistons in each 296-lb module (for
the EM100 engine). The pistons in each cylinder travel
in opposite directions, with the combustion chamber
between them. This eliminates the cylinder head and
valve train used in most conventional engines, which
means fewer parts.
For example, a 300-hp OPOC engine generating
325 lb-ft of torque @ 2,100 rpm with 100-mm cylinders
would have 62 moving parts compared to 385 for a
conventional engine with similar power. It would mea-
sure 22.8 41.3 18.5 in. The OPOC engine would not
have a separate head and all of its cams, valves, and
associated hardware, thus reducing costs and mainte-
nance. And each cylinder delivers a power stroke for
every revolution of the crank in each cylinder instead
of every other revolution, as is the case with conven-
tional engines, so power density increases.
The patented engine will run on a variety of fuels,
including gasoline, diesel, and ethanol, and still pro-
vide the emissions benefit of a four-cycle engine. The
engine is lighter, more efficient, and economical, with
lower exhaust emissions than current engines, accord-
ing to tests on working prototypes. It produces more
than 1 hp/lb of engine weight with half the parts of
traditional car engines while using conventional ma-
terials and manufacturing processes. It is an inherently
balanced design, so vibrations and noise are reduced.
The engine can be scaled down for 15-hp lawn-
tractor motors or scaled up into a 600-hp engine for
off-road equipment. And each pair of cylinders can
operate independently with electric clutches discon-
necting power modules when not needed.
To see Ecomotors OPOC in action, check out Engi-
neering TV at http://tinyurl.com/5r2z7ej.
RS#401
Outer piston Inner piston
LEFT CYLINDER
Inner piston Outer piston
RIGHT CYLINDER
Inner connecting rods Crankshaft Outer connecting rods
End cover Left and right
crankcases
End cover
Intake manifold Exhaust manifold Intake manifold Exhaust manifold
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Support arms move farther,
smoother, and last longer.
www.ametekhunterspr|ng.com
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2007 lntuitive Surgical, lnc.
Used with permission.
www.machinedesign.com/rsc
Smallest three-channel reflective encoder
The markets smallest three-channel
reflective encoder, the new line of
AEDR-850 encoders from Avago, San
Jose (www.avagotech.com), feature an
LED light source, photodetecting and
interpolator circuitry, and three chan-
nels in a 3.95 3.40-mm leadless pack-
age. The 1, 2, and 4 interpolation
circuitry, together with encoding reso-
lutions of 304 lines/in. (12 lines/mm),
gives users design flexibility. The op-
tical-based encoders are significantly
less susceptible to EMI compared with
Hall-effect devices.
The chips operate from a single 5-V
power supply and can handle tem-
peratures from 20 to 85C. The encod-
ers are also TTL compatible, letting
outputs interface directly with most
signal-processing circuitries.
The AEDR-8500 reflective encoder
is gated 90, the AEDR-8501 encoder
is gated 180, and the AEDR-8502 en-
coder is ungated 360. They are priced at
$6.75 each in 100-piece lots. RS#402
Codewheel
Reflective
encoder
RS# 117
Signal-
processing
circuitry
V
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nd
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Ch A
Ch B
Ch I
Sel 4xs
Sel 2x
G
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Request free information via our
Reader Service Web site at
REPORTERS NOTEBOOK
Resources:
FarrisAutomatedSystems
LLC, www.farrisautomation.
com RS#406
MisumiUSA, http://
us.misumi-ec.com/ RS#407
The RAD uses a gun assembly, motor
controller, and PC/software to rotate the input
shaft. The gun frame can use up to 16 different
motor and gearbox combinations. To quickly
set up different lengths of hex standoffs and
flange bearings for the gun, the Farris team
sources them from MisumiUSA, Schaumburg,
Ill. Misumi provides the parts on extremely
short lead times with no minimum order require-
ments, so Farris can assemble guns quickly without
having to stock all the variable combinations.
Farris Mechanical Engineer Brian Terry says engi-
neers there use Misumis fixed and configurable parts
in a variety of the companys automation devices as a
way of configuring mechanical components to precise
specifications. They also download 3D CAD drawings
directly into their SoIidWorks CAD program, as well as
use Misumis Web Ordering System to order parts. MD
When engineers at Far-
risAutomatedSystems
LLC,Hartland, Wis., were
designing a dynamom-
eter for checking rotating
parts, a major challenge was in configuring the
devices main hardware component a torque-
measurement gun to handle different applications.
The design team quickly found out that configurable
components would allow faster customization and
timely deliveries without the need for maintaining
large and expensive part inventories.
The dynamometer, called a Rolling Assembly Dy-
namometer (RAD), measures resistance in rotating
components and assemblies such as transmissions,
differentials, gearboxes, axles and pumps. Information
from the RAD lets designers figure out how smoothly
the tested component will spin. The RAD notes incon-
sistencies by measuring the torque needed to spin
the rotating assembly, then records a series of torque
signatures, which takes about 30 sec. The tool is most
commonly used in setting the proper bearing preload,
but is also used to test for proper gear mesh and for
changes in pumps rolling resistance.
RoIIingAssembIyDynamometer
(RAD)systemsmainhardware
componentisatorque-
measurementgun.
Configurable components
get dyno done quickly
JouleBug
The JouleBug app
helps you use
energy wisely in
your everyday
life. You try to
win as many
badges as
possible and,
thereby, add
points to your
collection.
Open the
app and the
top of the
screen shows
a lineup of
icons, each of
which has an
energy-re-
lated theme. Swipe the screen to
the icon of interest. For example,
tapping an icon showing a com-
pact fluorescent light (CFL) brings
up a Light Saver window. Tap the
Earn the Badge button, and a new
window shows a picture of a CFL
and an incandescent bulb with
the phrase do a switcheroo? Tap-
ping the screen shows a cartoon
guy comparing the two forms of
energy usage in a thought cloud
above his head. In the thought
cloud a graph illustrates that CFLs
save lots of energy. The cartoon
guy makes the switch. Keep tap-
ping the screens each of which
tells a story about the guy going
to the store, buying a CFL, and
screwing in his new CFL. The last
screen has an I Did It badge,
which awards 10 points. Other
badges encourage you to recycle,
turn off your computer, and join
the JouleBug forum. The app is
intended as a kind of game. The
idea is that everyone trying to
garner points will all add up to
a lot of energy never generated
(coal not burned or not even
mined, for instance).
Unit and Hardness
Converter
The Unit and Hardness
Converter app from
7reIIeborgSeaIingSo-
Iutions, Fort Wayne, Ind., converts
frequently used units and curren-
cies, as well as common hardness
scales for various material types
based on ISO and ASTM standards.
Open the app, and select from Con-
verter or Hardness at the bottom of
the window. Tap the arrow to move
to the unit of interest, for example,
Area, Current, Energy, Data, or
Dynamic viscosity. Tapping Data,
for instance, brings up a screen
that lets you switch between Bits,
Bytes, and Terabytes. Just tap the
numbers to enter the units of inter-
est. Turns out that 45 GB (Gigabyte)
= 360 Gbit (Gigabit). Tapping the
Hardness button at the bottom
of the screen lets you convert
Rockwell, Vickers, and Brinell hard-
nesses. Tapping Videos lists various
YouTube videos you can watch
about the companys products, in-
cluding sealing products. A Contact
button lets you send an e-mail to
the company or visit its Web site.
Trimensional
The Trimensional app from
Grant Schindler, research sci-
entist in Ceorgia7echsCoI-
IegeofComputing, is basi-
cally a 3D scanner that works
on the iPhone 4. The soft-
ware uses both the screen
and the front-facing camera
on your device, detecting
patterns of light reflected off your
face to build a true 3D model. An
in-app purchase lets you export
any scan as an OBJ, STL, or PLY file
via e-mail. (OBJ: texture-mapped
polygonal model compatible with
most 3D software packages; STL:
watertight geometry suitable for
3D printing; PLY: point cloud with
position (X, Y, Z) and RGB color
information per vertex.) The app
also lets you create and share vid-
eos and animated GIFs of your 3D
scans. MD
iPHONE APPS FOR
ENGINEERS
Symmcos impressive
inventory of stronger, longer-lasting
stock products includes bearings,
bars and plates in a wide range
of sizes.
Discover the Symmco Advantage
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Symmco also offers:
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Short- & Long-Run Capabilities

Why Symmco Bearings?
Exceed industry standards
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Have longer in-field life
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Offer numerous
lubrication possibilities
SYMMCO STOCK PRODUCTS:
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For the Strongest,
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Phone: 814.894.2461
sales@symmco.com
www.symmco.com
REPORTERS NOTEBOOK
Crease here, fold here and here
and Voila! a collapsible,
steel grocery bag
Some engineers are trained in the art of building things out of folding
sheets of paper and metal into useful objects (origami). One design that
came from this training was a solar panel that folds up for transport and
then unfolds once it is in orbit. Now, two engineers from the Universityof
0xford have developed an origami-based method of making a collapsible
grocery bag. It is loosely based on a five-year-old design from a mathemati-
cian from the MassachusettsInstituteof7echnoIogy. That designs major
flaw was that it needed a material with zero thickness. The new design, on
the other hand, starts with a large piece of plastic with steel plates glued to
it. Folds and creases are made where the steel plates meet. Thus, the flex-
ible plastic holds the bag together despite being folded. The bag collapses
down to a relatively thin, flat sheet. No word yet on how much the bag
weighs or if designers plan on adding handles.
More details are available on Proceedings of the Royal Society A (http://
rspa.royalsocietypublishing.org). MD
RS# 118
www.zero-max.com 800.533.1731
2010 ZERO-MAX
Together a w|nn|ng comb|nat|on for today's
servomotor app||cat|ons.
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couplingshavebeenrecentlyredesigned
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RS# 119
REPORTERS NOTEBOOK
Resources
CMC, www.gmc.com
Howtheystackup
CMC7errain
AWDSL7-2
Forddge
AWDSL
3.0-Iitersix-
cyIinderD0HC
ngine 3.5-IiterV6
264
Horsepower
(hp)
285
222@5100 7orque(Ib-ft) 253@4,000
17 City(mpg) 18
24
Highway
(mpg)
25
3,798
Curbweight
(Ib)
4,265
112.5
WheeIbase
(in.)
111.2
185.3 Length(in.) 184.2
72.8 Width(in.) 76
66.3 Height(in.) 67
5
Standard
seating
5
3,500
7owing
capacity(Ib)
3,500
Canadian-built engine
connects to a smoothly
shifting six-speed
automatic transmis-
sion made in Mexico. I would
have liked to see how the stan-
dard 2.4-liter four cylinder with
its 172 hp performed with the
3,800-lb vehicle.
The smaller engine would be
the way to go if you wanted to
save on gas. Its EPA ratings are
20/29 mpg city/highway in AWD.
The larger, more powerful 3-liter
engine gets 17/24 mpg. And if you
The Terrain is touted as GMCs
all-new small SUV, but it seems
to be a rebadged Chevy Equinox,
which isnt necessarily a bad thing.
Overall, the vehicle is solid, if a bit
pricey ($31.4K without options).
As one of the rela-
tively new crossover
vehicles an SUV
built on a smaller
chassis the Ter-
rain is easier to get
in and out of than
conventional SUVs
and doesnt ride quite as
tall. But it only holds
five passengers which,
in reality, ends up being
more like four full-sized
adults, the same as any
midsized sedan.
Inside, the SLT version we
tested has all the comforts, includ-
ing seat heaters, rearview camera,
lots of leather, and video screens in
the back of the front seats hooked
to a DVD player to keep those
rear-seat occupants entertained (a
$1,300 option).
The Terrain is comfortable to
drive, and I wouldnt hesitate to
take it on an extended
road trip. Some review-
ers complain about it
having too little cargo
room. The Terrain might
not have as much as
other crossovers, but
it seems as if it could
accommodate four
peoples luggage. GMC
says the Terrain has
31.6 ft
3
behind the pas-
senger seats and 64 ft
3
if
the passenger seats are
folded down. The same
figures for the Edge are
32.2 ft
3
and 68.9 ft
3
.
The 3-liter V6 (a
$1,500 option) puts
out 245 hp, more than
enough to let the Ter-
rain keep up with or
ahead of traffic. The
RS# 120
2011 GMC Terrain AWD SLT-2
really want to save, go for the
front-wheel drive four-banger;
it gets 22/32 mpg city/highway.
The car carries TPMS, an acro-
nym I had to look up to be sure
what it stood for. Turns out its
the tire-pressure-monitoring
subsystem. A sensor mounts
on the valve stem of each
tire, which can include the
spare. Each one detects
temperature and pressure
and sends this data, along with
a unique ID code, to a control
module via radio frequency.
The module compares the data
to the manufacturers recom-
mended pressure, and if its too
high or too low, a warning light
on the dashboard illuminates.
Im not sure how much it adds to
the price of the vehicle, but Im
pretty sure my 10-year-old tire-
pressure gage is just as accurate,
costs less, and wont need as
much servicing.
The Terrain SLT we tested
carried several other options
besides those already men-
tioned. They include a $245
cargo-management package
(cargo net and a security screen
for the rear cargo area), a $2,145
navigation and upgraded audio
package (AM/FM/CD player,
radio data subsystem, 7-in.
touchscreen, voice recognition,
and 40-Gbyte hard drive), $900
19-in. chrome-clad aluminum
wheels, $350 for trailering
equipment, and $195 for the
carbon-black metallic paint.
This brings the tab to $38,030.
Stephen J. Mraz
Tight seal for a solar-
powered fan
Solaro Energy,LakeIsinore,CaIif.,
makesasoIar-poweredfanthat
automaticaIIyventsattics.7he
assembIyrequiresastrong
adhesivetobondthesoIarpaneI
tothetopofthefan,asweIIas
anedgeseaIanttoprotectthe
paneIeIectronics.EIS Fabrico,
kennesaw,Ca.,provideda
conductiveacryIicadhesive
forthejobthatexhibitsIow
outgassingandgoodionic
quaIities.ItaIsodeIiversthe
necessaryshearstrengthto
handIeoutdooruse.
AdditionaIIy,Fabrico
seIecteda3McauIking
productforawatertight
seaIontheedgeofthe
unitthatwiIIstandup
toyear-roundweather.
7hesiIiconeedgeseaI
protectsagainstmoisture
fasteners.MD
Resources:
FabricoDiv.,IS, www.fabrico.com
RS#408
SoIaronergy, http://solaroenergy.
com/ RS#409
RS# 121
andcontaminantswhiIeeIiminatingtheneedformetaI
Solving your Ultra Low Power Optocoupler Puzzle
Find the Missing Part Number
for these applications
PARTS LIST
ACPL - W _ _ L - 0 0 0 E
ACPL - K _ _ L - 0 0 0 E
ACPL - M _ _ L - 0 0 0 E
W - 6-pin stretched surface mount
L 3.3-V supply voltage
E Lead-free option
K - 8-pin stretched surface mount
M - 5-pin mini- at surface mount
Avagos Ultra Low Power Optocouplers
Problem
Solved
Fill in the blank squares so that each column,
row, and 3-by-3 block (within bold lines) contains the numbers 1 thru 9.
The numbers in the shaded squares will tell you which
optocouplers you need to solve the applications.
Once youve solved the puzzle, go to http://www.avagoresponsecenter.com/438 to check your answer.
The rst 100 entries will receive a ash drive and a chance to register to win an Apple iPad. Puzzle by websudoku.com
Your Imagination, Our Innovation
7
9
3
2
5
8
9
7
3
7
8
9
5
2
8
5
9
1
3
5
2
8
9
8
3
7
7
4
2
9
RS# 122
REPORTERS NOTEBOOK
Resources:
Understanding Economic and
Environmental Impacts of Single-
Stream Collection Systems,
ContainerRecycIingInstitute,
Culver City, Calif., 2009
StrategicMateriaIs,
www.strategicmaterials.com
AnchorCIassContainerCorp.,
www.anchorglass.com
RS#410
Sustainable design:
What can you make
with old glass?
Most U. S. communities have recycling programs. So it should be
easy to reuse common materials such as glass and plastic, right?
Not quite, at least when it comes to glass. A recent industry report
claims that 40% of glass chucked into recycling bins ends up in
landfills. But experts say that almost all glass is recyclable, so why
does so much of it just get added to the waste pile?
Many municipalities now collect recyclables
such as newspaper, glass bottles, plastic pouches,
and aluminum cans in the same receptacle, using
a method called single-stream collection. This
lowers collection costs compared to separating glass, plastic, and so
forth into their own collection containers. But by the time the mix-
ture reaches a material-recovery facility (MRF), much of the glass is
broken into particles too small to handle and, therefore, too expen-
sive to separate for remelting into
fiberglass or new glass containers.
Also, any large pieces of glass that
remain are typically not sorted by
color, a necessity for making glass
containers.
After trucks dump their
loads at an MRF, the facility uses
magnets to pull steel out of the
garbage, leaving everything else
on the conveyor, says Curt Bucey,
president of materials processor
AproductionIineat
AnchorCIassContainer
Corp.ismanufacturing
newbottIes.
Glasscontinued on page 29
RS# 123
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ball screw technology, Steinmeyer has everything
it takes to improve performance in your design.
Our innovations include
I4+ techno|og, for increased efficiency,
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Most adranced ba|| def|ector for Dn values
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colossal 19 mm diameter.
RS# 125
RS# 124
RS# 126
REPORTERS NOTEBOOK
StrategicMateriaIsInc., Houston. Nonferrous magnets capture
aluminum, and screens sort cardboard and paper. Lastly, air jets
blow off the plastic. MRFs make individual economic decisions and
sell high-value materials such as aluminum, but dump glass typi-
cally considered a commodity in landfills. When the MRF sells
whats left on the conveyor, we purchase the remaining mixture of
glass shards, paper shreds, banana peels, and whatnot. We sepa-
rate out the glass with specialized equipment and sell it to glass-
container companies and fiberglass manufacturers. At this point the
glass is called cullet.
Glass recycling is mostly a free-for-all because there is no uniform
definition of recycling and no meaningful way to track of discarded
glass, according to Bucey. Most people think recycling means keep-
ing material circulating through as many product lives as possible,
he says. But some might be surprised by uses for reclaimed glass.
For example, certain cities equate the diversion of glass with recy-
cling, as when crushed shards are sprinkled on top of a landfill to
form a cover. Contrast that with the example of old bottles being
remelted, over and over, almost an unlimited number of times, with
the result always being a pristine bottle.
Also, depending on a variety of factors, there are obvious differ-
ences in recycling rates from city to city, and state to state. For ex-
ample, Wisconsin has made it a goal that all materials going through
MRFs must get reused and not placed in landfills, says Bucey. And
areas with mandatory deposit laws, such as the New England states
and Michigan, have much higher recycling rates up to 90%. Con-
trast that with Ohio, where rates are about 5 or 10%, he claims.
Many bottle companies are desperate for recycled glass, says vice
president of Product Development Sam Wilson of glass-container
manufacturer AnchorCIassContainerCorp., Tampa, Fla. Part of
the problem is the lack of color processors, he says. Different colors
of crushed glass all mixed up is almost worthless to us. Even if an
MRF could remove just the glass from the other waste materials, if
its mixed brown, green, and clear, what we call tricolor, we can only
use a little of it for amber bottles maybe 2 or 3%. But we cant use
it to make clear or green bottles. There is iron in amber glass and
chrome in green glass and they cannot be mixed. When we buy cul-
let from Strategic Materials, it comes in separate colors.
According to Wilson, in many areas of the country it is cheaper to
buy the raw materials sand, soda ash, and limestone and melt
them, than it is to buy good clean cullet. If we could get cullet, we
would definitely take it, he says. Crushed glass melts at about 2,100F,
but melting raw materials takes 2,800 to 3,000F. So cullet reduces
costs and cuts particle pollution, which helps the environment.
The glass-container industry has shrunk substantially over the
last 10 years, with 68 plants closing, according to Wilson. So there
are not as many places to recycle glass. And when the transporta-
tion costs become too high, recycling becomes uneconomical. In
contrast, recyclables in Europe are collected and kept separated, and
there are lots of returnable bottles. You see little plastic packaging
in Europe. And, interestingly, Canada has more glass than it knows
what to do with, probably because of transportation costs. There
are only four glass-container plants in Canada, not many for a whole
country. MD
Glass continued from page 27
RS# 127
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RS# 128
REPORTERS NOTEBOOK
Resources:
LUXResearchInc.,
www.luxresearchinc.com
so these changes cost less than
switching to composites.
And while composites are
usually touted as having higher
strength-to-weight ratios than
steel, automakers can get similar
weight savings by switch-
ing from standard steels to
other metals. Aluminum,
for example, is lighter
than steel and replaces it
in many auto parts. And
ultrahigh-strength steels can sup-
port as much or more than stan-
dard steel.
However, these factors dont
mean theres no future for com-
posites in automotive manufactur-
ing. At low-production volumes,
it can be cheaper if several steel
parts are consolidated into a
single, complex, nonstructural or
semistructural composite part that
couldnt be made from metal.
Composites in the form of
sheet-molding compound mats
of random fibers impregnated
with resin that easily form to con-
tours can work at higher pro-
duction rates in applications such
as body panels.
Advanced material technolo-
gies that may help composites
pull ahead in the future include
nanoparticle additives, high-
throughput structural-component
molding, and bio-based materials,
all of which are currently under
development. MD
The primary factor that will drive
the automotive sector to adopt
composite materials will be lower
costs, not weight savings that
increase mileage, according to a
recent report from LuxResearch
Inc., Boston.
Chasing cars:
Can composites
catch up to steel?
analyzes surveys
from automakers
and composite-material suppliers.
It explores what would impede
or advance the adoption of new
materials, examines composites
potential to replace metals in cars,
and identifies early-stage tech-
nologies that could change how
composites perform.
The conventional wisdom that
says automakers will adopt com-
posites solely for weight reduction
misses the mark, says lead author
David Hwang. In reality, compos-
ites will be used when they help
cut manufacturing costs, such as
in low-volume production and
electric vehicles.
The report notes that auto-
makers can also boost efficiency
less expensively by improving
powertrains. For instance, adding
turbochargers or switching to a
gas/electric hybrid improves fuel
efficiency by up to 50%. Automak-
ers can adopt these changes with-
out significantly altering produc-
tion methods and supply chains,
W0RkPLACXCLLNC
7reIIeborgSeaIingSoIutions, Broomfield, Colo., has been recognized
by the U.S.Dept.ofLabors0ccupationaISafetyandHeaIthAd-
ministration for excellence in its employee safety and health program.
The Broomfield facility has been designated as a star site in OSHAs
Voluntary Protection Programs. Trelleborg Sealing Solutions develops,
manufactures and supplies precision seals. MD
COMPANY NEWS
RS# 129
Manufacturing costs keep
composites out of cars,
despite the weight savings
Mechanical Components Inc.
Call us at 1-888-260-7466 or fax us at 516-867-5656
or Email us at sales@rinomechanical.com
See us at www.rinomechanical.com/gears.htm
We use gears, not just make them!
Solutions provided!
+ ISO 9001:2008 certified
+ Quick and timely shipments
+ Standards and customs
+ Gears, pinions, worms, worm gears
We manufacture gearboxes of all types and know how to use gears
of all kinds. Solving gearing problems is part of our DNA.
KissSoft software: gearing and analysis, AutoDesk Inventor: design
REPORTERS NOTEBOOK
LOOK|NGBACK
10 YEARS AGO 2001
Pardonme,isthatyourjacketringing!:France
7eIecomR&Dhasdevelopedaprototypecom-
munications[acketthatfunctionsasamobiletele-
phonewithoutavisiblescreenorkeyboard.The
phonesitsinsidetheliningwithakeypadinsidethe
[acketflapandmicrophonesinthecollar.
Numberscanbedialedbyspeakinganameor
keyingitin.Pesearchisprogress-
ingonaring/vibratefunction
thatwilldiscreetlynotifythe
wearerofanincomingcall.An-
otheroptionintheworkswarms
thefabricthattouchesthewear-
ersskinasanalertingmecha-
nisminnoisyenvironments.
30 YEARS AGO 1981
SLAPtestproves7itanIIstiII
ready:Thestage-oneengineof
a16-year-oldTitan|||C8Mwas
test-firedatAerojetsrocket-test
facility.The
engineignited
andprovided
therequired
amountof
thrust,indicat-
ingtheTitan
|||C8Mcould
havebeen
successfully
launched.
Eachyear,
twoTitan||
propulsion
systems,containingstage-oneand
stage-twoengines,areshippedto
thefacilityfromAirForceopera-
tionalbasesforSLAP(ServiceLife
AnalysisProgram)testing.
50 YEARS AGO 1961
UItrasonicenergyreplacesheat
andadhesivesinSonoseala
newmachine
forwelding
polyesterfilms.
Thedeveloper,
InternationaI
UItrasonics,
Cranford,N.1.,
saysthat90to
100%ofthe
originalmate-
rialstrength
isretained.
8esidesmaking
hermeticplas-
tic-to-plasticseams,theultrasonic
machineweldsplasticstopaper,
cardboard,orcloth.|tignoressurface
water,oils,photographicemulsions,
andabrasives.MD
Reduce turbine size
and costs will follow
As wind power is gaining momentum, turbine
manufacturers are looking for ways to make
production more efficient and less costly.
SKF engineer Matthias Hofmann offers a
solution: the SKF Nautilus main shaft bearing.
This innovation enables very compact nacelle
designs with main gearboxes or directly-driven
generators mounted close to the rotor hub.
The result is a drastic reduction in size, weight,
maintenance and turbine costs.
This is a great example of what we call
Knowledge Engineering. And yet another way of
how we apply our know-how by utilizing our wide
range of products and services to help increase
efficiency, save energy and reduce environmental
impact. Read the full story at www.skf.com
The Power of Knowledge Engineering
Compact turbines Matthias Hofmann, SKF SKF Nautilus
RS# 131
REPORTERS NOTEBOOK
COMPANY NEWS
AU7H0RIZDPR0VIDR
DanfossVL7Drives, Loves Park,
Ill., has been reapproved by the
InternationaIAssociationforCon-
tinuingducationand7raining
(IACET) as an authorized provider
of continuing-education units. The
recognition period extends for five
years, and includes all programs of-
fered or created during that time.
IACET is a nonprofit association
dedicated to quality continuing-
education and training programs.
Danfoss is a manufacturer of pre-
cision mechanical and electrical
components.
AWARDS
Electronic components distributor
Digi-keyCorp., Thief River Falls,
Minn., was honored by PUIAudio
Inc., Dayton, as the 2010 Distribu-
tor of the Year. PUI Audio provides
prelaunch, postlaunch, engineering,
and design support, and tools and
software for integration into existing
systems.
AS7earings, Montville, N. J., a
supplier of bearing products and
services, has earned recognition
as a Partner-level Supplier for 2010
and was also inducted into the Sup-
plier Hall of Fame in the 1ohnDeere
Achieving Excellence Program. The
Hall of Fame status is only given after
a supplier attains a Partner-level rat-
ing for five consecutive years.
PRS0NNL
Richard J. Huss has been appointed
as the new CEO of FestoUS, Haup-
pauge, N. Y. Mr. Huss comes from
oschRexroth, where he was Vice
President and General Manager for
the past 10 years. Festo provides au-
tomated motion-control solutions.
U.S.SALS0FFIC
7ranstecnoCroup, a European sup-
plier of aluminum gearboxes, dc mo-
tors, and gearmotors for the Power
Transmission Industry, has opened a
sales office in Iowa.
PAR7NRS
&RIndustriaIAutomation, Ro-
swell, Ga., an automation-equip-
ment manufacturer, has appointed
kundingerControIs as a partner in
North America. Kundinger, based
in Auburn Hills, Mich., distributes,
designs, engineers, manufactures,
installs, and provides ongoing ser-
vice support.
INVS7MN7
Motion-control specialist PI(Physik
Instrumente), Auburn, Mass., and its
piezo ceramics division, PICeramic,
plan to invest approximately $13 mil-
lion for the third extension of their pi-
ezo ceramics factory and R&D center
in Thuringia over the next three years.
RS# 132
Associated Spring Raymond - USA
370 West Dussel, Suite A s Maumee, OH 43537
800.872.7732 s asraymond.com/spec-spd/
We are an ISO/TS 16949:2009 and ISO 9001: 2008 certied company 2011 Barnes Group Inc. SPEC is a trademark of Barnes Group Inc.
The difference is in the details.
and shipping available 24/7/365.

