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Dng de-04012012

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Dng de-04012012

  1. 1. PM40069240 Canadian firm, General Fusion, aims to fire up the first net gain fusion reactor. 14 Solidworks World 2012 looks to the future of CAD software 22 Resolvers stage a come back in motion control applications 38 Fluid Power Roundtable 2012 $27.00 | March/April 2012 aims to fire up the first net gain fusion reactor.Commercial Fusion FLUID POWER BUYERS’ GUIDE P.30 1-DES.indd 1 12-04-18 12:04 PM
  2. 2. Solid Edge. Design better. The best product designers have an edge. Solid Edge 3D CAD Software Product designers have never been more important to the success of their companies. Creative, efficient designers are the key to delivering better products faster. Too often, however, CAD tools get in the way of their tal- ent—and the company’s success. Solid Edge with synchronous technology is different. It helps you create designs more intuitively. It helps you instantly revise any design, even complex designs from other CAD systems. And it’s built on our bulletproof Parasolid kernel – the industry-standard for reliable performance. Our new “Get the Edge” program shows how Solid Edge will help you reach your design potential—and help your company realize greater success. Learn more today at www.siemens.com/plm/gettheedge or call 800-807-2200. 2011siemens_SE_DE_OCT2011.indd 1 10/3/11 8:38:46 AM 2-5-DES.indd 2 12-04-11 12:27 PM
  3. 3. :38:46 AM 2-5-DES.indd 3 12-04-11 12:27 PM
  4. 4. SCHAEFFLER GROUP INDUSTRIAL The Straight Line on Linear Solutions Operational reliability begins with design. INA linear products from Schaeffler are designed with maximum load capacities across the range, as well as high rigidity and misalignment compensation within series designs. Patented lubrication and sealing technology ensures maintenance free operation, while continuous product innovation embraces linear solutions with increasingly longer and quieter service lives. Behind design is versatility and service. INA offers an extensive range of products backed by a comprehensive service center to quickly create and deliver highly customized linear assembly solutions. INA linear solutions from Schaeffler… the straight line to operational reliability. www.schaeffler-group.com Straight Line 10/24/07 12:06 PM Page 1 2-5-DES.indd 4 12-04-11 12:27 PM
  5. 5. 5IN THE NEWS 8 Canadian Satellite Design Challenge heats up 8 Schneider Electric Canada appoints new president and vice president 8 General Donlee Canada appoints new CEO 10 Canadian bike maker leverages CFD for latest model 10 EADS, Creaform form partnership 10 SCS Supply Group changes name 10 NKK Switches names new president 12 Canadian automotive R&D receives a funding boost 12 COM DEV one of the best employers for new Canadians Annual Subscription Rate In Canada: $52.95 (1 year) $71.95 (2 year) Outside Canada: $99.95 (1 year) Single Copy In Canada: $10.00 Outside Canada: $22.00 Directory Rates In Canada: $27.00 Outside Canada: $45.00 Reader Service Contact Information ecallaghan@bizinfogroup.ca T: Toronto 416 442 5600 X 3538 Elsewhere -866-543-7888 Mail: Business Information Group Design Engineering Circulation Dept 80 Valleybrook Drive North York, ON M3B 2S9 Printed in Canada READER SERVICES Contents | Volume 58, No. 2 14 CAD Report Solidworks World 2012: As CAD software approaches maturity, Solidworks pushes to generate excitement and satisfy user requests at annual conference. 22 Motion Control When choosing between position feedback components, resolvers may just have an edge over optical encoders. 24 Idea Generator The latest in industrial products including motion control, power transmission and robotics 28 Canadian Innovator Kick Starter: Canadian engineer perfects a low-cost prosthetic to help amputees. Columns 18 Commercial Fusion Canadian firm aims to fire up the world’s first net gain fusion reactor 34 Maximizing Hydraulic Efficiency Choosing the most efficient control option requires a full understanding of a hydraulic application. 38 Fluid Power Roundtable 2012 Canadian leaders discuss the market, globalization and the next generation of fluid power professionals. 42 On the Ball Integrator saves time and expense with new ball valves and end connections. Features 14 22 28 38 www.design-engineering.com March/April | 2012 18 2-5-DES.indd 5 12-04-11 12:27 PM
  6. 6. 6 EditorialViewpoint I enjoy hearing from you so please contact me at MMcLeod@design-engineering.com and your letter could be published in an upcoming issue. @ Every year, another federal budget comes out, sending various sectors into a flurry of cheers for increased spending and dire warnings of the consequences funding cuts will bring about. There may be much to argue about in the budget unveiled in March, but it’s hard to dispute that innovation isn’t high on its list of objectives. In total, it allocates almost $1.6 billion in innovation spending. Specifically, the budget is interested in fostering the broader sense of the word ratherthanfocusingonthenarrower“invention”definition.Inotherwords,itplaces greater emphasis on the “D” rather than the “R” in Research and Development. Thrown into the mix is the often unstated “C” for Commercialization. While it can be argued that Canadians are every bit as creative as their counterparts in other industrialized countries, we often get poor marks for successfully bringing those creations to market. Since the 1980s, the Conference Board of Canada has given Canada a “D” grade in innovation. That’s not due as much to a lack of patent filings or ground-breaking research, but to the comparatively little profit derived from either. According to the Global Innovation Index for 2011, Canada ranked eighth in innovation inputs and tenth in outputs but 54th in terms of innovation efficiency. To engineer this shift towards measurable results, the budget closely follows recommendations put forward in the Expert Panel Report, Innovation Canada: A Call to Action. First and foremost, the report advocated restructuring the Scientific Research and Education Development (SR&ED) tax credit program. The most significant change is that, starting in 2014, capital expenditures will no longer be eligible.TheintentbehindthepolicychangesistotakecomplexityoutoftheSR&ED application process and shift compensation toward SME’s labour-related costs. While the budget squeezes SR&ED, new funding is being pumped into more direct forms of support, again, in line with the Expert Panel Report. For example, the budget proposes doubling contributions made to the Industrial Research Assistance Program (IRAP), an initiative administered by the National Research Council to fund innovation within SMEs. In addition, the Canada Foundation for Innovation will receive $100 million annually,fornextfiveyears,tosupporttheprivatesectorthoughresearchconducted in Canadian Universities. And, to address the dearth of Canadian VC money, the budgetallocatesanextra$100milliontotheBusinessDevelopmentBank’sventure capital activities as well as $400 million to create large-scale venture capital funds. The only panel major recommendation missing from the budget was the forma- tion of a proposed Industrial Research and Innovation Council, an arm’s-length funding and delivery agency with focus on supporting business innovation. While not formally addressed, the government hasn’t rejected the idea for the future. It’s hard to anticipate what affect all this budgetary effort will ultimately have on Canadian innovation. Socially engineering success is a tricky business; govern- ment funding and economic incentives have a tendency to bounce in unanticipated directions. But whatever your political leanings, the government is at least making an honest effort to foster innovation. Like any government initiative, it will depend on how the recipients choose to use the money allocated. Mike McLeod Engineering R&D www.design-engineering.com Publisher Alan Macpherson (416) 510-6756 AMacPherson@design-engineering.com Group Editorial Director Lisa Wichmann (416) 510-5101 LWichmann@canadianmanufacturing.com Accounts Manager Laura Gergley (416) 510-5230 lgergley@design-engineering.com Editor Michael McLeod (416) 442-5600 ext. 3231 mmcleod@design-engineering.com Technical Field Editor Pat Jones, P. Eng. Art Director Kathy Smith (416) 442-5600 ext. 3215 KSmith@plant.ca Market Production Manager Jessica Jubb (416) 510-5194 jjubb@bizinfogroup.ca Circulation Manager Cindi Holder (416) 442-5600 ext. 3544 CHolder@bizinfogroup.ca BIG Magazines LP Executive Publisher Tim Dimopoulos Vice-President of Canadian Publishing, Alex Papanou President of Business Information Group, Bruce Creighton Publications Mail Agreement #40069240 ISSN number: 0011-9342 Privacy Notice: From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 E-mail: privacyofficer@businessinformationgroup.ca. Mail to: Privacy Officer, 80 Valleybrook Drive, North York, ON M3B 2S9 Subscriber Services: To subscribe, renew your subscription or to change your address or information contact us at 1-800-387-0273. Subscription Price: Canada: $52.95 for 1 year; $71.95 for 2 years; $10 for single copy. Outside Canada: $99.95 for 1 year; $22 for single copy. Directory/buyer’s guide: Canada $27; Outside Canada $45. Design Engineering, established in 1955, is published 6 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. Published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. Tel: 416-442-5600, Fax: 416-510-5140 80 Valleybrook Dr., Toronto, ON M3B 2S9. Contents of this publication are protected by copyright and must not be reprinted in whole or in part without permission of the publisher. DE receives unsolicited features and materials (including letters to the editor) from time to time. DE, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. DE accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. DE is indexed in the Canadian Business Index by Micromedia Ltd., Toronto, and is available on-line in the Canadian Business & Current Affairs Database. We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities. March/April | 2012 www.design-engineering.com 6-7-DES.indd 6 12-04-11 3:57 PM