Look closely at Associated Spring-Raymond SPEC
.
our new product catalog.
RS# 133
We are the leading source for stock precision components, and we
take our responsibility very seriously. Our compression, extension and
torsion springs and spring washers are the highest quality, engineered
for superior performance. And we continue to introduce new products
that meet these high standards for example, our complete line of
316 Stainless Steel compression, extension and torsion springs,
Inconel compression springs, and new lines of gas struts.
But the difference is also in our extra service. Rapid shipping from
facilities in the Americas, Europe and Asia. Custom work capabilities
for materials, coatings, kitting and secondary processes. Ordering
Get our 2011 catalog. See the difference.
Call 1.800.872.7732 or visit asraymond.com/spec-spd/ for
FROM THE SAFETY FILES
Despitethepresenceofahookdeviceonthe
endofthepressbrakethatIetworkersturnthe
dieoutforcIeaning,theinjuredworkerwas
reachingintotheoperationaIareatocIeanthe
diewhentheaccidenthappened.
safetydevicesuntiItheIight
curtainwasinstaIIed,afterthe
ramcrushedfourfingersona
workershand.
WANT MORE?
Focus on this code image
using your smartphone and
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neoreader.com and you will be
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http://tinyurl.com/6bgh3gd
The price of slow safety correction:
Crushed fingers
A worker was reaching into the operating area of a press brake
to clean the die when he depressed the foot pedal that cycled
the machine. The ram descended, crushing four of his fingers.
The machine carried one prominent placard warning
against reaching into the die area. The dual-foot-pedal control
also had a warning at floor level.
The workers supervisor had taught him to use a hook at
the end of the ram to turn the die out of the operating area for
cleaning without reaching into the operating area. However,
he was cleaning the die in its operational position when the
accident happened.
Company officials knew safety features on the machine,
which was used for bending sheet metal, were not up to
date. A voluntary OSHA walkthrough about a year before the
accident had noted the press brake lacked safety devices or
guards.
Clear plastic guards for the press brake would have
interfered with some of the sheet-metal parts. And two-hand
palm buttons wouldnt have worked for 25% of workpieces
which needed operators to support them during bending.
Eight months after the OSHA visit, the company chose a
light curtain that could be programmed to work with the
variety of parts. The equipment took two months to arrive on
site. Shortly thereafter, the safety coordinator
alerted OSHA that the light curtain was in
use and avoided having to request a sixth
correction-date extension.
In reality, maintenance personnel tried
intermittently for another month to install
the light curtain without success. Nor could
a third-party company hired for the task set
up the device so it wouldnt shut down the
machine each cycle.
During this year, workers were still
operating the press brake without
modifications. Safety staff had shown
workers a video about the dangers of
reaching into energized equipment and
occasionally reminded them during staff
meetings. A formal training process where
workers signed off on what they were taught
was still in development.
After the accident, the third-party light-
curtain installers took a full week of work
to get the device running properly, but the
effort came too late to save the injured worker from going through two
surgeries and losing movement in his hand. MD
This months safety violation comes from the files of Lanny Berke, a regis-
tered professional engineer and Certified Safety Professional involved in
forensic engineering since 1972. Got a safety violation to share? Send your
images and explanations to jessica.shapiro@penton.com.
Edited by 1essicaShapiro
Warning
placard
Ram
Die
Light curtain
Foot pedals
Ram
Hook
Die
7hepressbrakeforbending
sheetmetaIhadnoguardsor
onvi ol l c.com
Ameri can: [ uh- mer- i - kuhn]
Nati ve or i nhabi tant of Nor th Ameri ca
I ngenui ty: [ i n- j uh- noo- i - tee]
Ski l l or cl everness i n devi si ng i nventi veness
Versati l e: [ vur- suh- tl ]
Hi ghl y capabl e of adapti ng
and changi ng di recti ons
Automati on: [aw-tuh-mey-shuhn]
Automati cal l y control l i ng apparatus
by el ectromechani cal devi ces
1.866.685.0404
Ameri can I ngenui ty. Versati l e Automati on.
RS# 134
VANTAGE POINT
Meeting the
efficiency challenge
Next to the economic recovery taking hold in most mar-
kets, two topics dominate business conversations: the
environment and energy. Also, the current debate about
sources of energy (not least since recent events in Japan)
and how its used especially demonstrates there are cost,
safety, engineering, and environmental challenges that
no currently available technology can fully meet. Given
that promising alternatives are not yet fully developed or proven, we have to
live with an energy mix for the foreseeable future.
Thus, the only short-term means of reducing CO
2
is to save energy. At the
same time, in industrial production we want to safeguard productivity. Saving
energy and maintaining productivity is no contradiction. It is possible, if we
improve energy efficiency.
Other drivers for energy efficiency include:
- Giowing ecological awaieness woildwide.
- Enoimous eneigy demand in new, booming maikets.
- Constantly iising eneigy costs.
- Incieasing legal and iegulatoiy obligations. Aiound the woild, legislation is
being drafted and rules implemented to reduce CO
2
emissions, and many com-
panies want to meet these targets sooner than required.
What is Rexroths strategy? First, we will reduce our own CO
2
emissions 20%
by 2020 at all our plants worldwide.
Initial analyses at our major facilities reveal this is not only beneficial for the
environment, but can also be done in a cost-effective way. Our advantage: We
have experience across all drive and control technologies and with almost all
types of industrial and mobile machines.
We intioduced the Rexioth 4EE system foi eneigy efficiency in 2009. It's
based on four principles:
Efficient components, such as seivomotois that aie moie than 93 efficient
and new axial-piston pumps with minimal mechanical and hydraulic losses.
Recover, store, and reuse surplus energy, with systems such as electric drive
controllers that recover braking energy, hydrostatic regenerative brakes for mo-
bile machines, and pneumatic cylinders that reuse compressed air.
Energy on demand. Demand-oriented, closed-loop control generates only as
much power as a task requires and can reduce power consumption in electric,
hydiaulic, and pneumatic actuatois by up to 30.
Energy-system design. Weve developed software design tools that precisely size
components to combine energy efficiency with the shortest possible cycle times.
Just as important is the intelligent linking of pneumatics, electric drives, and
hydraulics to fully realize a systems energy-efficiency potential as well as de-
liver the exact performance, precision, reliability, and safety the user demands.
Now, based on expeiience gained at oui own plants, we plan to use 4EE as a
basis for a new energy-efficiency consultancy service to support our customers.
Trained energy consultants will analyze existing machines and production lines,
implement changes, and verify the results. Pilot projects have been quite suc-
cessful. A French food group, for example, says the resulting energy saving paid
for the investment within a year.
This is our answer to the challenges we are facing in energy and the environ-
ment. Our experience shows CO
2
emissions in industrial production can be
ieduced. Even bettei: We can do it quickly and in an economical way. MD
Leain moie about Rexioth eneigy-efficiency consultancy and 4EE piogiam at
www.boschrexroth.com/energyefficiency.
Edited by kenneth1.korane
Karl Tragl
President and CEO
oschRexrothAC
Lohr am Main,
Germany
RS# 135
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RS# 136
INVENTORS CORNER
Edited by Leslie Gordon
technology, every kind of suspen-
sion system would have already been
invented. But the VXI by inventor
Winthrop Dada is an entirely new
kind of vehicle-suspension system.
Dada says it eliminates most if not all
of the problems inherent with prior
suspension designs. Dada calls his
invention the VXI because the sus-
pension links form a V or X shape,
and the system is fully independent,
thus the I. An off-road enthusiast
who owns a modified Suzuki Side-
kick with a strut front and a live-axle
rear, Dada initially set out to build a
high-travel independent suspension
for rock crawling. He eventually realized the VXI also
eliminates common problems such as wheel scrub
and unwanted camber change.
Most cars at neutral resting compression where
the suspension is neither loaded or unloaded are
set up with the front tires at negative camber, says
Dada. The trade-off is less rolling-resistance efficiency
for a little more traction midcorner. The second pro-
totype (V2) of the VXI allows control of the camber
to optimize it for cornering. Users can set the camber
link, which is attached to a variable-angle knuckle
it sits like any knuckle, but varies in angle for as
much or little camber change as desired. As the cam-
ber link is moved ever higher up the adjustment holes
on the longitudinal arm, the suspension will supply
progressively more camber change both positive
and negative.
In V3, which I just started building, the camber link
will instead be active. Rather than adjustment holes
on the arm, there will be a slot, which will let the link
move up and down depending on the steering input.
This makes the active link like an on-off switch for
either no camber change or as much camber change
as youd like, eliminating the effect of body roll on grip
and traction, says Dada. The active link will provide
optimized camber at all times, eliminating the need
for static negative camber and thereby boosting ef-
ficiency. With the active camber link, the VXI will offer
no camber-change during bump/jounce and dive/
squat yet will provide full control of camber in body-
roll (while cornering). (A vehicle dives when its nose
goes down while braking. It squats while accelerating
and the rear lowers. Bump and jounce happen when
A new twist on a fully
independent vehicle suspension
the car hits a bump on one side of its suspension.) In
these circumstances zero camber change is desirable
because it maximizes grip. However while cornering,
the VXI provides the camber change needed to maxi-
mize the tire contact-patch when encountering roll in
midcorner situations.
Also important to the design are the floating pivot
points which Dada says have never been used before.
These pivot points attach either to the wheel car-
riage (also previously unknown) or the chassis at one
end but are free to float up and down, allowing large
amounts of wheel travel in a compact arrangement.
Suspension geometry is maintained by the cross brac-
ing of the suspension arms. One reason the VXI can
provide more travel than other independent designs is
the floating pivot points let the suspension arms fold
One might think that after more than
100 years of advances in automotive
into each other compactly, sort of
like a hinge, says Dada.
In addition, because where the
pivot points attach to the chassis
are wide apart and high up, Dada
says the VXI is more stable than
other suspensions kind of like
the greater stability of a wide-
beam lifeboat as compared to a
canoe. The roll center is higher
than the vehicles center of gravity
higher than almost any other
design yielding enhanced sta-
bility. So the vehicle is less likely to
roll over in case of an accident.
Importantly, the XVI also provides zero track
change and the wheels do not move on any arc of
motion, says Dada. Zero track change means when
two opposite wheels (e.g., front) go through com-
pression, they never get further away from or closer
to each other. This contrasts to other independent
designs, including strut, double-wishbone, or mul-
tilink. A changing track width results in wheel scrub,
which makes the vehicle unstable, results in exces-
sive tire wear, and is less efficient because the wheels
are traveling in a crooked line. Although a live axle
does provide a fixed track width, the wheels are still
moving on an arc of motion its just a longitudinal,
not a lateral arc, meaning the wheel base is getting
longer and shorter, rather than the track width get-
ting wider and narrower.
On suspensions such as double wishbones or
struts, the tie rod is on the same arc of motion as
the A-arms when the vehicle travels straight ahead.
But as soon as you turn into a corner, the tie rod is
pushed outwards or inwards from the arc of motion
of that suspension arm, which causes an unwanted
steering effect known as bump steer, says Dada. In
contrast, the VXI uses a tie rod that attaches to a slid-
ing or telescoping slip yoke steering
input. Thus, the wheel carriage (to
which everything on the suspension
attaches) never goes out of phase with
the tie rod they always operate on
the same plane, effectively eliminating
bump steer.
Another important consideration is
instant center, which is the point on a
double wishbone or a short-long arm
suspension, say, at which the angle of
the top arm intersects the angle of the
bottom arm. On conventional designs,
the instant center moves around de-
pending on where the suspension is
and its deflection, says
Dada. Live axles are
pretty crude. But they
do have a few good at-
tributes, one of which
is that the instant
center is off to infinity.
The VXIs instant center
is also off to infinity.
The wider the instant
center of a given sus-
pension geometry,
the more stable the
vehicle, and the less
weight-transfer during
body roll. Independent-suspension engineers have
previously struggled with the trade-off between de-
signs with good instant center, roll center, and wheel-
travel attributes, which all act counter to one another.
The VXI optimizes all these aspects with no compro-
mises or trade-offs.
Dada says the VXI does have a few downsides.
Compared to, say, the double wishbone, the un-
sprung mass the weight of the wheel, tire and
suspension going up and down as the tire hits un-
dulations in the road is probably greater, he says.
Although not nearly as bad as that of a live axle, its
probably similar to a strut design. Another weak area
is the high number of parts. But, my hope is the tire-
wear performance and fuel-efficiency gains will more
than offset the additional cost and complexity.
This XVI can work on any two or four wheel vehicle,
and even on airplanes. An Australian group is develop-
ing the VXI with Dada for a road-racing application
a time-trial event for super-modified production ve-
hicles. Also, the U. S. military has expressed an interest
for its next Humvee. Dada says he will grant free rights
use to interested racing teams and individuals. He can
be reached at vxisuspension@gmail.com. MD
Top/bottom of
longitudinal arms
Floating pivot
point on the
longitudinal arm
Floating pivot point
on the lateral arm
Top and bottom
of lateral arm
Wheel carriage
Variable-angle
knuckle
Camber link
Bottom half
of telescoping
slip yoke
OEM SERVICES
FestoAC, www.festo.com
Formoreinformationon
theFinCripper,visit http://
machinedesign.com/article/robot-
imitates-an-elephant-s-trunk-0913.
Edited by kennethkorane
ods create
prototypes
with all the
properties
of mass-produced products,
says Mller-Lohmeier. But
parts are fabricated quickly
and economically because the
processes require no expensive,
complex tooling or molds. They
are especially advantageous
when there are many product
variants.
The ultimate goal, he ex-
plains, is to make parts and fin-
ished products in hours or days,
instead of weeks or months. By
designing products with the
customer, from sharing 3D mod-
els and simulations to making
prototypes, speed becomes a
competitive advantage for the
customer. We can quickly cre-
ate sample components and
use them to illustrate special de-
signs and alternative solutions,
explains Mller-Lohmeier.
The types of parts they make
Engineers looking for quick pro-
totypes or a few custom parts of-
ten face limited choices: build
them in-house or seek out a
rapid-manufacturing ser-
vice. Now FestoAC, a ma-
jor supplier of pneumatic
and electromechanical
components and systems, of-
fers customers another option.
The Esslingen, Germany-
based company recently estab-
lished the Festo Fast Factory,
a service that includes a range
of rapid-manufacturing equip-
ment, along with a staff of engi-
neers and technicians.
Founded in 2009, the Fast
Factory builds customer proto-
types and parts, along with prod-
ucts for new-product develop-
ment within Festo. It also handles
small-series production, serving
as a secondary parts source or
alternative manufacturing ap-
proach in some cases, creating
parts that would not be possible
or economically viable if made us-
ing other methods.
The goal, according to Klaus
Mller-Lohmeier, head of ad-
vanced prototyping technol-
ogy at Festo, is to support the
companys R&D efforts, but also
help customers get products to
market faster.
The group relies on four rap-
id-prototyping technologies: se-
lective laser sintering of plastics
and other materials, laser melt-
ing for metals such as aluminum,
fused-deposition manufacturing
or FDM for polymer products,
and EDM wire cutting.
These manufacturing meth-
Quick parts
from a
new source
7heFestoFast
Factorymadean
aIuminumheatexchanger
withinternaIconformaIcooIing
channeIsthatanautomotive0M
neededforbenchtesting.7hedevice
measures24420859mmand
weighsabout2.5kg.Usinganonstop
additivemanufacturing(SLM)process,
thepartwascompIetedinfivedays
significantbecauseitwasnotpracticaI
tomanufacturetheheatexchanger
usingothermethods.
From 10 Springs to 10 Million Springs,
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For Stock or Custom Springs, Wire
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you can count on Lee Spring to deliver.
he emphasizes.
Currently, more than 40% of the Festo Fast
Factorys production goes to outside customers.
In the first year, the unit produced more than
1,000 customer prototypes, 5,700 parts for R&D
within the company, and 12,800 small-lot pro-
duction parts for external sale. This generated
total revenue of about 750,000 Euro. MD
vary. Recent examples include:
- Pllot valves for a control unlt. 8ased on the 3D
concept model, they generated five units in
two days.
- Qulck turnaround of nonstandard pneumatlc
cylinders. FFF delivered, in less than three
days, a series of alternative cylinder-body
geometries the customer could
qulckly lnstall and evaluate.
- Por a deslgn study, they
manufactured a valve
housing using SLS, then
functional aluminum valve
components using SLM. The
parts, measuring up to 145
65 50 mm, have a 99.5%
material density, and were
delivered in three days. The
same parts would have taken
elght months to make uslng
die casting.
- Addltlve fabrlcatlon of l2,000
polymer snap-fits. Compared
to plastic injection molding,
the parts were delivered in two
weeks versus two months, at
about two-thirds the cost.
FFF is also aiding Festo R&D,
says Mller-Lohmeier, particu-
larly for molded parts. One ex-
ample is the bionic FinGripper,
a gripper based on a fish fin,
fabricated by selective laser
sintering. 0.1-mm-thin layers of
plastic powder were precisely
applied to a base and fused by
laser, progressively building the
final component. This reduced
weight by 90% compared with
traditional metal grippers, so
it requires less energy to move
and operate. Following the re-
ceipt of an internal order, the
FFF generated 150 FinGrippers
ln [ust 24 hr. A key conslder-
ation, says Mller-Lohmeier, was
that the FinGripper could not
be economically produced with
conventional techniques.
Addltlve manufacturlng llb-
erates design engineers from
restrictions imposed by tradi-
tional manufacturing methods.
Thls klnd of deslgn freedom and
flexibility are leading to design-
driven manufacturing, not
manufacturing-driven design,
RS# 137
AUTOMOTIVE
Its a Hummer,
an armored Corvette,
no its a
Super Terrain
Terra Hawk; a high-speed coupe, the Street Hawk; and
a slightly less-expensive, less-capable entry-level ver-
sion, the Steel Hawk. The vehicles will hit the market
late this year, with the company planning on building a
dozen over the first 12 months. After that, they intend
to manufacture 15 to 18 per year, with the least expen-
sive, the Steel Hawk, going for $750,000, and the rest
starting at $1 million. It should take about 18 months
What do you get when you cross a Corvette with the
original military Hummer? A heck of a hybrid. But it
still wouldnt have the outrageous performance and
capabilities of the Super Terrain Vehicles (STV) being
designed and built by Shadow Hawk, Broomfield, Colo.
The company has plans for six versions of its STV: the
Desert Hawk, an off-roader; two for the military, the
Armor Hawk and Battle Hawk; an RV version, the
Shadow Hawk raises the bar for high-performance cars.
Vehicle!
Authored by:
Stephen J. Mraz
Senior Editor
stephen.mraz@penton.com
Resources:
HawkVehicIes,http://
shadowhawkvehicles.com
WANT MORE?
http://tinyurl.com/6epc7g2
to build each one, and buyers will be able to customize
nearly every aspect of the car.
Engine and chassis
At the heart of all the Hawks, except the Steel Hawk,
is a 6.6-liter diesel V8, a pumped-up derivative of a mass-
produced engine. A diesel was chosen based on its abil-
ity to crank out lots of power at usable rpms. The engine
7heShadow
Hawkcompany
pIanstobuiIdsix
simiIar-Iooking
vehicIes,each
combining
performance
andcapabiIities
suitedtoa
specificniche.
7herewiIIbean
RVversion,an
off-roader,and
twomiIitary-
themedversions.
uyerscan
customizeeach
tomeettheir
ownneeds.
AUTOMOTIVE
unprecedented in a transmission this size, according to the
company. But Shadow Hawk engineers wanted to ensure
transmissions wouldnt fail, wouldnt even hiccup, when
the vehicle is a thousand miles from civilization.
The engine nestles into a monocoque structure that
combines the chassis and skin of the vehicle in a sin-
gle component. Much of the engine actually stretches
back into the passenger compartment, putting the center
of gravity near the center of the vehicle, ideal for han-
dling. A 50-gallon fuel tank, which gives most STVs a
1,100-mile range, also mounts close to the center of grav-
ity. (The Steel Hawk is slightly heavier and carries a dif-
ferent engine, so its mileage figures will be slightly less.)
The 1,600-lb monocoque made of 3/16-in.-thick titanium
is rigid, strong, relatively light, and rustproof. The strength
is needed to support the highly adjustable and articulat-
ing suspension in which each wheel is supported by an air
spring. Hydraulics at the top and bottom of the springs let
the driver alter the vehicles pitch and roll attitudes.
The driver can independently extend each wheel
44 in. or retract it by up to 2 in. Retraction, which must
uses compound turbocharging, high-pressure direct fuel
injection, and state-of-the-art computer controls to gen-
erate 1,100 hp, 1,805 lb-ft of torque, and 0 to 60 times of
3.5 sec. Top speed is about 208 mph, which takes about
11 sec to reach. Still, the vehicles get 20 mpg and meet
current and expected emission standards.
To make the engine rugged and reliable, it sports a
double-vacuum-melted alloy-steel crankshaft and rods
and special alloy pistons. A partial vapor-deposition
coating on the camshaft, valve train, and pistons cuts
friction so the components last longer.
A Spider Drive splits engine power, sending torque
to each wheel. It consists of a mechanical transaxle and a
series of geared shafts that transmit power through elec-
tronically controlled hydraulic clutches. The transmission
is not friction based, which means it can take the abuse
and forces generated when off-roading or towing. It can
also provide traction and stability control said to be far
better than the brake-based versions found on other cars
and trucks. The Spider Drive can handle up to 2,500 lb-ft
of torque, more than an STVs engine can generate and
AIIS7Vsare
buiItaround
amonocoque
structurethat
combinesthe
chassisandskinof
thevehicIe.Inmost
cases,itismadeof
/-in.titanium,
buttheSteeIHawk
sportsasteeI
version.
Atwo-doorS7VissimiIarinsizetoa
2011Corvette,whichmeasures
72.6-in.wide,174.6-in.Iong,
and49-in.high.
49 in.
79 in.
180 in.
AcastofHawks
7he7erraHawkfeaturesapop-uproofthatgives
occupantsa7-ftceiIing.ItincIudesamicrowaveoven,
recIiningchairs/beds,andarefrigerator.
no electrical, brake, or fuel lines go outside the
monocoque. The bottom of the vehicle is a smooth
sheet of titanium. And it rides on run-fat tires.
attIeHawk: Built specifcally for the military, many
of its features and capabilities are proprietary. But it
will be able to carry a variety of ofensive weapons
and defensive countermeasures, everything from
small arms to missiles. The retractable wheels let
Battle Hawks be stacked for transport on trains, trucks,
or aircraft. The C-130 Hercules transport aircraft, for
example, will be able to carry eight Battle Hawks but
can only accommodate three Hummers. This Hawk
and the Armor Hawk also make use of the titanium
monocoque in that it provides a nonmagnetic
shell. This should defeat metal-seeking weapons,
magnetically attached explosives, and magnetically
triggered mines. To make the magnetic signature even
smaller, users can opt for an aluminum engine block.
The Shadow Hawk company
makes a half-dozen varieties
of its Super Terrain Vehicle (STV).
They come standard with certain fea-
tures, but any feature can be added
as an option to any other STV. Heres
a brief description of each:
SteeIHawk: The least-expensive
STV, this vehicle is powered
by a 6.6-liter turbocharged
engine cranking out up to
360 hp and 650 lb-ft of torque.
The monocoque chassis and
body consists of 3/16-in. 4130
chromoly, a strong, relatively
lightweight alloy of steel. A
Steel Hawk tips the scales at
5,900 lb.
StreetHawk: This is the
best STV for on-road
performance. Its engine
generates 1,100 hp and
1,805 lb-ft of torque.
A 3/16-in. titanium
monocoque gives it a
curb weight of 4,800 lb.
It can go from 0 to 60 mph
in 3.5 sec, and top speed is
208 mph.
7erraHawk: The RV of STVs,
the Terra Hawk carries a pop-
up roof, a pair of reclining chair/beds, a
stove, and a refrigerator.
DesertHawk: Designed for of-roading, this STV
comes with a roof-mounted air intake to cope with
harsh driving conditions. An of-road lighting package
uses the latest in visible and IR illumination. And if the
car fips on its side or rolls on its back, the driver can
activate a hydraulically powered fipper which extends
from the side or top to put the Desert Hawk back on
its wheels. A spare tire can mount on the rear or roof.
ArmorHawk: This STV has speed and maneuverability
to escape while also being small enough (Corvette
sized) to make it dif cult for gunners to track and
target. For protection, the company provides the
latest armor, including ceramics, titanium alloys,
graphite, and Kevlar. Even the windows and camera
lenses can be battle hardened with transparent
ceramic. Ceramic windows struck by small arms fre
fracture and powder, dissipating the impact force.
Hardened windows can also take several hits before
being penetrated. But it is impossible to see through
a fractured window. In such instances, drivers would
rely on camera views to navigate. For protection,
AUTOMOTIVE
a bump or rock, the shock absorbers dissipate much of
the force while letting the wheel move rearward, raise up
and over the obstacle, then return to its previous driving
position.
All four tires on the STV are the same: 40-in-tall,
15.5-in. wide, and mounted in 22-in. wheels. According
to design calculations, a Street Hawk will withstand 1 g
on a skid pad.
The STVs do not rely on friction brakes for stopping.
Instead, wheels are forced to run gear pumps, with a
control valve on each pump dictating how much brake
pressure is applied. This, plus some computer controls,
contributes to the vehicles ABS and traction control. An
accumulator stores hydraulic pressure built up during
braking, which can be released on demand to turn the
gearmotors and, by extension, the wheels, providing a
power boost when needed.
Driving in comfort
Shadow Hawk engineers took a nontraditional ap-
proach to positioning the driver seat and console. They
start with the goal of putting the drivers eyes at a spe-
cific height and location to get the best view through the
windshield. So the seat is mounted in the proper place,
but it, along with the console and pedals, can be adjusted
to fit the driver.
The modular seat can be sized for almost any person,
with driver-controlled webbing and air bladders provid-
ing a custom fit in terms of width, length, and depth. The
seats mount on an air spring for additional shock absorp-
tion, and are heated and ventilated. Two-door STVs have
two seats, while four-door versions carry an additional
be done when the vehicle is stopped, is used for a couple
of reasons. By raising one wheel and letting the vehicle
balance on the remaining three, the driver can change
the raised tire without using jacks. And with all wheels
retracted, one STV can be stacked on top of another for
efficient storage or transportation.
Wheel extension also depends on vehicle speed, with
full extension available at speeds up to 10 mph, but ex-
tension is limited to between 2 and 14 in. when traveling
faster. The independent control lets the driver handle
some tough situations. For example, to avoid a fallen log
or boulder blocking the path, the driver can fully extend
three wheels. The STV will balance and drive on those
three wheels, while the fourth goes over the obstacle.
Once cleared, the driver can extend the fourth wheel
and lift another so it can avoid the obstacle. In fact, with
practice, a driver could make a Shadow Hawk STV climb
a set of stairs while constantly maintaining at least three
points of contact.
The active suspension includes camber control to
keep each tires contact patch flat and on the ground
whether the Hawk is going straight or through a turn
whether the wheels are extended or not. This lets the in-
side tires work nearly as hard as the outside wheels dur-
ing hard cornering. Caster, which the driver can set, is
also automatically maintained regardless of wheel exten-
sion. So the driver can fine-tune the amount of feedback
he gets from the road.
An Energy Impact Control subsystem on the suspen-
sion absorbs impacts without damaging the vehicle or
affecting driver control. It consists of horizontal and ver-
tical shock absorbers at every wheel. When a wheel hits
S7Vscanextend
eachoranywheeI
by44in.andretract
thembyupto2in.,
dependingon
vehicIespeed.
Avagos new generation optocouplers,
ACPL-x6xL series and ACNW261L,
oer signicant power e ciency
improvements for industrial
communication interfaces.
www.avagoresponsecenter.com/575
2011 Avago Technologies. All rights reserved.
Avago Technologies Optocoupler Solutions
Ultra Low Power
Digital Optocouplers in
Industrial Communication
Interfaces
90% less power than standard optocouplers
40% lower power than alternative opto-isolators
To request a free evaluation board go to:
Controller Transceiver
Optocouplers
ACPL-M61L/064L/W61L/K64L
B
u
s

L
i
n
e
Key Features
r 6MUSBMPXQPXFS
r )JHIUFNQFSBUVSFBOE
TVQQMZWPMUBHFSBOHF
r )JHIOPJTFJNNVOJUZ
(35 kV/s dynamic and
static common mode
rejection)
r $FSUJFEGPSTBGF
JOTVMBUJPO
(up to 1140 Vpeak
continuous working
voltage)
RS# 138
AUTOMOTIVE
day and nighttime (infrared) cameras mounted on the
front and back of the STV. The cameras do away with
both blind spots and rearview mirrors, while two IR
cameras looking out from either side provide security
day and night. Every control knob has a different shape
or texture, so drivers can quickly learn to use them with-
out having to glance down at them.
The interior is also completely waterproof. Accord-
ing to the company, you could flood the interior and the
screens and controls would still work. MD
two seats in the back. An optional fifth seat fits between
the two rear seats. Seats can be upholstered in leather,
cloth, canvas, or synthetic materials. Theres also almost
30 ft
3
of storage behind the seats, and the rear-seat bot-
toms fold up for more cargo.
The console or instrument panel is actually a col-
lection of LCD touchscreens. The driver and front-seat
passenger decide what goes on each screen, and options
include nav data, engine and suspension gages, Internet
feeds and pages, and views from one or more of the 12
7hedriverand
passengersassign
variousviewsto
theirLCDs,whiIe
thedrivercanaIso
assignavarietyof
functionstothe
arrayofcontroIs
andswitches
onthesteering
wheeI.Andthe
consoIeand
pedaIsadjustso
thatthedriveris
bestpositioned
toseeoutthe
windshieId.
MostS7Vsarepoweredbya6.6-Iiter
dieseIwithcompoundturbocharging
andhigh-pressurefueIinjection.It
putsout1,100hpand1,805Ib-ft
oftorque.7hisgivesthe
4,800-IbvehicIeabout1hp
forevery4.4Ib.