  7. 7. Jefferson Electric Buck-Boost Transformers Buck-boost transformers are designed to maximize the performance and life of electrical equipment. They are typically used to power loads with specific voltage requirements that differ from the available line voltage. When connected as an autotransformer, these units can buck (lower) or boost (raise) available line voltage from 5 to 20 percent. When connected as an isolation transformer, they can be used to step down supply power to low voltage circuits at the nameplate rating listed. Features • Single-phase units from 50VA to 2kVA (individual units required for multiple phases) • Encapsulated with electrical grade resin • Cores of high-quality electrical steel • 60 Hz operation • NEMA 3R-rated enclosure • Slotted mounting holes for quick and easy mounting • 10-year limited warranty (mfg. defects) • Built in accordance with UL1446, CAN/CSA - C22.2 No. 0 • Agency Approval UL File #E4466 www.automationdirect.com/power www.automationdirect.com 1-800-633-0405 Go online or call to get complete information, request your free catalog, or place an order. Control Transformers starting at: $37.50 (PH50PG) Encapsulated Transformers starting at: $86.00 (C1FC10WE) Also Available Free standard shipping is available for orders totaling over $300 U.S. (except for orders which require LTL shipping, see Web site for details). Also, save on brokerage fees when shipping standard ground to Canada - you can choose to allow AutomationDirect to nominate a broker for your shipment for parts shipping via standard ground. This can save you big on brokerage fees. See Web site for details and restrictions - www.automationdirect.com/canada Two series available: • 240 x 120 VAC to 24 x 12 VAC • 240 x 120 VAC to 32 x 16 VAC Applications • Air conditioners • Heating elements • 277 Volt supply for lighting systems Our shipping policies make it easier than ever to order direct from the U.S.! 6-7-DES.indd 7 12-04-11 12:26 PM
  8. 8. 8 Schneider appoints new president Schneider Electric Canada has appointed Daniel Peloquin as President, replacing Gary Abrams, who has been appointed Transforma- tion Leader, Schneider Electric North America IT Transformation Initiative. Peloquin’s background includes executive leadership in general management, engineer- ing, sales, marketing and operations. He graduated from the École Polytechnique de Montréal with a Bachelor of Engineering degree, majoring in power systems and is a registered Professional Engineer from the Ordre des Ingénieurs du Québec. Replacing Peloquin as VP of services & projects, Leonce Fraser will lead activities that include installed base services of electrical distribution systems; energy management services; the projects and engineering center; and customer operations. Leonce holds a Bachelor’s degree in mechanical engineering from the University of Québec and an MBA from HEC Montreal in international business. www.schneider-electric.ca General Donlee Canada appoints CEO General Donlee Canada, Inc. announced that Garen Mikirditsian has been appointed CEO and CFO. In addition, Bruce Van Nus has joined the company as Chief Operating Officer. Prior to joining General Donlee in April 2011, Garen was VP of a private investment firm and spent three years in the mergers & acquisitions group of BMO Capital Markets. He is a graduate of Concordia University’s John Molson School of Business where he received a Master of Business Administration degree, and holds a Bachelor of Engineering degree from the mechanical engi- neering honours program at McGill University. Bruce Van Nus, Chief Operating Officer, brings over twenty years of manufacturing experience, including fourteen years with Bombardier Aerospace. www.generaldonlee.com Up Front Canadian Satellite Design Challenge heats up Following a critical design review held at the CSA’s David Florida Lab in Ottawa this past March, the Canadian Satellite Design Challenge (CSDC) has come down to three leading Canadian University teams. Theprimaryobjectiveofthechallengeisforuniversitystudentstodesign and manufacture an operational “cubesat” satellite, predominantly using off-the-shelf components. Of the 12 universities competing, teams from Concordia Univer- sity, University of Manitoba and University of Saskatchewan have taken the top three positions so far. Concordia University’s ConSat-1, designed by a 30-student team, is tasked with studying the South Atlantic Anomaly of the Van Allen radiation belt, to discover how it works and affects space weather. University of Manitoba’s T-Sat cube satellite carries two scientific payloads. The primary payload will study a colony of small organisms calledtardigradesandmonitortheirbehaviorwhenexposedtotheharsh space environment. The second remote sensing payload is designed to learn more about the Sun through spectroscopy. University of Saskatchewan Space Design Team’s (USST) nano- satellite is intended to measure and map plasma densities in the Earth’s ionosphere to help improve the accuracy of multi-million dollar GPS satellites. Presently, the satellites are undergoing full space environmental and launch qualification testing. When the contest wraps in October, one or more winning teams will be chosen to have their satellite launched into outer space where they will conduct its experiment at 26,280 kilometres per hour, approxi- mately 700 kilome- tres above the Earth. www.geocentrix.ca DesignNews March/April | 2012 www.design-engineering.com Daniel Peloquin Leonce Fraser Members of University of Saskatchewan’s Canadian Satellite Design Challenge team. Concordia’s ConSat-1 is one of 12 “CubeSat” satellites vying for a trip to Earth orbit. 8-13-DES.indd 8 12-04-13 2:06 PM
  9. 9. Wire leads to be 7” + 1/8” with crimped terminal 10258333-2 FKM seals 5-volt coil less than 0.5 watt “Cleaned for Oxygen Service” internal components Brass base (no plating needed) Toggle-operated manual by-pass valve in base Integrated needle valve for precise flow control 1/2” maxMounting holes Stainless Steel coil housing CUSTOM er - solutions Clippard Instrument Laboratory,Inc. 513-521-4261 www.clippard.com/customsolutions Wainbee Ltd. 888-WAINBEE www.wainbee.com Providing custom products and value-added assemblies based on the most successful miniature pneumatic line in the world! 8-13-DES.indd 9 12-04-11 8:05 AM
  10. 10. 10 SCS Supply Group changes name Applied Industrial Technologies, LP announced that its SCS Supply Group Inc. business, includ- ing Toronto Bearing Belting, CBS Equipment, and Jake’s Bearings, has changed its operating name to Applied Industrial Technologies, effec- tive April 1, 2012. Applied Industrial Technologies, LP, head- quartered in Saskatoon, is the Canadian- operated subsidiary of Applied Industrial Technologies, Inc. that operates more than 40 locations in Canada. www.appliedcanada.com NKK Switches names new president NKK Switches has appointed Michael Wada as president of NKK Switches, succeeding Kiyoko Toyama. Wada has been with NKK since 2006, previously serving as vice president of business development. www.nkkswitches.com Up Front Canadian bike maker leverages CFD analysis for latest racing model Canadian high-end bicycle company, Cervélo—known for the distinctive airfoil shape of its bikes’ down pipe—teamed up with, Intel, R Systems and engineering software company, CD-adapco, to test the design of its S5 racing bike before its release. As a result, the company says the S5 doubles the aerodynamic advantage its S3 model had over traditional road bicycles. Anyone who has ridden a bicycle on a windy day knows aero- dynamics play a huge role in cycling. Drag makes up 80-90 percent of the resistance experienced by an average rider on a flat road— 80 percent of this drag is due to the rider, with the remaining 20 percent down to the bicycle itself. In the design of the S5, Cervélo ran simulations using the STAR-CCM+ Power-on-Demand licensing scheme on R Systems HPC resources powered by multi-core Intel processors. STAR- CCM+ Power-on-Demand allows users to run STAR-CCM+ simulations using an on-demand cloud computing service. Based on extensive wind tunnel testing and Computational Fluid Dynam- ics (CFD) simulation, Cervélo says the S5 is the most advanced aerodynamic road bicycle it has yet developed. www.cd-adapco.com www.cervelo.com EADS, Creaform form partnership EADS and Creaform have entered into a technological partnership agreement covering 3D optical measurement for aerospace and defence applications. This 5-year agreement provides for the development of innovative applications in the field of optical 3D measurement for non-destructive testing (NDT), test monitoring and form and surface measurement, applied to aeronautics, space and defence. “EADS has successfully implemented Creaform’s 3D scan- ning and optical measurement technologies since 2008. The developments planned will enable EADS to reduce its develop- ment time cycle, create synergies and reduce the time-to- market of its new products,” said Yann Barbaux, Head of EADS Innovation Works. Comprising Airbus, Astrium, Cassidian and Eurocopter, EADS employs more than 1600 people in Canada through EADS Canada, Eurocopter Canada, Composites Atlantic, Cassidian Communications, Aerolia and Vector Aerospace. www.creaform3d.com DesignNews March/April | 2012 www.design-engineering.com Rod Ends and Spherical Bearings designed and manufactured to Aurora's exacting standards for quality and durability. Registered and Certified to ISO-9001 and AS9100. From economy commercial to aerospace approved, we've got it all ! Aurora Bearing Company 901 Aucutt Road Montgomery IL. 60538 Complete library of CAD drawings and 3D models available at: w w w . a u r o r a b e a r i n g . c o m Aurora-Where_the_Action_Is:Aurora 11/5/10 2:27 PM Page 1 8-13-DES.indd 10 12-04-13 2:06 PM