RS# 130
ALTERNATIVEENERGY INDUSTRY FOCUS
WASTE HEAT:
Best
green power
source?
For most manufacturers, a
good portion of the energy bill
goes up the smokestack. Heat
recycling may be the surest
way to go green.
forewarned. The design of heat-transfer equipment is not
a field for amateurs. Professionals with experience say a
number of factors can make heat-harvesting equipment
less than efficient and result in a disappointing payback.
As you might expect, one key is the ability to differ-
entiate between low-grade heat and useful amounts of
thermal energy. Advice comes from Tim Golden, director
of aftermarket services at Megtec Systems Inc., De Pere,
Wis. Megtec, among other things, makes heat-recovery
systems that use heated air from process dryers, ovens, and
air-pollution control systems. The majority of Megtecs
heat-reclamation work has been in capturing heat from
oxidizers that oxidize pollutants out of air coming from
a wide variety of processes. But the same principles ap-
ply to any situation that involves waste heat. Applications
under 250F and volumes under 2,000 or 3,000 scfm are
never going to make sense for heat recovery because of the
equipment cost, Golden says. The sweet zone is 250 to
700F, where you can use mild steels or low-grade stainless
in the heat exchanger and you dont have to get into super-
Trying to boost your green credentials?
Back-burner your plans for the roof-top
solar panels and on-site wind turbine. For
many businesses, the most economical way
of saving energy is to make use of the heat
that industrial processes generate. No ques-
tion that a lot of this heat gets wasted. Three
years ago, researchers at UC Berkeley esti-
mated the U. S. consumes 100 quadrillion
Btus of energy annually and as much as 60%
of that energy gets dissipated as waste heat.
Data centers and server farms are classic
examples of wasted-energy problems. Experts
say most of the energy dissipated at these fa-
cilities gets consumed by air conditioners
needed to cool the electronics. Long term,
data centers will generate less waste heat as
power supplies and electronics become more power effi-
cient. But servers and computer equipment will be throw-
ing off excess heat for some time to come. They also il-
lustrate a problem shared by other industrial facilities that
house heat-generating equipment: Much of this heat is
low grade though it accounts for a lot of energy, theres
often not enough of it to make a heat-recovery system
worthwhile.
It often takes an expert to figure out whether heat re-
covery is worth the effort and, if so, decide on the best way
to approach the problem. The usual means is to configure
a heat exchanger in an exhaust stack or as part of a cooling
system. Makers of boilers, chillers, and other heating and
cooling equipment frequently offer reclamation gear that
works with their products. And numerous firms special-
ize in solving the problems that accompany reclaiming
heat from buildings, smoke stacks, specific industrial pro-
cesses, and refrigeration systems.
But those who might be tempted to grab a heat ex-
changer and take a stab at recycling some heat should be
xProtection class IP40
xMeasurement range:
0 ... 9.8 / 19.7 / 29.5 in. (WS31)
0 ... 29.5 / 39.4 in. (WS42)
xAnalog, incremental output
OEM-Sensors for
position / angle /
inclination measurement
xProtection class IP60
x Measurement range 0 ... 360
x Analog output
x Protection class bis IP64
x Measurement range:
180 for 1 or 2 axes (PTAM27)
180 for 1 axis, 60 for 2 axes (PTDM27)
x Analog, digital output (CANopen)
WS31 / WS42
PRAS20 / PRAS21
PTAM27 / PTDM27
POSIWIRE