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  12. 12. 12 Canadian automotive RD receives funding boost Six new projects—supported by Automotive Partnership Canada initiative—were announced at the University of Windsor in March. Intended to advance RD in Canada’s automotive industry, these university-industry partnerships will receive approximately $34 million from Automotive Partnership Canada and other industry partners, including Natural Sciences and Engineering Research Council of Canada (NSERC), Canada Foundation for Innovation (CFI) and National Research Council Canada (NRC). The projects include a million- dollar investment to assist in the devel- opment of manufacturing processes to produce lighter-weight car parts, headed by Daniel Green, a UWindsor mechanical automotive and materials engineering professor. In addition, Dalhousie University received a total of $6.4 million to develop a low-cost method of producing titanium parts for automotive applications and another project to identify cell chemistries optimize battery life. Other awards include $3.7 million to the University of Waterloo to examine multi-material automotive structures; $5.5 million to Simon Fraser University to develop polymer electrolyte membrane fuel cells with lower platinum require- ments; and $2.3 million to McMaster University to identify improvements to lithium batteries. Announced by the Government of Canada in April 2009, Automotive Part- nership Canada is a five-year, $145-million initiative that supports collaborative RD and pushes the Canadian automotive industry to greater levels of innovation. www.apc-pac.ca COM DEV one of the best employers for new Canadians COM DEV International Ltd., a leading manufacturer of space hardware subsys- tems, announced that it has been named one of the “Best Employers for New Canadians.” This designation, awarded by the editors of Canada’s Top 100 Employers, recognizes employers that offer programs to assist recent immi- grants in making the transition to a new workplace and a new life in Canada. At its head office in Cambridge, Ontario, the company’s cafeteria displays 84 flags representing every country which is the birthplace of at least one of COM DEV’s 1,000+ employ- ees. The company also partners with agencies such as the YMCA to mentor new immigrants in efforts to orient them to Canadian culture and assist them with job searching. COM DEV also offers on-site, one-on-one English language programs. www.comdevintl.com DesignNews March/April | 2012 www.design-engineering.com 8-13-DES.indd 12 12-04-13 2:06 PM
  13. 13. Introducing the first wireless and battery-less push button that can be used worldwide Harmony XB5R installs easily and is globally compatible, enhancing mobility of operations anywhere in the world The innovation built into the Harmony™ XB5R wireless, battery-less push button benefits everyone: easy set-up for you, improved mobility of operator and equipment for your customers. Easier for you With its unique wireless technology, the Harmony XB5R requires no cabling, saving you time and money with every installation (up to a 20 per cent reduction in overall installation costs compared with hard-wired solutions). Plus, its 2.4 GHz radio frequency makes it suitable for use anywhere in the world without fear of creating interference with other wireless devices. Now, you can ship anywhere in the world with confidence while giving your customers the ability to unlock the full potential of your machines and applications wherever they might be. Easier for your customers, too They will love Harmony XB5R for its robust design and freedom of mounting, making it especially useful on equipment such as conveyors and mobile devices. Customers can add external antennas to extend the coverage range and have more than one unit controlling the same equipment, i.e., many buttons can turn on/off a single receiver and vice versa, which becomes critical for industries where people and equipment constantly move around. And, with the battery-free design, they’ll never have to worry about replacing or recycling batteries and can benefit from the uninterrupted availability of their operations. Build with Harmony XB5R wireless, battery-less push buttons and build your competitive edge. Discover the rest of the Harmony family Harmony XB5 Ø 22 mm plastic push buttons and pilot lights Ease through innovation ©2012 Schneider Electric. All Rights Reserved. Schneider Electric and Harmony are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. All other trademarks are property of their respective owners. 1415 S. Roselle Road, Palatine, IL 60067 • Tel: 847-397-2600 • Fax: 847-925-7500 • www.schneider-electric.com • 998-4551_US Visit www.SEreply.com Key Code m921v Harmony XB5R transmitter Harmony XB5R receiver Harmony XB5 Ø 22 mm plastic push buttons and pilot lights Harmony XB4 Ø 22 mm metal push buttons and pilot lights Limited time offer! Download the FREE application video and be entered to win an Apple iPad2! Harmony XB4 Ø 22 mm metal push buttons and pilot lights 2011 Winner ©2012 Schneider Electric. All Rights Reserved. Schneider Electric and Harmony are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. All other trademarks are property 8-13-DES.indd 13 12-04-11 8:05 AM
  14. 14. March/April | 2012 www.design-engineering.com 14 If a CAD user conference is any indication, the healthy attendance at SolidWorks World 2012 suggests that the economic rebound is taking hold in North America. Nearly 5,650 registered attendees descended on San Diego Conven- tion Center this past February. That’s significantly larger than the approximately 4,300 of the year previous. To kick off the conference, CEO Bertrand Sicot’s remarks during the first general session were somewhat overshadowed by the small, child-like robot—called the NAO—that intro- duced him. Designed in SolidWorks, NAO robot is the brain- child of Paris-based Aldebaran Robotics and is intended to, among other things, help autistic children learn. Other highlights of the show included presentations by Mike Rowe from Discovery’s Dirty Jobs; NEPTUNE Canada, the world’s first underwater observatory network; and a sit- down interview keynote address between Sicot and the father of the Apple iPod, Tony Fadell. While these presentations were entertaining and informa- tive, SolidWorks World this year lacked the buzz of prior years. In the history of the event, Day 3 is typically the big reveal when execs show off what’s coming in the next release. Typically, attendees sit at the edges of their seats, eager to hear how their favorite design software will become that much more powerful. The 2012 event lacked that kind of excitement. There was simply a lack of cool new stuff. IsthisonlyaSolidWorksproblem?Notreally.It’sanindustry problem. Now that CAD tools are so robust, it’s questionable if they can be pushed much further; 3D CAD has matured to the point that most of the real cool stuff has been done. Running downthetop10bestenhancementstoexpectinthe2013release shows that there are only one or two real enhancements and a handful of nice-to-haves but one disappointment in the lot. 10Assembly visualization: You will be able to sort parts and assemblies depending on which is more graphically intensive. Combined with the feature lock capability of last year’s 2012 release, it could make working on large assemblies much easier. 9eDrawings markup import into SolidWorks drawings: Not too many people use eDrawings but for design shops that do, this is a must have. Being able to import the markups from an eDrawing into a SolidWorks drawing will likely save having to flip between multiple windows (SolidWorks and eDrawings) to get a drawing done and just do it all directly in SolidWorks. Two thumbs up! 8SectionXpert: You will be able to create sections quickly without having to make a sketch to start the command, saving a few mouse clicks. Everyone wants to save mouse clicks so this is a definite win-win. Plus, there is some added functionality to make more complex section cuts. 7Revision clouds: This is self explanatory and been in the industry since God was a child. In this case, all I have to say is that it’s about time they added this to the software. 6Bring multiple components into assembly at once: Again, this is a mouse click saver. Anything to keep carpal tunnel syndrome at bay is good in my books. 5Favorite features folder added to feature manager: Put- ting common features you use in an accessible folder in the feature manager is a good idea but to get users to put this to use might be a bit of a challenge. 4Dowel holes added to the hole wizard: Much like the revision cloud ability, this comes under “It’s about time”. 3Surface intersect: With this command, you can add and subtract material to a solid body in one step using surfaces. This is something that could be pretty awesome. CADReport As CAD software and the industry approach maturity, Solidworks pushes to generate excitement and satisfy user requests at annual conference. By Ben Eadie S m S SI to in th an th al 14-16 DES.indd 14 12-04-11 8:05 AM
  15. 15. SINAMICS – General purpose and motion control drives www.siemens.ca/sinamics Seamless and integrated drives SINAMICS is the most comprehensive drive family available today. It is based on a simple, integrated engineering concept, inherently providing innovative, energy-efficient solutions for the future. Whether it’s a matter of efficient pumping, ventilating and compressing, or precise movement, processing, or machining, the number of application areas for frequency converters is almost endless. So it’s good that there is one family of drives for all of these areas that fulfills every requirement perfectly. Our SINAMICS portfolio represents uniform engineering, extremely high-efficiency, and convenient operation. No matter which direction you wish to go, Siemens offers you the optimum drive – from one source for every application. For more information contact Siemens Customer Interaction Centre: 1-888-303-3353 14-16 DES.indd 15 12-04-11 8:05 AM