Cable Extension
Position Sensors
POSIROT
Magnetic Angular Sensors
POSITILT
Inclinometers
ASM Sensors, Inc.
www.asmsensors.com
info@asmsensors.com
Tel. 1-888-ASM-USA-1
WANT MORE?
http://tinyurl.com/3lstm29
Authored by:
Leland Teschler
Editor
leland.teschler@penton.com
Key points:
- Lxperts estlmate as much as 60%
of the energy dissipated in the U. S.
goes toward waste heat.
- A rule of thumb ls that lt ls dlfflcult to
justify recovering heat from industrial
appllcatlons under 250P and
volumes under 2,000 or 3,000 scfm.
Resources:
7heCMMCroupLLC, www.
thecmmgroup.com
LytronInc., www.lytron.com
MegtecSystemsInc., www.megtec.
com
WuIfinghoffnergyServicesInc.,
http://tinyurl.com/6baqpy3
insulated refractory-lined ductwork.
A clean stream of air is also important. You must be careful in environments
where flux and acids are present, as in foundries. Air streams with a lot of mois-
ture are problematic, and you should stay away from air with a lot of condens-
able material in it, he says. Another caution: Recovery systems must not extract
so much heat that the air stream falls below its dew point. Smoke stacks and
similar exhausts pose problems because they contain particulates such as soot.
The air must be cleaned before it hits a heat exchanger to prevent buildup that
can degrade thermal efficiency.
The addition of heat-recovery equipment generally also puts a back pres-
sure on the exhaust stack. If there is an exhaust fan involved, it will need to push
air through the hot side of the recovery heat exchanger. The resulting pressure
constitutes an extra load on the fan motor, so the motor must be sized for the
additional load.
There are other factors in play when the airstream contains gases that can be
hazardous, such as carbon monoxide. Such applications call for double-walled
heat exchangers that isolate the exhaust gas from any fresh air that could be
used to heat a room. Refrigerant introduced into the heat exchanger also typi-
cally circulates at a pressure higher than that of the exhaust gas, so any leak in
the heat-transfer equipment puts refrigerant into the exhaust rather than the
SomesuppIiersnowmake
skid-mountedheat-recovery
systemsthatarepreassembIed
andtested.0neexampIe
isasystemfromMegtec
SystemsInc.inwhichthefIow
arrangementconsistsofa
sIipstreamofheatedairdrawn
fromanexhaustductorstack,
whichispassedthroughaheat
exchangerandreturnedtothe
exhaust.Freshoutdoorairis
drawninandpassedthrough
theheatexchangerwhereit
isheatedandcontroIIedtoa
setpointof70to125Fto
providesuppIementaI
buiIdingheat
orsummer
cooIing.
RS# 142
7heeasiestwayto
recoverheatfrom
achiIIeristodivert
thecondenserwater
throughaheat
exchangeronitsway
tothecooIingtower.
7hismethodrecovers
theheatthechiIIer
rejectsandaugments
thecooIingofthe
cooIingtoweras
IongasthecooIing-
towerwaterwouId
bewarmerthanthe
minimumaIIowabIe
temperaturewithout
heatrecovery.7he
cooIingtowerfanaIso
needntworkashard.
systems that can encompass seven cold-plate technologies
and seven types of heat exchangers. With a tube-and-
fin heat exchanger, you must ensure contact between the
tubes and fins. Manufacturers typically have proprietary
software for the fin design that ensures transfer efficiency,
he says.
Makers of heat exchangers also typically make avail-
able software tools for selecting among standard products
and for configuring such factors as the number of fins and
their density, and the length of the tubes. Typical inputs
include the mass of the fluid and of the hot gas, and the
temperatures of the two fluids. The toughest part of the
heat-exchanger design, says Miller, typically comes from
staying within size constraints while still extracting the
required amount of heat. And, of course, the smaller the
temperature difference between the two fluids, the less the
heat transfer. Miller says a 20C temperature difference is
generally the minimum needed to extract a useful amount
of energy.
Harvesting refrigeration heat
One prime area for heat recovery is in large-scale re-
frigeration and cooling systems. The field is large enough
that manufacturers of refrigeration and A/C equipment
generally also offer heat-recovery gear. Nevertheless, heat
other way around.
It can also be a challenge to introduce the waste heat
back into the facility economically. Energy-recovery sys-
tem maker CMM Group LLC, De Pere, Wis., says site
layout is one of the biggest factors determining whether a
heat-recovery scheme is practical. Long runs of ductwork,
for example, boost costs. To avoid this expense, the ideal
situation is to use the waste heat in the same process that
generates it, CMM says.
Designing heat exchangers
The heat exchangers inserted in industrial smokestacks
must be designed with materials that can take high heat
such as stainless steel. They are a far cry from ordinary alu-
minum and copper that typically go into applications that
are less harsh. Aluminum-and-copper heat exchangers
generally have a temperature limitation of about 200C.
But the design of a heat exchanger, regardless of its
make-up, is probably not a task for novices. In tube-and-
fin heat exchangers, for example, The copper tube ex-
pands to get the best contact with the fin for the heat to
transfer effectively. That wont happen without planning
and it takes heat-exchanger design out of the realm of the
do-it-yourselfer, says Lytron Inc. Application Engineer
John Miller. Lytron, in Woburn, Mass., makes cooling
Heat
exchanger
Heat-recovery
system
Condenser
To heat-recovery
application
Cooling tower
Fan
7ypicaIcooIing-towerheatrecovery
Solar panel
positioning
to 0.0006?
www.kaydonbearings.com
Recently a solar energy system
developer had a bright idea:
rotate each panel with one
bearing instead of two a
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And since solar positioning
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of a standard bearing, we
designed one with radial
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class ABEC 5).
Kaydon can solve your design
problem, too. Visit our website
today for examples and 3-D
drawings, or call 800-514-3066.
No problem.
Typical of industrial heat-
recovery operations today is an
air-to-oil heat-transfer system
designed and installed by Megtec
Systems Inc. (left and above)
The equipment is tied into an
industrial boiler and captures
about 4 million Btu of heat energy
that would otherwise be lost.
harvesting from industrial-scale refrigeration is not always a no-brainer. Large-
chain grocery stores frequently harvest the heat from their refrigeration com-
pressors, but smaller establishments often dont bother. Major chains often
have in-house engineering departments that will tack a heat-recovery exchanger
onto a conventional chiller, says Donald R. Wulfinghoff of Wulfinghoff
Energy Services Inc., Wheaton, Md., an energy-efficiency consulting firm.
But there is a great deal of variability among grocery stores. Your small local
stores probably dont recover heat because it is a technical subject. If you are in
the grocery business, what you know is groceries. Your life is too complicated
and your margins are too small to be fussing with heat recovery.
The issues surrounding the recovery of heat from chillers can become com-
plicated. The terminology in the field sometimes doesnt help clear things up.
For example, the ratio of heat transfer to work input for a refrigeration cycle
is not called the efficiency, but rather the coefficient of performance (COP) or
advantage.
And there are complexities associated with even with the systems that are
conceptually the simplest, those involving cooling towers. For one thing, cool-
ing-tower water is dirty and often gets treated with toxic chemicals. So it may be
necessary to use a heat exchanger to isolate the tower water rather than use its
heat directly.
Some recovery systems for cooling towers might also employ an auxiliary
condenser in which clean water circulates in a closed loop between it and the
heat-recovery equipment. The compressor discharges to both the main and
auxiliary condenser and refrigerant flows to both. In one type, called a double-
bundle condenser, one of the tube bundles is cooled by cooling-tower water
RS# 143
Providing Solutions
Sealing. Shielding. Guiding.
Positioning. Static Control.
r.FUBMCBDLFETUSJQCSVTI
BOEIPMEFSTDVTUPNGPSNFE
GPSZPVSBQQMJDBUJPO
r(BMWBOJ[FEPSTUBJOMFTTTUFFM
CSVTIDPOTUSVDUJPO
r8JEFTUWBSJFUZPGCSVTITJ[FT
BOEMBNFOUT
r)PMEFSTGPSNFEQVODIFE
BOEQBJOUFEUPZPVS
TQFDJDBUJPOT
800.787.7325
e-mail: industrial@sealeze.com
www.sealeze.com
Our experienced Sales
Representatives and in-house
engineering staf and design
services are available to help
you fnd the right
brush solution for your
application.
P
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m
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(
Q
/
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Water fow
Tube fn
Plate fn
Oil coolers
7ypicaIheat-exchangerperformance
while the other tube bundle gets used for heat recovery.
There can also be trade-offs between the temperature of a chillers COP and
the condensing temperature. Some facilities might depend on heat recovery for
a specific amount of heat. To ensure they get it, they sometimes raise the con-
densing temperature above what it would be otherwise if refrigeration was the
only goal. But boosting the condensing temperature can also reduce the chiller
COP. Experts say experience plays a part in evaluating the trade-offs involved.
Different refrigeration setups use different compressor technologies that each
have special considerations for reclaiming heat. Screw-compressor chillers are more
frequently applied in smaller refrigeration applications, particularly in grocery
stores, because they tend to operate quietly. Some models have variable-discharge
ports that let them handle different pressure differentials more efficiently. They are
particularly helpful when the cooling load and heat-recovery load vary widely and
where the desired heat-recovery temperature varies as well.
Reciprocating chillers are also found in smaller applications, but have a
lower COP than other types. Large heat-recovery applications also may use cen-
trifugal heat-recovery chillers, which have the advantage of working efficiently
at their design-condensing temperature, less so at condensing temperatures
below the levels they were optimized for. Installing variable-speed drives on
centrifugal compressors helps them better handle lower temperatures, but the
application has to justify the extra expense of the drive.
Some heat-recovery situations may also call for a special kind of heat ex-
changer called a desuperheater. These devices get their name from the fact that
compression often raises the refrigerant-gas temperature to a level higher than
the saturation temperature in the condenser. The excess heating of the refriger-
ant over its saturation temperature is called superheat. A desuperheater installed
between the compressor discharge and the condenser removes heat higher than
the condensing temperature. But it doesnt affect the performance of the chiller
because it does not affect the condensing pressure or temperature. MD
This chart from Lytron Inc. compares the performance of different
heat-exchanger technologies, including plate-fin heat exchangers,
flat-tube heat exchangers, and tube-fin heat exchangers. Performance
is shown as Q/ITD, the heat load divided by the difference in incoming
temperature of the liquid and air. Units are not shown so heat-
exchanger technologies can be compared regardless of size. Heat
exchangers are often customized, so a range of typical values is shown
for each heat exchanger technology. All performances are compared
using water as the cooling fluid.
RS# 144
CUSTOMENGINEERED
FORYOURAPPLICATION
A&A Manufacturing Company
is your single-source provider
of innovative protective cover
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s
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A&A can design and deliver
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DYNAMIC SOLUTIONS
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Email: sales@gortite.com
Toll Free: 800-298-2066
Fax: 262-786-3280
RS# 141
RS# 139
Connectable (PC) Belts available in diameters ranging from .093 through .562.
CUSTOM MADE IN INCH, METRIC & O-RING SIZES
Ve|] C|ea| || 0pe|a||c| E||r||a|e Te||c||| Oe.|:e
E/:ep||c|a| Ao|a|c| Re||a|:e
Line Shaft Conveyor Belts - 0||||a| E(u|pre|| & Cc||e:|ao|e
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COLORS AVAILABLE
Round, Flat and Connectable Polyurethane Belts
A||cW |c| a::u|a|e, |c|
de||u:||.e reau|ere|| c|
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Available in Standard and
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DIAMETAPE BELT
MEASURING TOOL
Samples available at little or no cost
POWER TRANSMISSION-PART CONVEYING
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RS# 140
MOTION
Helical gears
help
manufacturers
go green
Authored by:
Adam Mellenkamp
Product Manager
S70RDrivesInc.
Maysville, Ky.
Edited by kenneth1.korane
Key points:
- Hlgh-efflclency hellcal
gears save energy, require
less maintenance, and last
longer that worm and spur
gears.
- Manufacturers that replace
low-efflclency gear reducers
with helical gears usually
see substantial savings.
Resources:
S70RDrivesInc., http://
stober.com
cal gearing is machined with angled teeth, then hardened
and ground, which is complex but necessary to achieve
a high-efficiency gear mesh. Because teeth are cut at an
angle, the gears gradually mesh. Two or three teeth of each
gear are always in contact with other gears. This alleviates
the load on each tooth and creates a smooth transition of
forces from one tooth to the next. The result: less vibra-
tion, wear, and noise, and longer life.
Some helical gears are virtually maintenance-free.
Tooth profiles are so precise there is practically no wear
and units packaged in sealed, oil-filled housings may re-
quire no oil changes, which is a boon for the environment
as well as the bottom line.
Helical-gear reducers also come in many shapes, sizes,
and configurations, letting machine designers eliminate
high-wear and high-maintenance parts such as belts, pul-
leys, chains, and sprockets.
So, although worm and spur gears are less expensive,
they have much shorter life spans than helical gears. After
about three years they are usually replaced. And frequent
replacement requires more capital and drives up mainte-
nance, downtime, and waste-disposal costs.
Higher quality
Another way to compare performance and efficiency
A trend gaining ground at industrial plants over the past
decade has manufacturers replacing traditional spur and
worm gears with high-efficiency helical gears. While
sometimes viewed as a pricey alternative, in reality,
helical gears save energy, run cooler and quieter, require
less maintenance, and last longer.
This can mean big savings for manufacturers. Replac-
ing spur gears with helical gears in a 150,000 ft
2
snack-food
plant, for example, will save one STOBER customer about
$1.5 million over the next 15 years.
Despite that kind of savings, an estimated half of U. S.
manufacturers rely on outdated worm and spur gears that
might have low up-front costs, but waste energy and tend
to fail prematurely.
Helical advantages
The problem is worm gears are typically bronze, a soft
metal, and the gears sliding surfaces generate friction
that causes wear. This mandates frequent oil changes and
means relatively short gear
life. (Ironically, hardening
worm gears accelerates wear.)
In comparison, helical gears
experience minimal wear and
are practically maintenance-
free.
Spur-gear surfaces have
rolling contact, but the teeth
are cut straight across on a
face; one or two teeth are al-
ways in contact with another
gear. This incomplete face en-
gagement means spur gears
are noisier and vibrate more
than helical gears.
Another advantage of heli-
cal gears over spur gears is in
torque capacity. Spur gears, by
design, are weaker than helical
gears because loads are trans-
mitted over fewer teeth. Heli-
High-efficiency gears are
environmentally friendly
and save money.
0vertheIife
ofamachine,
high-efficiency
heIicaIgears
cangenerate
substantiaI
savingsover
spurandworm-
gearreducers.
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Noise from helical gearing is ap-
proximately 10 to 12 dB(A) lower
than that from spur gearing. In hu-
man terms, that means 16 helical
gear units generate as much noise as
eight worm gears or a single spur-
gear unit.
The second quality indicator is
excessive heat. It equates to low effi-
ciency and wasted energy. Heat gen-
eration in rotating machines can also
have many causes, including ineffi-
cient design, misalignment, incor-
rect fits, and seal drag. Unfortunately,
low-quality gear reducers are major
contributors to excessive energy con-
sumption. These gearboxes typically
get so hot you cannot keep your hand
on them for more than a second or
two.
Helical gearing is 20 to 30% more
efficient than single-stage worm
gearing. That not only means cooler
operation. With a 2-hp motor, heli-
cal gears can save up to 4,000 kW-hr
annually. Or engineers can opt for
a smaller motor simply because of
lower gear-reducer losses, which
saves on the initial investment.
Applications abound
For U. S. manufacturers to re-
main competitive, they must mod-
ernize assembly lines. There are end-
less miles of conveyors and tons of
equipment being driven by ineffi-
cient motors and even less-efficient
gear drives. Energy audits we have
performed show that many facto-
ries and processing plants are oper-
ating equipment at only 60 to 70%
efficiency, leaving ample room for
improvement. And while high-effi-
ciency motors are now required by
law, gear reducers have unfortunately
been virtually ignored by legislators,
even though inefficient, low-quality
gear reducers are a major contributor
to excessive energy consumption.
Highly productive and efficient
equipment saves money, energy, materials, and time, and
helps domestic manufacturers compete against low-wage
labor markets. Going green in manufacturing is no lon-
ger an optional, feel-good choice. It is sound business and
our opportunity to regain a competitive edge in the global
economy. Manufacturers should go green just like every
other industry has over the past few years. And when they
do, theyll find that as efficiency rises, so do profits. MD
is to look at quality. There are two common gear-quality
indicators that all engineers understand. One is that too
much noise and vibration means low precision and limited
life. Rotating machines that are noisy and vibrate can have
any number of quality issues: improperly balanced rotat-
ing components; mating components with excessive toler-
ances; and components that are not rigid enough, flexing
under load and leading to misalignment.
RS# 146
CAD
Technology
Guide
0bjet, www.objet.com
RS#621
7rek, www.trekbikes.com
RS#622
Bicycle manufacturer Trek Bicycle Corp., Waterloo, Wis.,
relied on service bureaus to create physical 3D models of
bicycle components. The company also prototyped tooling
mockups and accessories such as shoes and helmets. It some-
times took a bureau several days and a lot of paperwork to
create a model. Now the company has moved prototyping
in-house and generates parts in just hours via a Connex50
3D printer from Objet Geometries Ltd., Billerica, Mass.
The machine is clean and office friendly, says Manager
of Treks Prototype Development Group Mike Zeigle. And
it produces parts that rival those made with SLA in terms
of quality and finish. But the biggest advantage is that the
machine unlike other technologies can print parts and
assemblies made of multiple materials, with different me-
chanical or physical properties, all in a single build.
Parts produced on the Connex have fine details and a
smooth and durable surface. The machine can print so-
called living hinges, soft-touch parts, and overmolds.
Printed parts closely emulate the look, feel, and function of a
wide variety of end products.
Most recently, the machine played a key role in the com-
panys launch of its new Speed Concept 9 Series bike a
time-trial bike used in the Tour de France and Iron Man
Hawaii. The frame design features aerodynamic cross sec-
tions that lower wind resistance and improve speed. Almost
every part of the new design was prototyped on the Connex
and then shipped from Trek in Wisconsin to a California
Mostpartsof7reksnewSpeedConcept
9Seriesbikewereprototypedonthe
Connex503Dprinterfrom0bjet.
wind-tunnel-testing facility, where sample frames were
tested at wind speeds of 30 mph or more.
The designers had several ideas for the aerodynamic
features and wanted to see the impact on wind resistance,
says Zeigle. We printed multiple parts on the Connex that
the designers could snap onto the bike frame and then test in
the wind tunnel. The team even 3D-
printed durable accessories such as
water bottles and bento boxes to make
testing conditions more realistic.
That we could print multiple iter-
ations quickly let us experiment more
while still making the deadline, says Zeigle.
The operator of Treks Connex printer, Lupe Ollarzabal,
says that having the machine in-house has boosted the com-
panys productivity. The Connex let us get a new product to
market quicker and get a better product to market on time,
he says. The machine, thereby, provides a win-win for us
and our customers.
Treks designers now find themselves prototyping a
lot more frequently. Most of the prototypes we create are
things we never would have prototyped before, says Zeigle.
When we outsourced or had to rely on our in-house mill-
ing operation, it was just too costly and time consuming
to do a lot of prototyping. The Connex has also helped us
significantly reduce tooling mistakes that can add weeks or
months to a product launch.
3DprinterheIpsbuiIdabetter7rekbicycIe
DassauItSystemes
SoIidWorksCorp.,
www.solidworks.com
RS#623
AutodeskInc.,
http://usa.autodesk.com
RS#624
SoftwaresimuIatespIasticinjectionmoIding
Autodesk Moldflow 2012 software provides plastic-injec-
tion-molding simulation tools for validating and opti-
mizing plastic parts, injection molds, and the injection-
molding process. The software
thereby helps CAE analysts,
designers, engineers, and mold-
makers see, communicate, and solve potential manufac-
turing problems early on.
The program provides real-time molding simulation.
The software can dynamically evaluate a range of plas-
tic-part designs in significantly less time than it takes to
perform a standard simulation. Moldflow even makes
suggestions on how to resolve
molding problems. A results
viewer lets nonusers visualize,
quantify, and compare simu-
lation results.
Enhancements and new ca-
pabilities include: Simulating
the filling and packing phases
of injection molding; calcu-
lating the orientation of short
and long-glass fibers; and de-
termining the temperature
variation in a mold. Moldflow
2012 can import and mesh
solid geometry from Para-
solid-based CAD systems,
Inventor, Catia V5, Pro/Engi-
neer, and SolidWorks, as well
as IGES, SAT, and STEP.
SoIidWorksn!Fuze
IetssmaIIteams
coIIaborateon
designs
Avai l abl e t hi s June, t he Web- bas ed
SolidWorks n!Fuze lets users collaborate on
designs with engineers and designers inside
and outside of their organization. The pro-
gram targets smaller companies that lack a
formal PDM or PLM system or that have lim-
ited IT resources. The software ensures
that versions are managed properly and
it makes sure that comments are not
lost in a discussion thread.
As an add-in to SolidWorks soft-
ware, n!Fuze provides a window in the
software from which users can drop or drag
files. In another approach, users can simply
view designs or post non-CAD files with the n!Fuze Web
client. Lastly, users can view and comment on CAD data
using n!Fuze mobile-device apps. The add-in the Web cli-
ent supports Microsoft Windows. n!Fuze apps will work
on the iPhone, iPad, and other mobile devices in the future.
The Web and mobile versions let non-CAD users see and
interact with design files and collaborate as well. The pro-
gram will be available through the online 3DS App Store at
https://iam.3ds.com/service/social.
Mike Campbell
Divisional Vice President
Creo Product Development
P7C
Needham, Mass.
www.ptc.com RS#625
products that may have many hundreds or even thousands
of configurations, a CAD-based assembly approach may
not be scalable or feasible. In these cases, a PLM-based
approach is required. Today there is no deep connection
between the PLM system and CAD-based assembly mod-
eling. This limits PLMs impact on the creation, valida-
tion, and downstream use of highly configurable, serial-
number-specific product designs. CAD-based modeling
needs an intelligent assembly kernel that will make CAD
assemblies as dynamic as the real-world products they are
trying to model. This capability will give teams the power
and scalability to create, validate, and reuse information
for highly configurable products.
Technology lock-in. Many users feel trapped by legacy
tools. The inability to easily translate data between sys-
tems makes it difficult to retire old tools and migrate to a
new technology, application, or vendor. The result is that
companies either incur high switching costs or settle for
limited innovation with legacy tools. CAD software needs
to remove these constraints and let users incorporate data
from any CAD system, unlocking multi-CAD design ef-
ficiency and value.
The CAD market is ready for a scalable suite of right-
sized, interoperable, integrated design applications that
span the entire spectrum of product development. Solv-
ing these design software problems will help companies
unlock their potential by unleashing creativity, facilitating
teamwork, increasing efficiency, and, ultimately, realizing
value. MD
Many users indicate
they are still leery of
learning and imple-
menting 3D CAD
because it is too dif-
ficult to learn. But
CAD should be as
easy to use as other
productivity tools
such as PowerPoint
or Excel so everyone
on the product team
can contribute. In
devel opi ng Creo,
PTC broke down
the main barriers
keeping many stake-
holders from feeling
comfortable about
jumping on the 3D
CAD bandwagon:
Usability. This
concept goes well beyond simple user interface improve-
ments. Many CAD companies talk about their products as
having an ease-of-use advantage. In reality, all mainstream
CAD packages take at least a week for new users to come
up to speed. Plus, new users must use the software con-
sistently to remain productive. Whats needed is a design
process that includes both mainstream CAD jockeys and
casual users, such as project managers, marketing man-
agers, or application engineers out in the field. In other
words, providing customers the right tool for the right
user at the right time gives everyone in the organization
the opportunity to partici-
pate in the product-develop-
ment process.
Interoperability. The
lack of interoperability be-
tween modeling approaches
and even within 3D para-
metric programs sometimes
makes it difficult to use different tools of choice for vari-
ous tasks. It also makes it hard to work with suppliers and
other parties in a value chain using multiple CAD systems.
Interoperability issues often force companies to standard-
ize on a single system not necessarily optimal for all users.
CAD systems should challenge this model and deliver in-
teroperability between programs that lets data flow back
and forth seamlessly. Data created in any mode, whether it
is 2D, 3D direct, or 3D parametric, must be fully accessible
and reusable in any other mode. Users can then work with
their own or another users data in the approach of choice.
Assembly management. For designing relatively sim-
ple products with few variants, a pure CAD-based assem-
bly modeling approach is sufficient. For more-complex
reakingbarrierstoproductdeveIopment
P7CCreoproductsprovidevisuaIizationandmarkup
appIicationsforanyoneinthedesignprocesstosee
differentdesignvariantsatavarietyofstagesduring
designanddeveIopment.
Martin Tool and Forge is a full-service quality
manufacturer with services ranging from
engineering and design through to delivery of the
nished product.
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A Division of

Martin Sprocket & Gear, Inc.

1-800-USA-TO/,sWWWmartintools.net
ATTENTION FORGING BUYERS!
4ELMAILAMTAGATHONUSACOM
WWWAGATHONCOM )3/%.
,I!IGJLIGCM?1QCMM.L?=CMCIH
0RECISION,INEAR'UIDE%LEMENTS
MMDIAMETER
RS# 147
RS# 149
Tel: 215-957-9260 FDx: 215-957-9263
CounterBDlDnce CorporDtion
1025 /ouis Drive
:Drminster, 3A18974-2823
www.cbDl.com
Were GREEN and RoHS compliant
Follow us on Facebook
CounterBalance Corporation
for updates
RS# 148
FE UPDATE
Slava Djakov
Sensor Development Director
Microvisk7echnoIogies
Denbighshire, North Wales, U. K.
Edited by LesIieCordon
Resources:
ComsoIInc., www.comsol.com
RS#626
Microvisk7echnoIogies,
www.microvisk.com
RS#627
WANT MORE?
http://tinyurl.com/3pyc6v4
Handheld devices for monitoring blood viscosity typi-
cally use reactant-coated electrodes to induce
and detect chemical reactions in blood
samples. This technology has remained
unchanged for many years. Recently,
though, Comsol Multiphysics soft-
ware from ComsoIInc., Burlington,
Mass., helped Microvisk develop a
handheld unit for home use that em-
ploys microelectromechanical sensors
(MEMS) on a disposable strip which con-
tains a small cantilever to measure viscosity. The dis-
creetly sized monitor checks blood viscosity in a one-
stage process based on physics rather than chemistry.
Patients need only slip the test strip into the hand-
held device, prick their finger to produce a tiny drop
of blood, about 3 microliters of volume, and touch it
with the free tip of the test strip. The capillary action
takes the blood straight to the MEMS sensor and the
test commences. The device passes signals through
the microcantilever layers, each of which deflects in a
different way. The cantilever movements indicate the
samples rheometric properties and dynamic changes
in real time. In blood-coagulation tests, such changes
are fed back to the handheld unit for detecting the
onset of clotting.
Other cantilever designs found in atomic-force
microscopy or in biological research for probing and
assessing DNA, protein, and aptamer bindings with
drugs or antibodies, use crystalline-silicon (cSi) rigid
cantilevers. Because of their rigidity, cSi and similar
structures are delicate, brittle, and provide restricted
movement. Although cSi cantilevers can be sensitive,
through actuation in resonant mode, their restricted
mobility impedes performance once the microcantile-
vers are immersed in liquids.
In contrast, the MEMS-based devices microcanti-
levers comprise layers of different polymers. The can-
tilevers free ends can deflect significantly from their
resting positions, resulting in efficient and accurate
responses.
The big challenge in developing the monitor lay
in its sophisticated design, which required a holistic
approach to integration, packaging, and signal pro-
mechanical response and reproducibility as well as
reliability aspects such as cycling times and perfor-
mance deterioration.
When the research began on the early units several
years ago, there was no suitable software-modeling
option. Thus, it was not possible to conduct multiple
analyses of the MEMS. We were forced to rely on past
experience, basic know-how, and gut feeling. Need-
less to say, coming up with the initial design was a
long and tedious process involving countless labora-
tory experiments and real-life tests.
The multiphysics software helped speed this pro-
cess because it complemented the design flow and
real-life testing with simulation. The software let us
analyze individual materials each with unique ther-
mal and electric properties tangled together. The
program helped answer such questions as: Which ma-
terials are the most critical and how will they behave
in the presence of fluid?
The software can simulate complex designs
because it lets users analyze combined mechanics
and statics of beams systems, thermal and electric
properties of structural materials, and currents be-
ing applied to MEMS structures immersed in and
interacting with fluids. A current not only changes
Multiphysics software helps build
a better blood monitor
cessing. Once the con-
cept was proven, the big
questions in MEMS-based
microchip design were:
How likely are the chips
to perform, and what are
the set points? It was also
necessary to account for
7hehighIy
deformabIeandfIexibIe
microcantiIeversaIIow
theaccurateviscosity
readingoftinysampIes
ofbIood.
7heMicroviskdeviceuses
MMSonadisposabIe
stripwhichincorporatesa
smaIIcantiIevertomeasure
viscosity.
FE Update continues on page 73
VISIT LITS-ON-LINE: http://www.machinedesign.com
MAY 2011
QUALITY TRANSMISSION
COMPONENTS
Page 69 - Circle 31
FLOYD BELL INC
Page 67 - Circle 13-16
FABCO-AIR
Page 66 & 68- Circle 5 & 17
BRECOFLEX CO., L.L.C.
Page 67 - Circle 12 ACE CONTROLS
Page 66 - Circle 6
BOKERS INC
Page 67 - Circle 9
igus Inc.
Page 67 - Circle 10
REID SUPPLY COMPANY
Page 66- Circle 1
w

KANO LABORATORIES INC
Page 66 - Circle 2
CPV MFG INC
Page 66 - Circle 8
RADIAL BEARING
Page 68 - Circle 19
SMALLEY STEEL RING CO
Page 69 - Circle 25
Aircraft Ouality
Rod End & 8pherical Bearings
66 MAY 5, 2011 MACHINE Design.com
DEUBLIN ROTATING UNION CATALOG AVAILABLE
Deublin, the leading manufacturer of rotating unions,
has a new, updated 56-page catalog that includes
complete information for selecting unions for a vari-
ety of applications, from water and steam, to air and
hydraulic, oil and coolant.
Both operating data and dimensional specifications
are provided in one comprehensive catalog, along
with installation and service information. This refer-
ence catalog provides detailed information on over
50 application categories and over 500 models. The
catalog is available free via reader response, phone
or email.
Deublin Company
2050 Norman Drive West
Waukegan, IL 60085
(847) 689-8600;
E-mail: info@deublin.com;
www.deublin.com
FREE COPY - CIRCLE 7
TWIN ROD AIR CYLINDERS
Compact, non-rotating cylinders are suitable
for multi-axis assemblies and robotic arms.
Magnetic pistons and rubber bumpers are
standard. Choose sleeve or ball bearings.
Optional sensors mount in linear slots in
the housing. Five bores from 10~32mm pro-
vide industrial interchangeability. Strokes
to 100mm. For more information contact
FABCO-AIR at http://www.fabco-air.com
Fabco-Air, Inc
Gainesville, FL
www.fabco-air.com
PRECISION ORIFICES AND FILTERS
Bird Precision offers a unique series of laser drilled,
wire lapped Ruby and Sapphire orifices. Orifices and
filters are packaged in a huge variety of standard stain-
less, brass and plastic fittings ,connectors and inserts.
We offer over 150 precision orifice sizes starting at
.0004(10 microns). We now also offer our golden Ori-
fice series with .0001 total tolerance. With extreme
chemical and wear resistance these products insure
precise dependable control of even the most harsh
liquids and gas. Bird Precision continues to focus on
putting orifices and filters where you need them. We
also offer a number of Swagelok, Parker , Smc and
Value Plastic Retrofits. www.birdprecision.com
Bird Precision
Waltham, Ma.
1-800-454-7369
1-800-370-6308
sales@birdprecision.com
LEAKPROOF VALVES &
FITTINGS TO 10,000 PSI
CPVs product line brochure can be a val-
uable first step in identifying the exact
valves and fittings a particular application
may require. Once reader has identified
type of product(s) needed, the appropriate
CPV catalog with full specifications and
ordering instructions can be requested at
no cost.
CPV Manufacturing, Inc.
Philadelphia, PA
(888) 278-5449, FAX: (215) 387-9043
E-mail: sales@cpvmfg.com
Web: www.cpvmfg.com
2011 SPEC
CATALOG
Select from many new products in Associated
Spring-Raymonds SPEC
2011 catalog, including

our complete lines of 316 Stainless Steel Exten-
sion and Torsion springs, Incone
l
Compression
springs and new lines of gas struts and associated
hardware. Check our extended range of Belleville
and disc spring washers, our Clover
Spring Wash-
ers and our in-stock, precision-engineered springs
and washers for your prototyping and design
needs (in metric and English dimensions). And ask
about our custom work capabilities for materials,
coatings, kitting, secondary processes, etc.
Associated Spring-Raymond, Barnes Group Inc.
Maumee, Ohio 43537 U.S.A.
Phone: 1.800.872.7732
Fax: 1.419.891.9192
springsales@asraymond.com
www.asraymond.com/spec-spd/
MAINTENANCE IDEAS
FREE More than 100 maintenance
ideas collected from operations
personnel are revealed in a revised
brochure. Included are ideas for han-
dling hot or frozen bearings, loosen-
ing corroded bolts and frozen brake
cables, removing rust, and improving
engine performance.
Kano Laboratories
Call 615-833-4102 or order from the
Website at: www.kanolabs.com
GLOBAL DISTRIBUTOR OF INDUSTRIAL SUPPLIES
Free 900-page catalog featuring color-coded categories
including: knobs, handles and hand wheels, clamps
and workholding, tooling components, fasteners and
hardware, leveling devices and vibration control,
material handling, bearings and power transmission,
metalworking, MRO, pneumatics and hydraulics,
structural systems and safety supplies. Introducing
two new online categories Apparel and Footwear,
and Packaging and Shipping Supplies at ReidSupply.
com. Browse online at ReidSupply.com or call (800)
253-0421.
Reid Supply Company
Muskegon, MI
(800) 253-0421: FAX: (800) 438-1145
E-mail: mail@reidsupply.com
Web: ReidSupply.com
SHOCK ABSORBERS PLUS
NEW GAS SPRINGS
ACE Controls catalog features deceleration
and motion control products. Includes:
industrial, safety, PET & GLASS industry
shock absorbers, feed controllers & hydraulic
dampers.
Also includes: AGS Gas Springs providing
counterbalance motion control for lifting
and lowering lids, hoods, hatches, panels
and more. Made in USA.
ACE Controls Inc.
Farmington Hills, MI
T: (800)521-3320 (248)476-0213
E-mail: shocks@acecontrols.com
www.acecontrols.com
67 MACHINE Design.com
MAY 5, 2011
BOKERS FREE 2011 WASHER CATALOG
Bokers complimentary 2011 Washer Catalog offers
a selection of more than 25,000 non-standard flat
washer and spacer sizes available with no tool-
ing charges. With outside diameters ranging from
0.080 to 5.140, a wide variety of inside diameters
and thicknesses and over 2,000 material options
available, Bokers provides endless washer and
spacer possibilities. Materials include low-carbon
sheet steel, various spring steels, stainless steel,
aluminum, brass, copper and nickel silver. Non-me-
tallic options include ABS, acetal, polyester, nylon,
MD nylon, polycarbonate, fiber, polyethylene and
various phenolics. ISO 9001:2008 Registered.
Bokers, Inc.
(888) 927-4377, FAX: (800) 321-3462
Email: sales@bokers.com
www.bokers.com/mdlw
NEW CABLE CARRIERS AND CABLES CATALOG
The latest edition of igus
Energy Chain
cable carriers
and Chainflex
continuous-flex cables catalog is now

available. It features a completely revamped, easy-to-use
layout and a number of either new or expanded product
lines. Some of these include Guidelok: a horizontal guid-
ing system designed to keep the upper and lower runs of
a cable carrier apart in long-travel applications, RX40:
a completely chip-proof cable carrier ideal for machine
tool applications, new video, vision and robot cables,
and additions to igus
line of assembled drive cables.

Request your free catalog at www.igus.com/quickorder
<http://www.igus.com/quickorder>.
igus Inc.
PO Box 14349
East Providence, RI 02914
P. 401-438-2200
Toll free. 1-800-521-2747
F. 401-438-7270
E-mail. sales@igus.com
ELECTRIC CYLINDERS
RACO El ect ri c Li near Cyl i nders wi t h
ballscrews or acme screws are an environ-
mentally safe and low maintenance replace-
ment for hydraulic or pneumatic cylinders.
Thrusts to 200,000 lbs., speeds to 30/second,
and strokes to 20 ft. Modular system allows
custom built units using the special high
torque RACO actuator motor or servo and
stepper motors. Cylinders are built for heavy
duty industrial applications. Other types of
cylinders are available for high speed, high
positioning accuracy applications.
RACO International L.P.
Bethel Park, PA
(888) 289-7226, (412) 835-5744
FAX: (412) 835-0338
E-mail: raco@racointernational.com
Web: www.racointernational.com
ATN
CONVERTIBLE PROFILE TIMING BELT DESIGN

BRECOflex, the world leader in the polyurethane tim-
ing belt industry, has developed a patented timing
belt concept that allows the customer to rapidly and
easily attach, interchange, or reconfigure timing belts
in house or in the field with a multitude of profiles using
simple hand tools.
BRECOflex also offers a full range of accessories includ-
ing pulleys, clamps, tensioners and slider beds. For
free catalogs (print or CD), samples, and/or techni-
cal support call (732) 460-9500 or visit our website,
www.brecoflex.com today!
Brecoflex CO., L.L.C.
Toll free at 888-463-1400
Phone: 732-460-9500
Email: info@brecoflex.com
ULTRA LOUD PIEZOELECTRIC ALARMS
Ultra Loud selection of piezoelectric whoops, war-
bles, sirens, beeps and more offers 100Hz lower
frequency than industry counterparts. Available
in variety of voltages and output up to 108dB! Rug-
ged panel mount products are IP68 and NEMA 4X
when used with optional gasket. ISO 9001:2000 reg-
istered company all products made in the USA.
Floyd Bell Inc
(614) 294-4000; FAX (614) 291-0823
email: sales@floydbell.com
www.floydbell.com
AUDIOLARM II
PIEZOELECTRIC ALARMS
The industrys largest selection of piezoelectric
whoops, warbles, sirens, beeps and more. Avail-
able in variety of voltages and output up to 103dB!
Rugged panel mount products are IP68 and NEMA
4X when used with optional gasket. ISO 9001:2000
registered company all products made in the
USA.
Floyd Bell Inc
(614) 294-4000; FAX (614) 291-0823
www.floydbell.com
TURBO LIGHT
WATERPROOF LED
PANEL INDICATORS
Tiny (approx.1x1) LED Panel Indicators provide
BRIGHT output with super-sleek design. Avail-
able in variety of voltages and output up to 14,500
cd/m
2
! Rugged, tamper-proof, lo-profile panel
mount design is IP68 and NEMA 4X. Available in 5
colors and 3 brightness levels. ISO 9001:2000 regis-
tered company all products made in the USA.
Floyd Bell Inc
(614) 294-4000; FAX (614) 291-0823
www.floydbell.com
TURBO
MINIATURE PIEZOELECTRIC ALARMS

Tiny (approx.1x1) piezoelectric alarms provide
LOUD output with a super-sleek design. Available
in variety of voltages and output up to 103dB!
Rugged, tamper-proof, lo-profile panel mount
design is IP68 and NEMA 4X. Optional manual
volume control offers increased attenuation. ISO
9001:2000 registered company all products made
in the USA.
Floyd Bell Inc
(614) 294-4000; FAX (614) 291-0823
www.floydbell.com
MAY 5, 2011 MACHINE Design.com 68 68 MACHINE Design.com
MECHANICAL CABLES, CABLE
ASSEMBLIES, & PULLEYS
Cable Solutions! Call Sava Industries to request
our comprehensive 36-page Design Guide featuring
miniature and small steel cable from .006-3/8, push
pull varieties, high fatigue drive and low stretch
cables. Also available plastic and still idler pulleys
from 3/8-6.0 and a large section of end terminals
for the steel cable. Specializing in fast service.
ISO 9001 Certified
Carl Stahl Sava Industries, Inc.
Riverdale, NJ
Tel: (973) 835-0882 Fax: (973) 835-0877
E-mail: bruce@savacable.com
Web: www.savacable.com
www.savacable.com/medical
Design Guide for
Cable Solutions
ISO 9001 Certified

CABLE
S
O L U T I O N
S

Precision Cable Assemblies

Miniature & Small Cables
Small MIL-SPEC Wire Rope
Push-Pull Controls
Design Guide for
Cable Solutions
DG0508
Plastic & Steel Idler Pulleys
Wire Rope Terminals
Fittings & Hardware
Ferrous & Nonferrous Alloys
www.savacable.com www.savacable.com
AIRCRAFT QUALITY ROD END &
SPHERICAL BEARINGS (AS9100 / ISO 9001)
Since 1955 Radial Bearing Corporation has
designed and manufactured metal to metal
and self lubricating rod end and spheri-
cal bearings for use in aircraft, marine and
ground vehicles and industrial machinery.
Products range from standards to specials
designed to customer specifications and for
difficult environments. Bore sizes range from
1/8 to 3.
Aircraft Ouality
Rod End & 8pherical Bearings
Radial Bearing Corporation
Danbury, CT
(800)377-1937, FAX : (203)744-1691
sales@radialbearing.com
www.radialbearing.com
2010 KIT CATALOG
The Hercules 2011 Kit Catalog contains 1000
pages of hydraulic and pneumatic seal kit informa-
tion for both industrial and mobile applications.
Complete cylinder repair kits are available
for over 100 different brands of equipment includ-
ing: construction, logging, refuse, forklifts, cranes
and dump bodies. Popular kits include Caterpil-
lar, John Deere, Komatsu, Volvo
and many more. Online ordering is now available.
Hercules Sealing Products
Clearwater, Fl
Phone: 866-625-0627; Fax: 800-759-6391
website: www.HerculesUS.com
SMITH BEARING PRODUCT
CATALOG
Smith Bearing is a registered trademark of
Accurate Bushing Company. With over 50
years experience in designing and manufactur-
ing precision needle roller bearings, we can
handle your requirements for standard aero-
space and industrial bearings. As well as our
existing product line, we are ready to assist you
with the manufacture of custom made prod-
ucts, precision machine components and as-
semblies. ISO 9001 and AS 9100 registered.
Accurate Bushing Company
Garwood, NJ
(800) 932-0076, (908) 789-1121
FAX: (908) 789-9429
E-mail: sales@smithbearing.com
Web: www.smithbearing.com
EPOXIES MADE TO ORDER
For specialized needs, Master Bond can custom
formulate an epoxy adhesive, sealant, coating,,
potting, and encapsulation compound to meet
your specifications. We offer unsurpassed
technical expertise and have years of experience
in solving complex problems. Special formulations
can be made in small to large quantities. These
formulations can increase productivity, eliminate
waste and improve product reliability. Additionally,
our products can be supplied in simple, easy to use
packaging.
Master Bond, Inc.
Phone: (201)343-8983
Fax: (201)343-2132
E-mail: main@masterbond.com
www.masterbond.com
NEW SPRING BROCHURE
New brochure, The spring for the 21st
century, describes Helicals special ex-
pertise in designing and producing single
piece, maintenance free, machined
springs for a broad range of applications.
It also features examples of integrated at-
tachments plus data comparing wire-
wound and machined springs. Helical
machined springs are used in industries
such as medical, aerospace, military, nu-
clear, industrial and electrical/electronics.
HELICAL PRODUCTS CO., INC.
Santa Maria, CA
(888) 211-9589, FAX: (805) 928-2369
Web: www.Heli-Cal.com
ISO-6431 AIR CYLINDERS
Extruded body cylinders have standard
magnetic pistons, adjustable air cushions
and machined male rod threads with jam
nuts. Bores 32~125mm. Strokes to 1000mm.
Hard anodized aluminum cylinder tube I.D.
& O.D ensures corrosion resistance and lon-
ger product life. Lubrication is not required.
For more information contact FABCO-AIR at
www.fabco-air.com.
Fabco-Air, Inc
Gainesville, FL
www.fabco-air.com
FREE COPY - CIRCLE 17 FREE COPY - CIRCLE 21
69 MACHINE Design.com MAY 5, 2011
METRIC AUTOMATION AND DRIVE COMPONENTS
New Stock Drive Products/Sterling Instrument Metric
Components Catalog D805 contains product specs
for over 40,000 items such as: gears, timing belts,
timing belt pulleys, bearings, couplings, gearheads
and speed reducers, right angle drives and linear mo-
tion systems.
For FREE catalog and engineering assistance call: 800-
737-7436 or download 3D models and shop online at:
www.sdp-si.com.
SDP/SI Stock Drive Products/Sterling Instrument
New Hyde Park, New York
Phone: 800-737-7436 FAX: 516-326-8827
www.sdp-si.com
SPIRAL RETAINING RINGS &
WAVE SPRINGS
Smalleys complete product line is now
available in one easy to navigate catalog.
The new catalog includes over 7,000 stan-
dard wave springs, spiral retaining rings
and snap rings. Smalleys new catalog of-
fers simplified part selection, special de-
sign and engineering tools and the latest
applications of Smalley products.
Smalley Steel Ring Company
Lake Zurich, IL
(847) 719-5900, FAX: (847) 719-5999
E-mail: info@smalley.com
Web: www.smalley.com/getcatalog
FOR A GREEN FUTURE
All Metric Small Parts, a division of Designa-
tronics, Inc., has announced the availability
of a NEW 512 page catalog titled M100. The
catalog features over 5,600 RoHS compli-
ant, Metric components. The products de-
tailed include: Handles, Handwheels, Cranks,
Grips, Levers, Knobs, Latches, Locks,
Catches, Hinges, Screws, Washers, Springs,
Keys, Plungers, Pins, Leveling & Support Feet.
Request your FREE copy today.
ALL METRIC SMALL PARTS
New Hyde Park, NY
516-302-0152, FAX: 516-302-0153
Web: www.allmetricsmallparts.com
NEW ELECTRIC HEATER CATALOG
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 ele-
ments since 1952 and offer a wide variety of heat-
ers for OEM, industrial, medical, commercial and
military applications.
HOTWATT, INC.
Danvers, MA
Phone (978) 777-0070
FAX (978) 774-2409
E-mail: sales@hotwatt.com
Web Page: www.hotwatt.com
SHOCK & VIBRATION ISOLATION SOLUTIONS FROM AAC
Catalogs V100 & V110 from AAC feature a
wide selection of off-the-shelf vibration
mounts, shock absorbers and shock absorb-
ing couplings for use in both commercial and
military applications. To assist in problem
solving and component selection two com-
prehensive technical sections are included.
Call to request your free catalogs or shop
online at: www.vibrationmounts.com
Advanced Antivibration Components
New Hyde Park, New York
Phone: (516) 328-3662 FAX: (516) 328-3365
www.vibrationmounts.com
ADVANCED CERAMIC SOLUTIONS
Astro Mets unique advanced ceramics
provide cost effective solutions to material
performance problems in a wide range
of demanding applications. Amalox 68
a 99.8% alumina ceramic and Amzirox
86 an yttria stabilized zirconia provide
superior wear resistance, corrosion resistance,
high temperature stability, low thermal
expansion, high stiffness to weight
ratio, biocompatibility and high dielectric
strength.
Astro Met, Inc.
Cincinnati, OH
(513) 772-1242, FAX: (513) 772-9080
E-mail: fgorman@astromet.com
Web: www.astromet.com
FREE COPY - CIRCLE FREE COPY - CIRCLE 32
FREE COPY - CIRCLE 29 FREE COPY - CIRCLE 25 Stock Drive Products/Sterling Instrument
METRIC GEAR COMPONENTS
New 528-page catalog Q420 has technical
specs for 3,800+ standardized stock metric
gear components, including spur, helical and
internal gears, straight and helical racks,
straight and spiral bevel gears, worm and
worm gears, ratchets, splines and gear cou-
plings in modules 0.5 to 10. Materials include
carbon & chrome-moly steel, brass, bronze,
nylon and cast iron.
QTC- Quality Transmission Components
Garden City Park, New York
Phone: 516-437-6700 FAX: 516-328-3343
www.qtcgears.com
SELF-LUBRICATING GEAR SOLUTIONS CALCULATED
FOR LIFE
The Intech Power-Core gears are precision ma-
chined and offer solutions to applications in which
lubrication, wear, noise, vibration, inertia, shock load,
moisture and chemicals present a problem for ny-
lon, 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 du-
rability calculation using proprietary software.
Intech Corp.,
250 Herbert Ave., Closter, NJ 07624.
(201) 767-8066;
Fax: (201) 767-7797.
www.intechpower.com
FREE COPY - CIRCLE 31 FREE COPY - CIRCLE 27
ELECTRICAL/OPTIC SEALS
Standard and custom hermetic designs.
Low or high pressures or vacuums. Any
cable type or pin connector may be spec-
ified. Circular or rectangular seals in-
cluding micro D-sub. Design flexibility,
low cost, compact sizes, high corrosion
resistance, easy installation. Small or
large quantity pricing. Fuel pumps,
semi-conductor, moisture-proof, defense
applications, etc. Website in-stock price
list, catalog, quote request form.
PAVE Technology Co., Inc.
Dayton, OH
(937) 890-1100, FAX: (937) 890-5165
Web: www.PAVEtechnologyCo.com
INTERACTIVE WEBSITE ALLOWS
CUSTOMERS TO ORDER ONLINE
Trim-Lok Inc. launches a brand new website fea-
turing an interactive 24-hours-a-day ordering sys-
tem, which showcases an expanded product selec-
tion of new trims and seals. Customers will relish
in the ability to build their own products through
selecting the available styles, colors and textures of
the particular product. It easily allows customers to
order products online without the hassle of calcu-
lating product codes and numbers. Customers can
request a FREE sample of the final product to con-
firm the product meets their specific needs. Addi-
tionally, customers can utilize the new site to re-
quest a FREE copy of our new Catalog 500.
Trim-Lok, Inc.
Buena Park, CA
(888) TRIM-LOK, (714) 562-0500
FAX: (714) 562-0600
E-mail: info@trimlok.com
Web: www.trimlok.com
CROSS-REFERENCED TO METAL CAM FOLLOWERS
FOR EASY REPLACEMENT
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
SORBOTHANE
NEW ENGINEERING
DESIGN GUIDE
Your Guide to Shock and Vibration Solutions
This guide has been developed to assist engineers in
a practical, hands-on approach to designing with Sor-
bothane
. A windows-based program, which parallels