  16. 16. March/April | 2012 www.design-engineering.com 16 2Equation entry everywhere: Being able to add equations on the fly while designing is great to have. I take notes when coming up with conceptual designs on things I need to re- address once the initial approvals are done. The most common note I take is where to add smart dimensions using formulas to be able to generate multiple iterations quickly for final design and prototyping. Now, being able to add them while in concept phase will help speed up the prototype phase. 1Backwards compatibility: This issue has been seen on the top 10 list for years and, on the surface, it seems like it’s finally being addressed. But there is a significant limitation. Backwards compatibility is limited to 2013 files being saved back to 2012, provided you have the latest service pack. In general, I think SolidWorks is going in the right direc- tion; when a recent user group meeting was polled if they could use backward compatibility, everyone raised their hands. However, when shown the current backwards compatibility functionality being proposed and asked if this would help them, no one raised their hands. Why? The fact is that users are just as shy to upgrade to the latest service pack as they are to upgrade to a new version for fear that bad things happening to their data. So if someone is using one service pack back from the last released for 2012, then this functionality will simply not work. For this group of users, this is the critical detail that makes this a bitter sweet enhancement. On the one hand, SolidWorks is adding what the users asked for. On the other, the company has limited compatibility to such an extent that it misses the mark. Hope- fully, this is just the start of SolidWorks’ backwards compatibil- ity and it will improve in future releases. SolidWorks has been taking care of bugs and stability issues for the last few years and I see a little trickle of new innovative things coming to light now that the software is more stable and less buggy. It’s hard to say what the future holds for SolidWorks. There has been talk of some great stuff coming from the company’s staff, but it’s all just rumors at this point. The company has been tight lipped, and only time will tell if they can get their mojo back with some super cool features or innovative solutions to CAD issues in the next year or two. SolidWorks is now leaving the stability and bug phase of the development cycle, so my fingers are crossed that we will see a resurgence of cool things in the future. DE www.solidworks.com/sww Ben Eadie is an Aeronautical Engineering Technologist, as well as a prolific CAD industry blogger, developer, trainer and video caster. CADReport Anything Less Costs More sChUnK is the global leader in gripping systems, Clamping technology and robot eoAt components. turnkey solutions are available from sChUnK for oeM, integrator and end User needs in industrial, Packaging, Pharmaceutical and health Care. www.schunk.com | info@ca.schunk.com | 905-712-2200 EXCEPTIONAL PRECISION FROM THE COMPETENCE LEADER FOR CLAMPING TECHNOLOGY AND GRIPPING SYSTEMS. SCHUNK_GrippingSystems_91x130_CA_0112.indd 1 01.02.12 13:54 14-16 DES.indd 16 12-04-11 8:05 AM
  17. 17. 14-16 DES.indd 17 12-04-11 8:05 AM
  18. 18. March/April | 2012 www.design-engineering.com 18 By Treena Hein In a world beset by fossil fuel energy woes, fusion energy is holiest of Holy Grails. A working fusion reactor would not only release large amounts of energy but, unlike nuclear fission plants, they can’t melt down. They’re also significantly “cleaner,” in that a fusion reaction only uses small amounts of an abun- dant fuel (hydrogen isotopes tritium and deuterium), which is only weakly radioactive. The problem is, no one has yet created a net gain reactor (more energy out than in), although many well-funded programs are actively pursuing it. It’s not surprising, considering the daunting challenges involved. Similar to the process that drives the Sun, a fusion reaction—meldingtwohydrogenatomstoformhelium—requires heatingthereactorfueltogalactic-scaletemperaturesandcrushed underintensepressures.Ofcourse,youalsoneedavesselcapable of producing and containing these thermonuclear conditions. Consequently, building fusion reactors will take decades, as wellasenormousexpenditures,whichiswhyenthusiasmforthis type of energy production has dampened. However, these same issues have many in the field keeping a close eye on a Canadian company,GeneralFusion,anditscomparativelylow-techapproach tofusionpower.TheBurnaby,BC-basedcompany’smechanical design sidesteps the massive costs of other leading approaches. “Fusion reactions require plasma to be heated to near 150 million˚C, and that requires a lot of energy,” says Michael Delage, General Fusion’s vice president of business development. “Where you get this energy, and how you deliver it to the fuel, has a big effect on system cost.” Reactor Design 101 To appreciate General Fusion’s concept, it’s important to under- stand how it differs from the two leading projects. ITER, a multinational collaboration based in France, is the larger and uses an approach called magnetic confinement. Using this method, a stream of super-heated tritium and deuterium gas, or plasma, is contained in a donut-shaped vacuum vessel called a tokamak. Super conducting magnets heat and compress the plasma to create the fusion reaction. The National Ignition Facility (NIF) at Lawrence Livermore National Laboratories is pursuing the other approach, inertial confinement.Itemploys192laserbeamsfocusedondeuterium- tritium pellets inside a 10-meter-diameter target chamber to convert the fuel to plasma and generate X-rays. The radiation then compresses the plasma until fusion occurs. Both methods, saysDelage,requiremassiveamountsofinputenergyanddepend on expensive, complex equipment that drive development costs into the billions and time lines out to 2050 at best. In comparison, Delage says a commercial General Fusion reactorcouldbeonlineby2020andatafractionoftheprice.The company’sapproachisahybridbetweenthetwomainmethods, called “magnetized target” fusion, and employs a comparatively lesspowerhungryreactordesign.BasedonaconceptcalledLINUS first developed by the U.S. Naval Research Laboratory in the 1970s,GeneralFusion’sreactorstartswithasphericalvesselfilled withliquidlead-lithiummetal.Theliquidmetalisthenpumped in a circle until centrifugal force forms a vortex in its center. Into this vortex, plasma injectors on the top and bottom of the reactor inject doughnut-shaped “puffs” of plasma wrapped CoverStory Commercial Fusion Amid many competitors, a Canadian firm aims to fire up the first commercial fusion reactor. A successful test of this scaled down prototype of General Fusion’s reactor may change the future of energy production. 18-21-DES.indd 18 12-04-11 11:11 AM
  19. 19. Our Protogami design aid is a cool hexa-kaleidocycle that shows the effect of materials on finishes. Visit www.protolabs.com/parts today and request your free Protogami! Enter code DE12B. GET YOUR PROTOGAMI! Call 877.479.3680 or visit www.protolabs.com Realparts. Really fast. Check out our video design tips! Receive FirstQuote® interactive quote. Part ready for shipping. Part ready for shipping. Machining begins. Upload 3D CAD file. 1–15 Days 1–3 Days A product development team needs parts to meet its rapidly approaching deadline. Receive a ProtoQuote® interactive quote. Finalize quote and submit P.O. Mold design and milling. Receive order confirmation with gate and ejector layout. Approve. Part production. 1-10 parts 10-10,000+ parts How Many Parts? It’s easy to work with Proto Labs. Just upload your 3D CAD model and choose the best process for your project: CNC machining in 1–3 days or injection molding in 1–15 days. Real parts in real materials, in days—not weeks. And that’s the real story. ©2012 Proto Labs, Inc. ISO 9001:2008 Certified ITAR Registered Finalize options, order with credit card or P.O. Computerized automated toolpaths sent to CNC Machine. 18-21-DES.indd 19 12-04-11 11:11 AM
  20. 20. March/April | 2012 www.design-engineering.com 20 in a magnetic field. Like smoke rings blown into either end of a tube, these “magnetized targets” collide at the reactor’s core. Asthetargetscombine,approximately200steam-drivenpistons simultaneously hammer the spherical vessel, sending a shock- wave through the molten metal. The shockwave collapses the vortex and compresses the plasma, heating it adiabatically (like a diesel engine), to produce a short burst of fusion energy. During the reaction, the hydrogen isotope atoms fuse into Helium and throw off high-energy neutrons that pass into the swirling liquid metals, transferring heat and converting some of the lithium into tritium. After the reaction ends, the metal is pumpedoutofthechamberandpassedthroughaseparatorthat removes the helium and tritium, which can be directed back to theplasmainjectorsasfuel.Meanwhile,thehotleadpassesthrough a heat exchanger that creates steam, half of which will be used to re-power the pistons and the other half to generate electricity. According to Delage, each fusion pulse will result in approx- imately 100 MJ of net electrical output. The cycle repetition rate canbevariedtocontroltheoverallpowerplantoutput;ifrepeated oncepersecond,thenetoutputwillbe100MW.Inaddition,the reactorwoulduseonlysmallamountsofdeuteriumandlithium. If fusion reactors began generating enough electricity for the entire world, Delage says, lithium reserves would last for 207 million years and deuterium for more than 67 billion years. Fusion for Less For all its promise, the quest for net gain fusion has been a time consuming and costly endeavor. The ITER reactor is projected to take 10 years and 13 billion euros to construct. That doesn’t count the 25 years and counting since the project began and the millionspouredinbycontributorssofar.Evenwhenbuilt,ITER’s superconductingmagnetsandothercomponentswouldrequire 50MWworthofinputpowertostartandmaintainthereaction. Similarly,costsforLaurenceLivermore’sNationalIgnitionFacil- ityareestimatedatupwardsof$850millionanditsreactorrequires 500 trillion watts of laser light to kick-start fusion reactions. Where General Fusion’s magnetized target method stands apart is in its relatively low-tech, low-cost mechanical means of compressing the plasma. “As an energy storage medium, com- pressedgasisordersofmagnitudelessexpensivethancapacitors,” Delage explains, “but it’s hard to release this energy quickly.” That’s the problem that ultimately scuttled LINUS, the pre- decessor of the General Fusion reactor, in the 1970s. The LINUS concept proposed impacting the liquid metal directly, which resultedinarelativelyslowvortexcollapseofupto40milliseconds, whilethemagnetizedtargetholdsitsstructureforonlyabout100 microseconds. According to Delage, General Fusion has solved this problem by impacting the containment vessel itself. “Our sphere is in fact full of holes, like a Wiffle ball,” he explains. “Each hole is plugged with an ‘anvil’ and compressed gas is used to accelerate a 100 kg ‘hammer’ piston. This accel- eration takes about 80 milliseconds. When the hammer piston impacts on the anvil piston, it moves a small amount and trans- fers the energy into the liquid metal in about 80 microseconds. That’s a timescale shorter than the lifetime of the magnetized target and an increase in power of 1000 times.” The challenge is that as the energy delivery speeds up, the requirements for symmetry of compression increases. “Every piston has to be individually servo-controlled to achieve the necessary synchronization,” Delage says. “Achieving this wasn’t possible in the 1970’s, but we are able to nurse each piston’s trajectory using a fast-response, closed-loop control system and brake, so that the timing of the impact is controlled to within microseconds. It’s the use of modern electronics—the computing power that has only come available in the last ten years—that makes our proposed system possible.” Approaching the Finish Line Presently, General Fusion is creating a prototype and key sub- systems at full scale. These include a plasma injector that cre- ates the magnetized target; individual full-scale pistons that meet requirements for impact energy and timing; and a 1-meter- diameter sphere with 14 pistons to demonstrate the symmetric collapse of a liquid metal vortex. “We’re also performing a series of experiments to demon- strate the behavior of the plasma target at peak compression CoverStory General Fusion’s reactor will employ 200 steam-powered pneumatic pistons, like this one, to create the necessary pressures to induce nuclear fusion. The largest of its kind every constructed, this plasma injector is designed to inject “smoke rings” of magnetized tritium and deuterium plasma into the fusion reactor’s core. 18-21-DES.indd 20 12-04-11 11:11 AM
  21. 21. www.design-engineering.com March/April | 2012 21 in accordance with theoretical predictions, and developing simulation tools, matched experimental data, to be used in the design of the prototype system,” says Delage. “To date, the most challenging work has been related to the formation of the magnetized target plasma.” He says General Fusion’s plasma injector is the largest such device ever constructed. Rather than a straightforward extension of smaller systems, many issues have been overcome to achieve the necessary performance. “All our efforts have required significant innovation in mechanicaldesign,materials,electricalandpulsepowersystems, diagnostics and advancements in plasma science,” says Delage. “Italltakestime.”Thecompanyhopestohaveaprototypeoper- ating by early 2015, and a working reactor by 2020. “Thepathtoasuccessisaboutunderstandingthephysicsand the engineering and managing the outcome to produce energy safely and reliably,” notes Dr. Paul Wilson, associate professor of nuclear engineering at the University of Wisconsin-Madison. “The understanding of the physics of the mechanisms they are employing is less mature than with the two standard approaches, but they’re obviously learning more all the time,” Wilson adds. “Magnetized targets have been achieved in many experiments, but it’s a matter of determining how you can have atoms collide with enough symmetry that you get the bang and not a fizzle.” Wilsonbelievesit’spossiblethatacompany like General Fusion may beat large national and international programs to the finish line. Dr. Kevin Bowcutt, a senior technical fellow and chief scientist of hypersonics at Boeing, agrees.Heledanindependenttechnicalreview of General Fusion’s technology in 2008. “We found that their engineering challenges can be solved and they’ve been solving them since then,” Bowcutt says. “They have achieved things such as control of impact timing.” He notes that General Fusion will be holding an important physics test this summer of their plasma compression device. If all goes well, it’s likely to change the global fusion mindset. “The world has been saying that achieving fusion will cost billionsofdollarsandtakedecades,”saysBowcutt,“butGeneral Fusion’s approach, if it’s shown to work, will sidestep all that.” “I think a horse race metaphor works well,” Wilson observes. “We’reprobablygoingtoseeonehorsepullaheadandthenmaybe another catch up and maybe lead the group for a while, and so on. This will be an interesting decade.” DE www.generalfusion.com At the center of a liquid metal vortex, tritium and deuterium atoms fuse, releasing a short burst of energy. CoverStory 18-21-DES.indd 21 12-04-13 2:13 PM
  22. 22. March/April | 2012 www.design-engineering.com 22 When choosing between position feed- back components, resolvers may just have an edge over optical encoders. By Mark McCann, B.Sc. Electrical Engineering While most motion control systems can work with either resolvers or encoders to monitor shaft position, they are not interchangeable. Many engineers are unfamiliar with resolver electronics and opt for an optical encoder as a default. As with all components, it is important to understand the basic operation of both options and keep abreast of technological advances to build the most efficient and effective systems. Both resolvers and optical encoders function as transducers bytransformingmechanicalmotionintoelectronicinformation. This information is fed back to electronic devices that control the mechanical motion, providing feedback that closes the con- trol system loop and improves system performance. A resolver is an electromechanical device with a mechan- ical design similar to a motor or a small transformer. It con- tains a rotor with one or two orthogonal primary windings and a stator with two orthogonal secondary windings. AC voltage is applied to the rotor and the voltage induced in each stator winding depends on the position of the shaft. The voltage in one stator winding is Er Cos theta, where Er is the input voltage and theta is the shaft position, while the voltage in the other stator winding is Er Sin theta. A resolver-to-digital converter (generally mounted in the equip- ment to which the resolver is connected) compares the two voltages to give a highly accurate value of theta. The biggest upside to resolvers is their ruggedness. They are MotionControl Resolvers Stage a Comeback While less common than optical encoders, resolvers provide ruggedized and reliable position feedback in “extreme” environments. resistant to electrical distur- bances and, because they have no fine-pitch gratings through which light must pass, they can tolerate dust and dirt that would stop an encoder. In contrast, an optical encoder uses a scale with a pattern of lines deposited or engraved on its surface. A light source shines on the scale, and the transmitted or reflected light passes through the grating to a photodetector. Encoders are available with both incremental and absolute outputs. An absolute encoder has as many tracks as it has output bits. An incremental encoder outputs a stream of pulses as the shaft rotates and are specified in pulses per revolution (ppr). Incremental encoders can be optical, using a scale or disk with just one or two rows, or magnetic, using several different technologies. An incremental encoder does not provide any position information at start-up, but merely keeps track of how far it has moved. The only way to determine the absolute position of an incremental encoder is to set the equipment to a known reference position and then zero the counters. Unlike a resolver, encoders are intrinsically digital, which means they can interface easily to most modern control systems. However, optical encoders have had a reputation for being fragile. The thin glass disk at the heart of most optical encod- ers could be broken by excessive shock or misaligned by strong vibration. In addition, their integrated circuits could be dam- aged by a severe electrical disturbance or they could be obscured by dirt. Over the last decade, encoders gained popularity as the glass disks were replaced with steel and plastic disks and the electronics became more integrated and durable as a result. Resolvers have also undergone a transformation in the past few years, which affects the way engineers are thinking about them. Advances in electronics manufacturing have lowered the cost of circuits and provide an increase in resolution. In fact, 21 byte resolvers are now available with more than 2 million ppr. Resolvers are also gaining exposure through their use in automotive and green energy applications that deal with environmental exposure. Compared to optical encoders, resolvers are far more durable in extreme conditions, operate under greater temperature ranges, tolerate higher vibrations and are not as easily degraded by contamination. For these reasons, resolvers excel in modern application positioning feedback for hybrid vehicle electrical mechanical components and solar panel positioning systems. DE www.myostat.ca Mark McCann is the Lead Design Engineer at automation solutions provider, Myostat Motion Control. During his eight years with the company, Mark has worked on hardware, electronic circuit design, software, microcontroller firmware development and windows application programming. 22-23-DES.indd 22 12-04-11 8:07 AM
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  24. 24. March/April | 2012 www.design-engineering.com 24 Motion Control VLT Drive Danfoss VLT Drives introduced the VLT FlexConcept, an optimized drive solution engineered for food and beverage, and packaging applications. The system consists of the VLT OneGearDrive, the VLT Decentral Drive FCD 302 and/or the VLT AutomationDrive FC 302. Each component features a washdown coating designed to IP66/67 and IP69K standard that satisfies DIN 1672-2 Hygienic Design standards. The VLT FlexConcept supports AC or PM motors and can operate open- or closed loop. The system provides up to 90 percent energy efficient operation, reducing total cost of ownership by up to 25 percent when compared with conventional systems. www.danfossdrives.com Food-Grade Actuators Tolomatic’s IMA line, the company’s integrated motor rod actuator, is now available with a food-grade white epoxy coating and stainless steel components for washdown applications. Available in four sizes, the IMA line features stroke lengths from three to 18 inches (76.2 to 457.2 mm) and peak thrusts from 200 to 6,875 pounds force (890 to 30,594 N) at speeds up to 24 inches per second (610 mm/sec). The actuator series integrates a servomotor and a ball or roller screw. Its hollow-core rotor design allows the nut of the screw to pass inside the rotor. The motor features skewed stator windings to minimize cogging. www.tolomatic.com Rotary Encoder Leine Linde released its 700 Series of encoders that feature a thin design and a hollow shaft of up to 25.4 mm, often allowing for mounting on a motor’s shaft without an adapter. They also feature a dual set of heavy duty bearings, an encapsu- lated enclosure and a range of electrical inter- faces including TTL, 1VPP, HC HTL, HTL and RS422. On the mechanical side, the company offers shaft variants in both inch- and millimeter-based dimensions. www.heidenhain.com Servo Drive Rockwell Automation introduced its Kinetix 350 single-axis EtherNet/IP servo drive designed for low-axis machines. When