this calculation method, is available. Sorbothane, Inc.
also offers additional technical support. Engineers
worldwide choose Sorbothane
for applications re-

quiring shock absorption, vibration isolation and
damping.
RAPID PROTOTYPING
LOW-COST TOOLING
IAST TURN AROUND
MADL IN USA
Sorbothane, Inc.
Phone: 8OO.888.89O6 Iax: 88O.678.18O8
Lmai: saessorbothane.com
www.sorbothane.com
ENGINEERING
DESIGN
GUIDE
Your Guide To
Shock & Vibration
Solutions
Sorbothane, Inc.
2144 State Route 59
Kent, OH 44240-7142
330-678-9444
www.sorbothane.com
MAY 5, 2011 MACHINE Design.com 70 70 MACHINE Design.com
users can
browse video
libraries using
technology-
based
navigation
to focus
on specific
technology
topics. They
can also
browse by
company
brand, trade
show, or by
publication-
specific video
playlists.
From tutorials
to trade-show
coverage,
Engineering TV
is the video
site for design-
engineering
professionals.
At
EngineeringTV.com
visit us at
EngineeringTV.com
www.eetconference.com www.eetconference.com
Watch our site for details on the keynote and other speaker presentations.
Conference & Expo
M a y 2 6 , 2 0 1 1 S a n t a C l a r a , C A
ENERGY EFFICIENCY
T E C H N O L O G Y
Mark your Calendar
for May 26, 2011
Santa Clara Marriott, CA
The Energy Ef ciency & Technology Education Day is a one-
day event featuring technical sessions aimed at engineers
and technologists engaged in projects involving energy-
ef cient products and processes.
Typical sessions will cover topics in EVs, LEDs and solid-
state lighting, energy-harvesting applications, smart-grid
applications, energy-ef cient power supplies, legislated
energy mandates, and related subjects.
The EE&T Conference is one of the few venues focusing
strictly on technology and innovations related to energy-
ef ciency. There will be educational, product exhibition,
and networking opportunities throughout the day.
P
O
W
E
R

U
P
1st in - UL508 Manual Motor Controllers
Ring
Tongue
Box
Clamp
EIectricaI Rating:
0.3-60A: 480Y/277VAC
0.3-25A: 1 pole - 42VDC; 2 Pole - 80VDC
30-60A: 1 pole - 24VDC; 2 Pole - 60VDC
Short Circuit Withstand Rating:
(UL/CSA - Ratings)
0.3-60A (RC): 10kA with UL-listed
RK5 back-up fuse or MCCB
Interrupting Capacity (VDE - Ratings):
0.3-10A (RC): 10kA; 13-60A (RC): 5kA
no branch circuit protection required
New Improved Design Maintains Same UL/CSA Approved ReIiabiIty.
Altech UL508 Listed Manual Motor Controllers are Suitable as Motor Disconnect.
Standard DuaI Connection TerminaI
Unique for industry standard box & ring tongue terminal
Reinforced Housing
Added ridges and new housing design improves overall product strength
Modern Look with New CoIor
Dark blue handle and terminal caps enhance appearance and match imprint
Marking Window
Large marking area with
clear swivel window screen
908.806.9400 | altechcorp.com
INDEX TO ADVERTISERS
To receive catalogs or brochures described in this
issue of the Literature Express, simply circle the
inquiry number on the Reader Service Card. We will
rapidly computer process your requests.
www.machinedesign.com www.penton.com
While every effort has been made to ensure the
accuracy of this index, the publisher cannot be held
responsible for any errors or omissions.
ACCURATE BUSHING CO., INC . . . . . . . . . . . . 68
ACE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . 66
ADVANCED ANTIVIBRATION COMPONENTS . 69
ALL METRIC SMALL PARTS . . . . . . . . . . . . . . . 69
ALTECH CORP. . . . . . . . . . . . . . . . . . . . . . . . . . 72
ASSOCIATED SPRING/RAYMOND . . . . . . . . . . 66
ASTRO MET ASSOCIATES INC . . . . . . . . . . . . . 69
AVAGO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
BIRD PRECISION. . . . . . . . . . . . . . . . . . . . . . . . 66
BOKERS INC . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
BRECOFLEX CO LLC. . . . . . . . . . . . . . . . . . . . . 67
CARL STAHL SAVA INDUSTRIES. . . . . . . . . . . . 68
CPV MFG INC. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
DEUBLIN COMPANY . . . . . . . . . . . . . . . . . . . . . 66
FABCO AIR, INC. . . . . . . . . . . . . . . . . . . . . . . . . 66
FABCO AIR, INC. . . . . . . . . . . . . . . . . . . . . . . . . 68
FLOYD BELL INCORPORATED . . . . . . . . . . . . . 67
HELICAL PRODUCTS CO INC. . . . . . . . . . . . . . 68
HERCULES SEALING PRODUCTS . . . . . . . . . . 68
HOTWATT INC . . . . . . . . . . . . . . . . . . . . . . . . . . 69
IGUS INC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INTECH TRADING CORP. . . . . . . . . . . . . . 69 & 70
KANO LABORATORIES INC . . . . . . . . . . . . . . . 66
MASTER BOND INC. . . . . . . . . . . . . . . . . . . . . . 68
QUALITY TRANSMISSION COMPONENTS. . . . 69
RACO INTERNATIONAL, L.P.. . . . . . . . . . . . . . . 67
RADIAL BEARING CORP. . . . . . . . . . . . . . . . . . 68
REID SUPPLY COMPANY. . . . . . . . . . . . . . . . . . 66
SMALLEY STEEL RING CO . . . . . . . . . . . . . . . . 69
SORBOTHANE. . . . . . . . . . . . . . . . . . . . . . . . . . 70
STOCK DRIVE PRODUCTS . . . . . . . . . . . . . . . . 69
Some folks might think a diametral pitch is a roundabout way of selling
something, but we know better at Forest City Gear.
Our gearheads live with the math and physics of gears on their minds, every
day. Plus, they bring an unmatched knowledge of materials and CNC machine
tool functionalities to the difficult task of making the world's very best gears, to
exacting customer specifications, time after time after time. In our world, you
see, consistency is not the hobgoblin of little minds, with all apologies to Mr.
Emerson (the essayist, not the electric motor magnate). Doing something right
"most" of the time simply isn't good enough at Forest City Gear, as it isn't for
our customers.
They demand we make it right, every time, as our products help their products
perform better. As a result, their reputation rides, in part, on ours. This is a very
special trust and we do our best to preserve it, all the while trying to improve the
products we deliver. We do this by maintaining a machine shop that's the envy
of the gear world, from the first drawing to every step in the machining process
to the final inspection in our state-of-the-industry QC department and finally, to
the careful product handling and packaging.
For a sample of how good a gear company can be, when they maintain such
"top of mind awareness" for customers, check out www.forestcitygear.com.
We'll be thinking about you.
At Forest City, We Always
Have Gears On Our Minds...
Gearheads? You Betcha.
11715 Main Street, Roscoe, IL 61073 815-623-2168
typing, and cut development time.
The software also eliminated
the tedious method of solving
one problem, then another, and
plotting a graph after each step.
Previously, we collected data from
a number of test strips, which had
to be analyzed, understood, and
verified. One iteration typically as-
sessed 20 different design options
and the manufacturing and as-
sembly implications of each.
The multiphysics software
eliminated this problem, letting
us quickly start selecting the most
promising simulation options,
which we then confirmed with lab-
oratory testing. We estimate the
software took four or five months
off monitor-development time.
Medical-diagnostic equipment
has stringent requirements such
as the time allowed for blood-
sample testing. Because blood
clotting begins as soon as the
finger is pricked, the process had
to be quick. Here, the software
came in handy in simulating and
optimizing flow through the mi-
crocapillary channels that feed
fluid samples onto the microchips.
The microcantilever is immersed
immediately, so tests can begin
with just a quarter of the volume
needed by existing monitors. This
results in less pain for patients. In
addition, it is unnecessary to drip
blood onto a certain area of the
strip. The monitor shows test re-
sults in just 30 sec.
Point-of-care testing and
medical devices for home use are
emerging markets. The potential
for home blood testing is similar to
that of glucose testing by patients
diagnosed with diabetes, a market
in which 160 companies are now
established. Microvisk plans to
launch the new device in the last
quarter of 2011. MD
electrostatic fields, it also alters mechanical structures
and creates thermal effects.
Comsol Multiphysics let us simulate the microchips
mechanically, thermally, and electrostatically. It also
permitted analysis of the microfluids and their proper-
ties and how these interface with the chips and moving
cantilevers. By linking all the physical properties of the
design, the software speeded iterations, reduced proto-
FE UPDATE
The Comsol model is simulating the stresses delivered by
the different plastics contained in the microcantilever. The
different stresses provide the needed movement for an
accurate measurement of blood clotting.
RS=168
MAY5,2011 MAOHlNE Design.com 73
SPOTLIGHT GEARS & MECHANICAL DRIVES
R
eq
uest free inform
ation via
Linear drive offers automatic
shaft cleaning and
lubrication
Uhing linear drives now offer a combination shaft
scraper/grease-fitting option for automatic cleaning
and lubrication of the driveshaft. The option removes
excessive grease, dust, and dirt from the shaft while
the drive is running and simultaneously assures ad-
equate shaft lubrication. Accumulated debris can be
wiped away with a cloth. In most applications, the
Adjustable-speed and
right-angle drives
A new, 28-page catalog covers
adjustable-speed drives, right-angle
gear drives, and linear actuators.
Adjustable-speed drives can be
used as a primary or secondary drive
and eliminate the need for expensive
ac/dc drives or variable-pitch drives.
The drives accept input speeds from
0 to 2,000 rpm for quick and easy out-
put speed changes, whether the ma-
chine is running or idle. A new Micro
Dial design feature provides accurate
and repeatable speed settings.
Crown two and three-way right-
angle gear drives transmit power using spiral-bevel gears and
nonmagnetic stainless steel shafts. The drives fully enclosed
cast-aluminum housing prevents internal gears from getting
out of alignment, jamming up, or becoming contaminated
by debris, and offers maximum heat dissipation. These drives
are available in many sizes and shaft configurations including
squared, splined, extended, shortened and stepped. Applica-
tions include printing, packaging machines, off-highway ve-
hicles and special machinery of all types.
Zero-Max Inc., 13200 Sixth Ave. N, Plymouth, MN 55441, (800)
533-1731, www.zero-max.com RS# 447
scrapers can be used without the grease fittings to
clean the shaft while the drive runs. The grease-fitting
combination is recommended for heavy usage appli-
cations and when shaft rpms exceed rated speeds (1,000 rpm for
Model RG drives; 1,500 rpm for Model RS drives).
The shaft scraper is a specially formulated rubber O-ring that
is mounted in a Delrin plastic fitting. One scraper is attached to
each of the end bushings on the drive unit. When equipped with
the grease fitting, the plastic fitting is made larger to accommo-
date the addition of a felt wiper ring, which wicks oil out of the
grease and applies a thin oil film to the shaft as the drive runs.
Amacoil, 2100 Bridgewater Rd., Aston, PA 19014, (800) 252-2645,
www.amacoil.com RS# 446
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Planetary gears
The company is now offering a high-per-
formance and economical drive program
with the addition of planetary gears to its
line of synchronous and stepper motors.
The gears come fully mounted on 8LSA,
8LVA, 8JSA, and 80MP Series motors, elimi-
nating troublesome communication prob-
lems between the motor and gear sup-
pliers. Gears in both straight and angled
designs and with all conventional drive
flange geometries are available.
Standard single-stage gears for gear ratios
i = 3, 4, 5, 8 and 10 and have 8 to 15-arc-min
backlash. Two-stage or three-stage designs
are also available. The lines premium Series
provides backlash 1 arc-min as an option
paired with high-output torques.
B&R Industrial Automation Corp., 1250
Northmeadow Pkwy., S-100, Roswell, GA
30076, (770) 772-0400, www.br-automa-
tion.com RS# 448
ou
r R
ead
er Service W
eb
site at

154 Hobart Street Hackensack, NJ 07601
Te|. 201-343-8983 Fax. 201-343-2132
www.masterbond.com main@masterbond.com
We so|ve prob|ems.
One-component system.
no mixing needed
Cures at e|e.ated temperatures
Tq abo.e 220C
Outstanding e|ectrica| insu|ation
properties at 350F
Exce||ent durabi|ity
High bond strength
Resistant to shock and .ibration
100 reacti.e - contains no so|.ents
Minima| shrinkage upon cure
Withstands exposure to fue|s, oi|s and
many so|.ents
Easy app|ication
Con.enient packaging
5lrutlurul dheslve
5ervlteuble Ep
Ie 00f
Master Bond
EP17HT
INDUSTRIAL MICROSCOPE
Cutting edge product is ideal for digital
and analog imaging applications!
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SANTA BARBARA IMAGING, LLC
RS=150
RS=151
RS=153 RS=152
The versatility, flexibility and
close tolerance capability of Seal Master
engineered inflatables offer creative
solutions in applying forces and motion
control in a more effective manner than
common mechanical methods.
Sealing is just one of many tasks
for custom-built, fabric-reinforced,
elastomeric inflatables. They're ideal for
use as actuators, brakes, valves,
clutches, wipers and for other
innovative applications.
Backed by in-depth
technical/customer
service, they'll replace
cumbersome, hard-to-
maintain processing
and handling components
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800.477.8436 330.673.8410 FAX 330.673.8242
E-mail: info@sealmaster.com www.sealmaster.com
KEEP PRODUCTlON MOVlNG.
SEAL MASTER
CUSTOM ENGlNEERED lNFLATABLES
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PUMP AND COMPRESSOR SOLUTIONS FOR OEMS WORLDWIDE PUMP AND COMPRESSOR SO
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For more information visit gd-thomas.com/md5
PRODUCTS
Worm-gear screw jacks
The ActionJac line of worm-gear screw jacks consists of machine-
screw, ball-screw, stainless-steel, metric, and trapezoidal screw jack
options. Used individually or in multiple arrangements, each
jack is built to specification with customized travel lengths and
load-handling capacities ranging from to 100 tons.
Each models worm-gear-set arrangement uses an alloy-steel
worm, which drives a high-strength bronze worm gear (drive sleeve).
The worm shaft is supported
on antifriction tapered
roller bearings with
external seals to prevent
loss of lubrication.
Machine-screw jacks fea-
ture a lifting shaft made of alloy
steel with a minimum tensile
strength of 95,000 psi. Lead
accuracy is approximately
0.004 in./ft.
Ball-screw jacks fea-
ture a high-efficiency ball
screw and nut that re-
duces the required input
torque to about one-third the
torque required for machine-screw jacks.
300 Series Stainless-steel screw jack
are for environments where corrosion
resistance is essential. Stainless-steel lift-
ing threads are precision formed to Class
2-C (centralizing) thread profiles.
Nook Industries Inc., 4950 EAST
49th St., Cleveland, OH 44125, (800)
321-7800, www.nookindustries.com
RS# 465
Hollow-shaft clutches
and brakes
Magnetic-particle clutches and brakes
offer precise tension and torque con-
trol for winding and load-simulation
applications. The hollow-shaft style
features easy mounting, and quiet
and smooth slip torque that is varied
by dc electrical current. The brakes
and clutches are rated from 1 to15 lb-
in. up to 65 lb-ft and 800 W heat dis-
sipation. Solid shaft units are rated up
to 300 lb-ft torque and 1,900 W.
Placid Industries Inc., 139 Mill Pond
Dr., Lake Placid, NY 12946, (518) 523-
2422, www.placidindustries.com
RS# 466
RS=154
Nortn Amori oa Nortn Amori oa