the drive is paired with the company’s CompactLogix 5370 Series PAC and PanelView Plus HMI, the integrated architecture system scales from 200-10,000 I/O. The servo drive is also equipped with safe, torque-off func- tionality that allows tasks such as machine setup, cleaning, removal of jams and other maintenance tasks to be performed with- out shutting down. Instead, drive output can be disabled, allowing faster machine restart. The Kinetix 350 servo drive has an available 400W to 3kW power range and supports 120-volt AC input, typical to power outlets found in nonindustrial settings. www.ab.com/motion Industrial Ethernet DeviceNet Analyzer Balluff introduced its DeviceNet Analyzer, a tool for analyzing, commissioning, monitoring and maintaining DeviceNet/CAN bus installations. The unit allows users to analyze signal square wave quality; monitor overall network health by node; detect the location of cable breaks and short circuits; and locate weak points such as incorrect cable types, lengths and faulty plug connections. The DeviceNet Analyzer assists with making sure the network is healthy during startup and setup and also allows for the health of the network to be documented. www.balluff.com Ethernet Connector HARTING has launched an angled version of its next generation RJ Industrial 10G Ethernet connector. Rated IP 20 for the office IT envi- ronment, the flexible, lockable, eight-wire RJ45 requires no tools or expertise to assemble. The 45° cable outlet can be mounted in four different directions and features an industrial strength actuator with locking lever protec- tion as well as optional color coding tabs for saving patch cable- ID and parameters. The insulation displacement terminations are fitted for flexible and rigid wires with profiles ranging from AWG 27/7 to AWG 22/1. Cables with a diameter of between 4.5 mm and 8 mm can be connected. With data transfer rates up to 10 Gbit Ethernet, the RJ 10G series is twice as fast as previous versions. www.harting.com HMI Workstation Pepperl+Fuchs announced that its VisuNet IND SlimLine Operator Workstations have received Zone 2 certification for use in hazard- ous environments. The workstations are available in a NEMA 4/4x IP 64 Stainless or painted steel housing, and as a full PC, remote monitor or KVM monitor solution. The company’s remote moni- IdeaGenerator 24-27 DES.indd 24 12-04-11 8:58 AM
  25. 25. www.design-engineering.com March/April | 2012 25 tor (RM) technology requires no software installations, provides stan- dard Ethernet networking connections and provides access to multiple servers from a single workstation. VisuNet RM has been tested and approved by Thin Manager for use with ACP Thin Manager software. Pepperl+Fuchs visualization solutions also support RDP applications including Microsoft terminal services, Citrix ICA or VNC RFB. www.pepperl-fuchs.us Power Transmission Microslide Haydon Kerk Motion Solutions has released a microslide linear actuator capable of a resolution of 15 microns / step (0.0006-in/step) and a maxi- mum load of 13N (3 lb-f). The microslide is approximately 22mm (0.87-in) wide by 25.2mm (1.0-in) high and is capable of up to a 64mm (2.5-in) maximum stroke length. The slide load carriage is made from self-lubricating polyacetal and features a built-in clearance take-up mecha- nism for load rigidity during motion. The leadscrew is 303 stainless steel and is available in 5 different leads from 0.3mm (0.012-in), to 2.0mm (0.079-in). www.HaydonKerk.com Worm Gear Wittenstein has expanded its alpha V-Drive family of servo worm gears to include a size 040, designed for machine tool, automation and packaging applications. The VDH 040 features a duty cycle of greater than 60 per- cent; input speed up to 6,000 rpm; and running noise below 54 dB(A). In addition, the worm gear has a maximum axial force of 675 lb-f, maximum radial force of 540 lb-f and 20,000 hours of rated service life. www.wittenstein-us.com Rack Gears Misumi has introduced two rack gears that feature 1045 Carbon Steel construction and induction hardened teeth. The gears are designed for use in pinion (spur gear) mech- anisms to create a simple actuator that con- verts the rotational motion of the pinion into linear motion. The additions include the RGEAH Induction Hardened Rack Gears with machining options no hole, or bottom tapped, side tapped or side counterboard tapped holes. The company’s RGEAHL Induction Hard- ened Rack Gears offer user configurable hole machining, with bottom, side or side counterboard tapped options. Both new rack gears are manufactured in 1045 Carbon Steel with Black Oxide Finish, and both feature end face machining. The Rack Gears are available in a variety of sizes (Module 1.0, 1.5, 2.0, 2.5 and 3.0). http://us.misumi-ec.com Automation All-In-One Vision Sensor Omron Industrial Automation has introduced a vision sensor designed for pick-and-place applications. With a processing speed of 5,000 pieces per minute and 360 degree rotation, the FQ-M combines a camera, image processing functionality and communications options (Ethernet and EtherCAT) in a single IdeaGenerator www.globalencoder.ca 22 Commerce Place St. Catharines ON, Canada L2R 6P7 Toll free 1-888-277-6205 Fax 1-866-278-1301 info@globalencoder.ca Industrial Encoder Corporation Member of the GESgroup of companies Demand more... We always deliverDemand more... We always deliver Our only products are encoders. Whatever your industry, we’ll satisfy your expectations for exceptional quality and value supported by superior service. Our proven reliability allows us to offer the industry’s only FIVE-YEAR WARRANTY. Expect more... and get it. Our only products are encoders. Whatever your industry, we’ll satisfy your expectations for exceptional quality and value supported by superior service. Our proven reliability allows us to offer the industry’s only FIVE-YEAR WARRANTY. Expect more... and get it. 24-27 DES.indd 25 12-04-11 8:58 AM
  26. 26. March/April | 2012 www.design-engineering.com 26 package. The sensor’s object detection is based on a contour-based search algorithm that can cope with overlapped or partially hidden objects. The camera’s incremental encoder interface simplifies initial calibration of the system and enables on-the-fly tracking for synchronized control. Measuring 110 x 75 x 50mm, the FQ-M provides a standard C-Mount lens attachment and a 3.5-inch TFT color touch screen. The TouchFinder console provides image viewing, zoom in/out and a variety of measurements. www.omron247.com 6-Axis Robot DENSO announced that it has increased the maximum payload capacity of its VM Series six-axis articulated robots from 10 kg to 13 kg. Along with their new capacity, the robots offer reaches from 1,000 to 1,300 mm; standard cycle times of 0.89 to 0.95 seconds; and repeatability from ±0.050 to ±0.070 mm. In addition, their high maximum allowable moment of inertia (0.36 kgm² at J4 and J5 and 0.064 kgm² at J6) is 2.5 times greater than conventional robots. The robots are ANSI and CE compliant and can be mounted on the floor or overhead. Standard, dust- and mist-proof and Class 100 clean room models are available. www.densorobotics.com SCARA Robot Toshiba Machine introduced its THL Series, a line of low-cost and lightweight SCARA robots. Configured with a lightweight die cast aluminum arm, the robot is 50 percent lighter than existing Toshiba Machine models, the company says. The THL Series includes the THL500, THL600 and THL700 with arm lengths of 500mm, 600mm and 700mm respectively. Each THL offers a payload of 10kg. Cycle times (with 2 kg load) are .45s for the THL500 and THL600, and .50s for the THL700. All THL Robots feature a working envelope of 4 axes, with a Z-axis rotation of 360º. Maximum speeds range from 6.3m/s to 7.9m/s overall. Storage capacity totals are approximately 6400 point + 12800 steps. The programming language is SCOL (similar to BASIC). www.toshiba-machine.com IdeaGenerator Baumer Inc. · 4046 Mainway Drive · Burlington · Ontario · L7M 4B9 Phone 905-335-8444 · sales.ca@baumer.com · www.baumer.ca Rugged, Accurate, Programmable Unparalleled Flexibility „ IP67 design withstands temperatures -40 to +100C „ Industry leading precision and shock handling „ Field programmable resolution and output voltage HS35 Motor Feedback Encoder 24-27 DES.indd 26 12-04-11 8:58 AM
  27. 27. To advertise your solution in this section call Alan Macpherson at 416.510.6756 DesignSolutions www.design-engineering.com March/April | 2012 27 OMEGA’s Thermocouple/Voltage Input USB Data Acquisition Module Omega’s new OM-DAQ-USB-2401 series of USB 2.0 full speed thermocouple/voltage input data acquisition modules are fully compatible with both USB 1.1 and USB 2.0 ports. This module is user programmable for type J, K, T, E, R, S, B, N thermocouples or voltage input and features 8 Differen- tial or 16 Single-Ended Analog Inputs, 24 Bit Resolution with up to 1000 Samples/Sec throughput. This module is powered directly by USB port or an External DC Power Supply. Contact: info@omega.ca Visit us at: www.omega.ca Clippard Offers Miniature Pneumatic Products Catalog for Scientific/Medical Applications A leader in miniature pneumatics, Clippard provides the scientific/medical industry a variety of products and solutions. The product range is illustrated in a color brochure featuring the most complete line of miniature fluid power products for the medical, pharmaceutical analytical and dental fields. To get your copy today please visit our website at the address printed below. Contact: sales@clippard.com Visit us at: www.clippard.com/scientific-a Ideas To Improve Production Efficiency! Look to Seal Master® Inflatable Seals. Sealing is just one of many tasks for custom-built, fabric-reinforced elastomeric inflatable seals. Simple, versatile and with close tolerance capability, 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 proccessing and handling components to lessen downtime. Ask about our RSVP Design Assistance program Contact: info@sealmaster.com Visit us at: www.sealmaster.com The domestic source for perfect meshing timing belts and pulleys BRECOflex CO., L.L.C. is announcing their new pulley catalog “B216” for made-to-order and stock pulleys. The new domestic “CNC” state of the art pulley manufacture allows for very precise machining standards, leading to superior product quality and quick product availability. BRECOflex CO., L.L.C., is providing finished precision pulleys made-to-specification and stock pulleys with pilot bores, for immediate delivery. Made-to-order pulleys are available with normal backlash, reduced backlash “SE” or zero backlash “0” tooth gap design. Contact: info@brecoflex.com Visit us at: www.brecoflex.com EXAIR’s New Catalog 25 Is Packed With New Features, Products, New Solutions EXAIR’s new Catalog 25 is a full color technical guide offering solutions to common industrial cooling, drying, conveying, blowoff, cleaning, coating, and static electricity problems. This 164 page catalog features many new products that can help companies conserve compressed air and reduce dangerous noise levels. A detailed technical explanation, performance data, application photos, and dimensional drawings are provided for each product. A price list is also included. Contact: techelp@exair.com Visit us at: www.exair.com/cat25.htm New Parts and Engineering Catalog from Smalley Smalley’s new 132-page catalogue features comprehensive design and technical information for more than 10,000 standard parts. The updated content combines existing retaining ring and wave spring series with newly released series including Hoopster retaining rings, constant section rings, metric wave springs and small series wave springs. The catalog is an ideal resource for engineers needing detailed product information for quick prototypes. Smalley products are stocked in Toronto, Montreal and Vancouver by RotoPrecision Inc. Contact: applsupport@rotoprecision.ca Visit us at: www.rotoprecision.ca 24-27 DES.indd 27 12-04-11 8:58 AM
  28. 28. March/April | 2012 www.design-engineering.com 28 CanadianInnovator Kick Starter Canadian engineer perfects a low-cost prosthetic to help impoverished amputees. By Treena Hein Even if they are mobile and reasonably healthy, people in developing world countries face many challenges. When they lose a lower leg to a land mine or another factor, their circumstances become much more dire. What they need is a lower limb prosthetic that is durable and allows great func- tionality—but it also must cost little to make. That’s been the quest—and amazing achievement—of Jan Andrysek, assistant professor at the Institute of Biomaterial and Biomedical Engineering at the University of Toronto and researcher at the Bloorview Research Institute. “I’ve always been interested in inventing things and also fascinated by how the human body works,” he says, “so that led me to learn mechanical engineering and to use it to pro- vide bio-medical engineering solutions.” It’s been a journey of six years to create and perfect what is now known as the LC Knee—a very inexpensive, simple, tough and highly-functional lower limb prosthetic knee joint. The quest started in earnest during Andrysek’s Master’s degree on knee joints, when he investigated numerous existing types of simple lower limb prosthetics for children. “They’re all based on a handful of common mechanisms created after WWII,” Andrysek notes. “The main problem with many of them is that they do not provide stability to allow individuals to safely negotiate different terrains.” Some prosthetics are designed to provide a higher level of stability by restricting the knee from bending when the user’s weight is placed on the limb; however, this makes it difficult for the user to bend the leg as it swings forward during walking. But it’s exactly that ability of a prosthetic—to swing eas- ily—that Andrysek says provides an efficient and natural walking pattern for an amputee. He has achieved this through the creation of “Simplified Automatic Stance-Phase Lock” (SASPL) technology. “The system actually locks up the knee joint before you put weight on it, so that there’s a feeling of safety for the user,” Andrysek explains. “The unlocking occurs in response to the load conditions that occur naturally in walking. We studied this extensively and figured out that we needed to configure the limb so that the unlocking would automatically occur at the point where the weight is placed on the toe of the prosthetic, at the same time as it’s cued by the user’s hip flexion motion.” Andrysek also needed to create a mechanism that would provide a forward-swing motion that’s smooth, natural and properly-timed. “We optimized a spring and friction system that mimics the motion provided by hydraulics in more expensive prosthetics,” he says. “The faster a person walks with the LC Knee, the faster it swings forward.” But it wasn’t simply about engineering the limb to provide a natural gait—a big challenge in itself. The prosthetic had to be light, durable and cheap to make. “Plastic is great because it’s light, but the plastic parts had to be strong,” explains Andrysek. “With injection-moulding, which is the way we wanted to go because it’s so inexpensive, you can’t just make the part thicker to achieve greater strength. There are many other limitations, such as what’s possible with pulling certain shapes out of the mould.” After much tweaking and trial-and-error (and the use of a durable nylon plastic), Andrysek achieved manufacturing costs that are a stunning 90 per cent less than that required by other prosthetics with similar functionality. The final cost? Only about $100. The leg also had to be very low-maintenance, so Andrysek has incorporated self-lubricating plastic bearings and wear parts that are easily replaced after extended periods of use. Some long-term testing has been done in Central America, but Andrysek wants a broader look at how the LC Knee func- tions in different environments. A newly-awarded Grand Challenges Canada grant of $100,000 is about to help him to do just that in places like Chile, India and Tanzania. “The award is very nice,” Andrysek says, “but it’s also great to get direct feedback from the people using it or from the people who work with patients, to hear it’s allowing them to do this or that, things that they couldn’t do before. We wanted to provide a lot of function with a simple device, and it’s great to have done that.” DE www.hollandbloorview.ca Biomedical Engineer Jan Andrysek’s LC Knee is a light-weight knee joint that’s rugged, easy-to-make and works as well as standard prosthetics but at a fraction of the manufacturing cost. Com M H • F • M • L • H Design_Engineer28-29-DES.indd 28 12-04-11 8:59 AM
  29. 29. Commercial Support: 1 877 463 3786 Technical Support: 1 866 463 3786 www.festo.ca/ms-series MS Series Air Preparation High Level Safety Compliance Engineered to perform wherever you need it. • Four interchangeable sizes up to 12,500 Nl/min. • MS6-SV, category 4, level E safety compliant. • Lightweight. • High flow performance. Design_Engineering_Ms_series.indd 1 23/03/2012 4:20:47 PM28-29-DES.indd 29 12-04-11 8:59 AM
  30. 30. 30 FluidPower 8754-08 Contents 32 Fluid Power News • Pneumatic Air Guitar rocks trade show circuit • Hydraulic engineering app for iPad • Eaton appoints new director of hydraulics 34 Shoptalk Choosing the most efficient control option requires full understanding of hydraulic application 38 Fluid Power Roundtable ‘12 Canadian fluid power leaders discuss market and product trends 42 On the Ball Integrator saves time and expense with new ball valves and end connectors 44 Fluid Power Showcase The latest in hydraulic and pneumatic product technology. 47 Fluid Power Product Index 48 Fluid Power Product Listings 56 Fluid Power Supplier Listings Fluid Power Controls BUYERS’ GUIDE March/April | 2012 www.design-engineering.com 30-33-DES.indd 30 12-04-11 11:12 AM
  31. 31. 8754-08 Canada Oil Gas_DE_7.875x10.75.indd 1 1/31/12 8:23 AM30-33-DES.indd 31 12-04-11 11:12 AM
  32. 32. 32 Showing off the speed, repeatability and power density of pneumatic systems in a way that captures the imaginations of weary trade show attendees can be a challenge. However, Business Development Manager Rob Clippard and a team of inventive engineers at Clippard Instrument Laboratory, Inc. have combined their interests in music and fluid power to create one attention-grabbing pneumatic application. They’re creation is the Clippard Air Guitar, a pneumatically automated guitar playing machine that incorporates 62 cyl- inders, 58 valves and an iPad as the machine controller. More than 30 cylinders along the neck of the six-string guitar depress the strings on the fret board while another cylinder mounted horizontally at the bottom of the soundboard drives a pick to strum the chords. For the melody, six cylinders across the sound hole pluck individual strings. Additionally, the “clack” of the cylinders provide percussive accompaniment. In total, Clippard says the Air Guitar took about a month and a half of nights and weekends to prototype and build. “I have a new found respect for the human hand,” he says. “The biggest challenge came when we started prototyping. “When you play guitar, the pressure you put on or take off the strings varies dramatically depending on what you want to do next,” he adds. “When controlling basic components with very high speeds and variable pressures, it’s amazing how much complexity goes into playing a single note in the way the human hand does without thinking.” To date, the Clippard Air Guitar has a repertoire of 16 songs. Similar to the rolls of punched paper of a player piano, the musical machine uses midi song files that digitally des- ignate whether a particular note is played at any given moment. The iPad functions as a time-based PLC, outputting the binary song files through a midi soundboard that interprets the on/ off of the digital signal to control the relays of the individual pneumatic cylinders. The Air Guitar made its first appearance last year at PackEx in Las Vegas but is currently on its way back from the Analytica Show in Munich, Germany. Clippard says it will most likely make its next appearance in May at the Medical Design and Manufacturing East show in Philadelphia. For those interested in re-creating Clippard’s musical machine, the company has posted a video and component list on its web site. http://clippard.com/guitar Hydraulic engineering app for iPhone/iPad Education software firm, MultiEducator, has released Hydrau- lic Engineer for apple devices including iPhone and iPad. The comprehensive app includes more than 60 formulas required by hydraulic engineers, including sections on actuators, fluid power, hydraulic tubing, pumps, induction motor selection, and vehicle drive formulas. It also includes 60 area formulas and 300 conversion formulas. www.multieducator.net FluidPower: News DMR_Ess Eaton appoints new director of hydraulics Industrial manufacturer, Eaton Corporation, announced that Daniel F. Koehler has been named director of market intelligence and strategy for the Hydraulics Group. Koehler will be responsible for the analysis and communication of market data, leading the annual strategic planning process for the global hydraulics business, and coordinating the strategy deployment and communication activities across the product divisions, regions and functions. www.eaton.com March/April | 2012 www.design-engineering.com Pneumatic Air Guitar rocks trade show circuit 30-33-DES.indd 32 12-04-11 11:12 AM