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At 8AB, our lnnovutlon und
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PM BLDC motors
A family of modular brushless
permanent-magnet motors consists
of 75-mm (2.95-in.) squared motors
in three stack lengths. Peak motor
torque varies from 250 to 630 Ncm
(354 to 892 oz-in.), while peak output
power ranges from 420 to 1,000 W.
Axial lengths are 115 mm (4.53 in.),
140 mm (5.51 in.), and 165 mm
(6.50 in.), respectively.
The motors are available with Hall
sensors, an incremental position en-
coder with 4096 counts postquadra-
ture, and/or a multiturn absolute en-
coder AE65 Series with SSI interface.
Available winding voltages range
from 12 to 325 Vdc.
A speed and position motion
controller with CANopen, Profibus,
Modbus, or Ethercat can be fitted to
the motor.
Dunkermotoren USA Inc., 2511
Technology Dr., Elgin, IL 60124, (224)
293-1300, www.dunkermotoren.com
RS# 468
Linear-roller
bearings
The MX Series of linear-roller
bearings offer extreme
rigidity, high accuracy, and
smooth motion. Four rows
of cylindrical rollers provide a greater
contact area and deliver a higher load
capacity than slides using steel balls.
An extremely rigid guide rail elimi-
nates deformation under high loads
for stable performance under fluctu-
ating or heavy loads.
The MX Series provides damp-
ing to allow the bearings to deliver
machining accuracy, high-speed cutting, and precision
grinding under high vibration and shock conditions.
For maintenance-free operation, a C-Lube system
distributes lubricant to the loading area through the cy-
lindrical rollers as they circulate.
IKO International Inc., 91 Walsh Dr., Parsippany, NJ
07054, (800) 922-0337, www.ikont.co.jp/eg
RS# 467
RS=155
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PRODUCTS
Valve driver manages
proportional
valves
The D1 PWM valve driver drives and
manages proportional valves. The
D1 converts proportional command
voltage into a 1.11.1-A current
signal to drive the valves linear force
motor. The D1 lets a 12 or 24-Vdc
power supply accommodate most
applications. Its valve deadband,
dither amplitude, and maximum
current are all adjustable. For ap-
plications using PLCs or computers,
the D1 interfaces with the valve,
eliminating the need to write valve-
management routines.
The drivers digital closed-loop
current control compensates for
perturbations such as changea in in-
put voltage or in the coil resistance
due to temperature. Additional
features include short-circuit protec-
tion, highly efficient design (no heat
sink required), LED indicators for
power and status/fault activity, and
a temperature range of 40 to 65C
(40 to 150F).
The enclosed unit is suitable for
panel mount or applications where
the electronics will be exposed to
end users. The D1 has a DIN clip for
rail mounting, or the clip can be
removed for flat surface mounting,
either from within the enclosure or
the bottom.
Enfield Technologies, 35 Nutmeg
Dr., Trumbull, CT 06611, (800) 504-
3334, http://enfieldtech.com
RS# 469
RS=157
RS=156
Pre-calibrated, proven solutions
install fast and perform anywhere
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FREE CATALOG &
APPLICATION ASSISTANCE:
1-800-328-6170
www.electro-sensors.com
The original machine monitoring experts
TT420 Temperature Transmitters:
* 'ni|-uJnil iJ
1
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1
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ST420 Shaft Tachometers:
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Tin babbitt bushings
A new line of Graphalloy (graphite/
metal alloy) tin-based babbitt materi-
als handle high-temperature bearing
applications up to 350F (175C). The
materials perform reliably as self-lubri-
cating bearings in submerged and dry
applications.
Babbitt is environmentally safe to
machine and use, while eliminating
the need for grease or oil, reducing
contamination and maintenance.
The materials can replace plastics
because they offer heat dissipa-
tion and will not melt or cold flow.
In low-temperature applications
(400F/205C), the bearings solve
lubrication problems caused by the
viscosity of grease and oil that often
prevents proper operation of
equipment.
Graphite Metallizing Corp., 1050
Nepperhan Ave., Yonkers, NY 10703,
(914) 968-8400, www.graphalloy.com
RS# 470
ability of 0.2 micron. It can be pro-
vided as a classic XY stage without
adapter plate or configured as a
XYZ system. Driven by a piezomo-
tor, each stage includes stainless-
steel crossed-roller-linear bearings
for smooth motion and good load
capacity. Both the base and saddle
are made from high-stiffness alu-
minum. All other components and
hardware are selected for ultrahigh
vacuum use (10E-10 torr).
Steinmeyer Inc., 56 Middlesex Turn-
pike, Suite 200, Burlington, MA 01803,
(781) 273-6220, www.steinmeyer.com
RS# 471
Precision
vacuum
stages
Model
MT105-LM-
HV precision,
high-per-
formance
stages are
suitable
for ul-
trahigh vacuum
applications. A
compact, two-axis
(XZ) version offers 30 or 50-mm
travel range with a positioning
accuracy of 3 microns and repeat-
RS# 158
Encoder
The Benets of Capacitive Technology
Flexible- interchangeable shaft adapters and programmable resolutions
Rugged- resilient to dust & dirt, temperature & vibration
Green- less than 10 mA current consumption
Simple- quick & easy to assemble on a motor
Revolutionizing
Technology
AMT203
Absolute Encoder Series
AMT100
Incremental Encoder Series
AMT303
Commutation Encoder Series
www.amtencoder.com
PRODUCTS
Linear actuators
Linear actuators with precision-
ground metric ball screws
come in several different lead
accuracies (ranging from 8
to 50 micron) and backlash
specifications (ranging from 0/pre-
loaded to 20 microns). The actuators can be
configured with various
motor and position-
sensing technologies and optimized
for forces up to 500 lb or speeds up
to 20 ips.
Ultra Motion LLC, 22355 Route 48 #21,
Cutchogue, NY 11935, (888) 321-9178, www.
ultramotion.com RS# 472
IEC 61131-3 controller
The CoDeSys embedded controller,
for use with the CPX Series of multi-
functional control terminals, is an IEC
61131-3 compatible programming
environment. Current users of IEC
61131-3 can port over existing code,
libraries, function blocks, etc., reduc-
ing programming time. Six program-
ming languages provided by CoDeSys
let users select one that is most
comfortable for the programmer in a
particular application.
The CPX-CEC module handles
single and multiaxis applications and
operates autonomously or in con-
junction with a host controller, such
as a master PLC. It can also be used as
an intelligent slave in fieldbus-based
systems to provide localized signal
preprocessing.
Festo Corp., 395 Moreland Rd., Box
18023, Hauppauge, NY 11788, (800)
993-3786, www.festo.com/us
RS# 473
RS=159
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Ultrahigh-strength
steel alloy
Temper Tough is a new air-melted, co-
balt-free quench and tempered alloy.
It is a low-cost alternative to cobalt-
containing precipitation-hardenable
alloys.
Temper Tough has a 290-ksi ul-
timate tensile strength, a range of
toughness between 60 and 65 ksiin.,
and fatigue resistance properties
(axial-axial) of 120 ksi (827 MPa).
Carpenter Technology Corp., 2
Meridian Blvd., Wyomissing, PA 19610,
(800) 654-6543, www.cartech.com
RS# 474
The wire duct meets specifications
for control-panel installations in rail-
way stations, airports, hospitals, public
buildings, subways, and ships. Eight
sizes are available: 25 50 mm, 25
75 mm, 37.5 50 mm, 50 50 mm,
50 100 mm, 75 75 mm, and 75
100 mm.
The wire duct, made from Noryl
nonhalogenated, flame-retardant,
low-smoke 5110E material, has an
operating temperature range of 25
to 70C.
IBOCO, 26 Northfield Ave., Edison, NJ
08837, (732) 417-0066, www.iboco.
com RS# 475
Halogen-free wire duct
A new line of halogen-free wire duct
is designed to reduce flame propaga-
tion, eliminate toxins, and minimize
the amount of smoke produced in a
control panel.
RS=160
Turn to Gems Sensors & Controls.
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BUSINESS INDEX
This index includes all significant
references to parent companies
mentioned in feature editorial material
within this issue of MACHINE DESIGN. It
doesnt cite companies listed solely
in the Products and Lit Section. Page
numbers listed refer to the pages where
the articles begin.
Deublin . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Digi-Key Corp. . . . . . . . . . . . . . . . . . . 34, 88
Ecomotors . . . . . . . . . . . . . . . . . . . . . . . . 18
Fabrica Div., EIS. . . . . . . . . . . . . . . . . . . . 25
Farris Automated Systems LLC . . . . . 20
Festo AG . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Festo US. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
France Telecom R&D. . . . . . . . . . . . . . . 32
GMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Georgia Tech, College of Computing 21
Haydon Kerk Motion Solutions . . . . . . 6
International Association for
Continuing Education and
Training. . . . . . . . . . . . . . . . . . . . . . . . 34
International Ultrasonics. . . . . . . . . . . 32
John Deere. . . . . . . . . . . . . . . . . . . . . . . . 34
Kundinger Controls. . . . . . . . . . . . . . . . 34
Lux Research Inc. . . . . . . . . . . . . . . . . . . 31
Lytron Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 54
Massachusetts Institute of
Technology . . . . . . . . . . . . . . . . . . . . 22
maxon precision motors . . . . . . . . . . . 88
Megtec Systems Inc. . . . . . . . . . . . . . . . 52
Microvisk Technologies . . . . . . . . . . . . 64
Misumi USA . . . . . . . . . . . . . . . . . . . . . . . 20
NASA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Nook Industries . . . . . . . . . . . . . . . . . . . . 6
Northwire . . . . . . . . . . . . . . . . . . . . . . . . . 88
Objet Geometries Ltd. . . . . . . . . . . . . . 60
PI (Physik Instrumente) . . . . . . . . . . . . 34
PI Ceramics. . . . . . . . . . . . . . . . . . . . . . . . 34
PTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PUI Audio Inc. . . . . . . . . . . . . . . . . . . . . . 34
R+W America. . . . . . . . . . . . . . . . . . . . . . 88
SNC Space Systems . . . . . . . . . . . . . . . . . 6
Seal Master. . . . . . . . . . . . . . . . . . . . . . . . 88
Shadow Hawk . . . . . . . . . . . . . . . . . . . . . 44
Simrit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Smalley Steel Ring . . . . . . . . . . . . . . . . . 88
Solaro Energy . . . . . . . . . . . . . . . . . . . . . 25
SolidWorks . . . . . . . . . . . . . . . . . . . . . . . . 20
STOBER Drives Inc. . . . . . . . . . . . . . . . . . 58
Strategic Materials. . . . . . . . . . . . . . . . . 27
Sunstone Circuits . . . . . . . . . . . . . . . . . . . 6
Suzuki . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Thomson. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transtecno Group . . . . . . . . . . . . . . . . . 34
Trek Bicycle Corp. . . . . . . . . . . . . . . . . . . 60
Trelleborg Sealing Solutions . . . . 21, 31
UC Berkeley . . . . . . . . . . . . . . . . . . . . . . . 52
U. S. Dept. of Occupational Safety
and Health Administration. . . . . . 31
University of Oxford . . . . . . . . . . . . . . . 22
Wulfinghoff Energy Services Inc. . . . 55
Zero-Max Inc.. . . . . . . . . . . . . . . . . . . . . . 74
AAA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
AST Bearings . . . . . . . . . . . . . . . . . . . . . . 34
Aerojet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Altech. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Amacoil . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Anchor Glass Container Corp. . . . . . . 27
Autodesk Inc. . . . . . . . . . . . . . . . . . . . . . . 61
AutomationDirect . . . . . . . . . . . . . . . . . . 6
Avago. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B&R Industrial Automation Corp. 34, 74
Bosch Rexroth. . . . . . . . . . . . . . . . . . . . . 34
Bosch Rexroth AG . . . . . . . . . . . . . . . . . 38
CMM Group LLC, The. . . . . . . . . . . . . . . 54
California Energy Commission . . . . . . 6
Comsol Inc.. . . . . . . . . . . . . . . . . . . . . . . . 64
Container Recycling Institute . . . . . . 27
Danfoss VLT Drives. . . . . . . . . . . . . . . . . 34
Dassault Systmes SolidWorks Corp. 61
RS=161
While every effort has been made to
ensure the accuracy of this index, the
publisher cannot be held responsible for
any errors or omissions.
BistributedbyAmacoil,nc.
F0Box2228,AstonFA,1O014
Fhone.(610)485-8300
Zero backlash. Jam-proof design.
For positioning & reciprocating motion applications
Smooth movement; ultra-low maintenance
uhing
Rolling Ring lineardriveshave/erolaywhentheshalt

isrotatedevenduringreversal.Thethreadlessshaltwon't
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simlyslisinsteadolchurningandgrinding.
xamle allcallaas: material handling machines, winding
equipment, test and measurement devices, packaging &
converting equipment.
uklag rlves are available separately or
on shaft in custom assembly.
WlJe raage al slzes for varying linear
speeds & axial thrust requirements.
Simple set-up & operation
Some models feature mechanical control
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Request a Brochure or CD-ROM
1(800)252-2645
Email: amacoil@amacoil.com
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Manually slide drive
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Ro||ingRing
|ineardrives
ADVERTISER INDEX
RS# . . COMPANY . . . . . . . . PAGE
115 . . . . Aerotech, Inc.. . . . . . . . . . . . . . . . . 16
149 . . . . Agathon Machine Tools. . . . . . 63
162 . . . . Amacoil, Inc. . . . . . . . . . . . . . . . . . . 83
117 . . . . Ametek Inc.. . . . . . . . . . . . . . . . . . . 19
142 . . . . ASM Sensors . . . . . . . . . . . . . . . . . 53
133 . . . . Associated Spring/Raymond 35
128 . . . . Atlantic Design & Mfg. . . . . . . . 30
103 . . . . Automationdirect.com . . . . . . . .3
138 . . . . Avago Technologies U.S. Inc . 49
122 . . . . Avago Technologies U.S. Inc . 26
167 . . . . Bimba Manufacturing Co. . . . bc
136 . . . . Celesco Transducer . . . . . . . . . . 39
148 . . . . CounterBalance Corporation 63
159 . . . . CUI Inc. . . . . . . . . . . . . . . . . . . . . . . . 80
105 . . . . Digi Key. . . . . . . . . . . . . . . . . . . . . . . . .7
107 . . . . ebm-papst . . . . . . . . . . . . . . . . . . . . .9
158 . . . . Electro Sensors. . . . . . . . . . . . . . . 79
104 . . . . Exair Corporation . . . . . . . . . . . . . .5
146 . . . . Fabrico. . . . . . . . . . . . . . . . . . . . . . . . 59
168 . . . . Forest City Gear . . . . . . . . . . . . . . 73
161 . . . . Gems Sensors . . . . . . . . . . . . . . . . 82
139 . . . . Gortite, Div of A&A Mfg Co., Inc. 57
164 . . . . Gortrac, Div of A&A Mfg. Co., Inc. 87
130 . . . . Helical Products Co, Inc.. . . . . . 51
141 . . . . Igarashi Motor Sales. . . . . . . . . . 57
135 . . . . Intech Corporation. . . . . . . . . . . 38
120 . . . . Intelligent Motion Systems, Inc. 24
121 . . . . Intelligent Motion Systems, Inc. 25
143 . . . . Kaydon Bearings Division. . . . 55
109 . . . . KB Electronics Inc . . . . . . . . . . . . 10
137 . . . . Lee Spring Co . . . . . . . . . . . . . . . . 43
147 . . . . Martin Sprocket & Gear . . . . . . 63
150 . . . . Master Bond, Inc.. . . . . . . . . . . . . 75
114 . . . . Moog Inc . . . . . . . . . . . . . . . . . . . . . 15
112 . . . . National Instruments Corp . . 13
123 . . . . Nook Industries Inc . . . . . . . . . . 27
108 . . . . Novotechnik U.S., Inc. . . . . . . . . 10
160 . . . . Objet Geometries. . . . . . . . . . . . 81
163 . . . . Ogura Industrial Corp. . . . . . . . 87
134 . . . . Onvio, Llc . . . . . . . . . . . . . . . . . . . . . 37
102 . . . . Phillips Plastics Corporation . . .1
156 . . . . Photofabrication Engrg Inc. . 78
101 . . . . PTC . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC
140 . . . . Pyramid Inc. . . . . . . . . . . . . . . . . . . 57
124 . . . . Quality Bearings &
Components. . . . . . . . . . . . . . . . . 28
126 . . . . Quality Transmission
Components. . . . . . . . . . . . . . . . . 28
. . . . . . . . . Rino Mechanical Components
Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
111 . . . . Rockwell Automation. . . . . . . . 12
113 . . . . Roxtec Inc . . . . . . . . . . . . . . . . . . . . 14
155 . . . . SAB North America . . . . . . . . . . 77
151 . . . . Santa Barbara Imaging, Llc. . . 75
152 . . . . Seal Master Corporation. . . . . 75
144 . . . . Sealeze Corp . . . . . . . . . . . . . . . . . 56
166 . . . . Simrit Group. . . . . . . . . . . . . . . . . IBC
131 . . . . SKF Industries Inc . . . . . . . . . . . . 33
132 . . . . Smalley Steel Ring Company 34
110 . . . . SolidWorks Corporation . . . . . 11
106 . . . . Spirol International Corp. . . . . . .8
125 . . . . Steinmeyer, Inc. . . . . . . . . . . . . . . 28
118 . . . . Symmco Inc.. . . . . . . . . . . . . . . . . . 22
153 . . . . Techno Inc. . . . . . . . . . . . . . . . . . . . 75
154 . . . . Thomas Products Div.. . . . . . . . 76
165 . . . . Trim-Lok Company . . . . . . . . . . 88
116 . . . . Turck Incorporated. . . . . . . . . . . 17
119 . . . . ZERO-MAX . . . . . . . . . . . . . . . . . . . 23
157 . . . . ZOOM RP.COM . . . . . . . . . . . . . . . 78
RS=162
MAOHlNE Design.com 83 MAY5,2011
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The Great Moonbuggy race
Two teams from Teodoro Aguilar Mora Vocational High School,
Yabucoa, Puerto Rico, drove off with first and second place in the
high-school division of the 18th annual NASA Great Moonbuggy
Race. For the second straight year, the University of Puerto Rico in
Humacao blew past its competitors to come
in first in the college division. The University
of Puerto Rico is the only school that has en-
tered a moonbuggy in every race since the
event began back in 1994.
Students from around the world are chal-
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powered buggies. Over 70 high-school, col-
lege and university teams from 22 states,
Puerto Rico, Canada, Germany, India, and
Russia, participated. The overall goal of the
competition is to increase the interest in sci-
ence, technology, engineering, and math,
so students will pursue careers in technical
fields that will benefit NASA, the nation, and
mankind. The event is organized by NASAs
Marshall Space Flight Center in Huntsville.
This years race also celebrated the 40th an-
niversary of the first use of a crewed Lunar
Roving Vehicle on the moon in July 1971. MD
Photos courtesy of NASA/MSFC
Cheap gas
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BACKTALK
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List rentals: Marie Briganti,
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RS=165
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RS# 167

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