  33. 33. DMR_EssentialComponents_September-2011-outline_01.indd 1 8/15/2011 12:43:40 PM30-33-DES.indd 33 12-04-11 11:12 AM
  34. 34. March/April | 2012 www.design-engineering.com 34 Choosing the most efficient control option requires full understanding of a hydraulic application. By Pat Jones, P.Eng. As with all things technical, some decisions are not neces- sarily as easy as they first appear and require a better understanding of the application. In previous articles, I have discussedthebenefitsofademand-flowsystemusingapressure- compensated pump and also with a load-sensing pump. In those cases, it was easy to see the energy/cost saving of using variable displacement pumps over fixed displacement pumps. In applications where the flow supply can be matched to the flow demand, then power is not wasted moving fluid that is not used in the circuit. Fixed displacement pumps can also be used in load- sensing type circuits. This does offer power savings over a simple circuit with just a fixed displacement pump and a relief valve where unwanted flow is forced across the relief valve (which would be set at maximum system pressure). It may also offer power savings over using a pressure compensated variable displacement pump. In a fixed displacement/load-sensing circuit, a bypass type compensator is used with the sensing line from the compen- sator connected into the circuit downstream of the flow con- trol. With this type of circuit, system pressure is determined by the load pressure felt in the sensing line, plus the spring value of the compensator (typically 200 psi to 350 psi or so). Therefore, system pressure upstream of the flow control will always be 200 psi higher than the load so the pressure difference across the flow control will always be 200 psi. When the flow control is adjusted for the desired speed, the unwanted flow is forced across the bypass compensator at load pressure plus 200 psi. This unwanted flow across the bypass compen- sator is wasted energy, but not as much as would be wasted if dumping flow across the relief valve. So how can a fixed pump circuit be more efficient than a variable pump circuit? It depends on duty cycle and the load flow/pressure demands. Consider the following comparison at a certain point in the duty cycle: System pressure setting 2,000 psi Maximum pump flow 20 USgpm Flow to circuit 15 USgpm Load pressure 500 psi In this scenario, the system efficiency of the pressure com- pensatedpumpisapproximately25percentwhilethefixedpump with load sensing achieves about 44 percent efficiency. From the graphs 1 and 2 above, you can see that, in this condition, the pressure compensated pump circuit will be much less efficient due to the control’s inability to sense the load. In this high-flow/light-load situation, the fix pump with load sensing-type circuit is much more efficient. This example points out that the nature of the control and the motion profile of the load, as well as duty cycle, must be clearly understood to choose the most efficient control option. It may be the most efficient to always specify a variable load- sensing pump for all circuits; however, if the duty cycle is intermittent usage, then a total cost case can be made for a fixed pump, load-sensing circuit. In a previous article, I mentioned that closed loop hydrau- lic circuits represent an efficient circuit option. The advantage to these drives is that—because both the direction and speed of the load are controlled with the displacement of the pump— the throttling losses of open loop hydraulic circuits are eliminated. This type of circuit offers one of the most efficient hydraulic circuits possible. In a typical closed loop circuit, there are two pumps: The main loop pump that controls the load and the charge pump that supplies make-up fluid for main loop leakage and also Maximizing Hydraulic Efficiency FluidPower: ShopTalk AD-116 34 FluidPower: Shop Graph1: Pressure Compensated Pump Graph 2: Fixed Pump with LS Control 34-37 DES.indd 34 12-04-11 11:46 AM
  35. 35. Proven Solutions. Terrific track record. Superior results. Loctite® Threadlockers When it comes to: • resisting vibration • preventing corrosion and leakage • improving quality • reducing weight, size and cost, mechanical locking devices just don’t hold up. By filling the thread roots and preventing side-to-side movement, Loctite® threadlockers have dramatically increased the reliability of threaded assemblies for over 50 years. New advancements provide higher temperature resistance, improved oil tolerance and primerless performance. Don’t let your designs fall apart. Use Loctite® . To learn more about our newest threadlockers – Loctite® 243™ and Loctite® 263™ – go to www.useloctite.com/de. For technical assistance, call 1.800.263.5043. Excellence is our Passion Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates in the U.S. and elsewhere. ® = registered in the U.S. Patent and Trademark Office. © Henkel Corporation, 2010. All rights reserved. AD-116-11 (05/11) ■ Bolt with split ring lock washer and nut ■ Bolt with Loctite® liquid threadlocker and nut ■ Bolt with tooth lock washer and nut ■ Bolt with elastic stop nut ■ Unsecured bolt and nut 100 80 60 40 20 0 200 400 600 800 1000 0 Number of load cycles Clampload% CLAMPLOAD RETENTION COMPARISON AD-116-11 Design Engineering.indd 1 26/05/11 1:08 PM34-37 DES.indd 35 12-04-11 11:46 AM
  36. 36. March/April | 2012 www.design-engineering.com 36 typically supplies pilot fluid for main pump control. The charge pump is usually fixed displacement and continually forces fluid across a relief valve that is typically set from 350 – 500 psi. Thechargepumpsizewouldtypicallybe10-15percentofthe main loop pump. So the continuous wasted energy is always at least the charge pump flow across the charge pump relief. The worst-caselossiswhenthemainloopisatfullloadandthemotor and pump are at maximum leakage. This could typically repre- sent10percentofmainlooptotalflowbeingforcedthroughthe pump and motor clearances at full load pressure. Using the same flow and load pressure numbers from the example above and assuming a charge pressure of 350 psi we see that, in the worst case, the closed loop circuit efficiency will be approximately 83 percent. So, why aren’t closed loop circuits used everywhere if they offer such a distinct efficiency advantage? Considering that one main loop pump is required for each load, this is very practical on a stationary crane where there would be four main functions: Main boom, rotation, extension and winch. This makes for a very compact and efficient circuit. However, as the number of loads grows and possibly the distant between them, having a separate closed loop circuit for each load becomes less practical from a machine design point of view. One input power source, capital cost wise, is very cost effective as opposed to having multiple closed loop circuits and the necessity of multiple prime movers. Of course, the long-term energy costs need to be weighed against this. Fromanefficiencystandpoint,thereareclearstandardoptions available. It’s a matter of understanding the combined flow- pressureprofileoftheloadsandthemachinedutycycleandthen looking at capital and longer term costs to determine the best solution.Efficiencydoeshaveacost,butwecancalculatethereal cost of proper design if we understand all the variables. DE Pat Jones, P.Eng, is the owner of Consolidated Fluid Power (CFD) Ltd., where he is an instructor and consultant with more than 20 years of hands-on experience in the fluid power industry. FluidPower: ShopTalk Graph 3 represents the power consumption and heat generation of a closed loop hydraulic circuit. 34-37 DES.indd 36 12-04-11 11:46 AM
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  38. 38. March/April | 2012 www.design-engineering.com 38 Shane Monaghan The product capabilities gaining the most traction have to do with safety. So, high quality products, particularly those that protect the operator, are gaining the most in popularity. —Shane Monaghan, Product Manager, Fluid Power Division, Gates Canada Inc Canadian leaders discuss the market, globalization and grooming the next generation of fluid power professionals. By Mike McLeod DE:Formanyinthefluidpowerindustry,2011wasarebound year. How would you characterize 2012, so far? Shane Monaghan, Product Manager, Fluid Power Division, GatesCanadaInc:ForGates,2011wasanexcellentyear.Infact, Gates Canada was recognized as the largest growth region for all of Gates North America. You can attribute those high sales to forestry, oil and mining—our top three markets. In terms of 2012,wewereexpectinganotherstellaryear.For2012,thecom- panyhasreinventeditselftofocusonfiveidentifiedendmarkets: Energy, exploration and extraction; infrastructure and agricul- ture; transportation, automotive, and process and specialty. Those are the end markets we want to attack for 2012. SteveApps,SalesProductManagerforMobileMarkets,Bosch Rexroth: For us, 2011 was definitely a good year, and 2012 is looking the same if not better, although it’s a bit early to tell. Miningandforestryaretwoareasthathavecertainlyrebounded, although the mining industry has rebounded quicker. Prior to therecession,therewereagreaternumberofcompaniesineach ofthosedifferentsectors,butthedownyearstooktheirtoll,and somecompaniesdidn’tcomeback.Thosethathavearegenerally what I would consider larger OEMs—that is, companies that deal both locally and internationally. AndreasSobotta,VicePresident,ProductandMarketManage- ment, Festo Canada: We had a very strong start to 2012, more or less in all industries except automotive which was expected to be flat. Assembly and handling; food and beverage; and natural resources are all very strong. This is something that we anticipated, and we are getting stronger in these areas where we were already strong. The reason is that we aren’t just selling products; we sell solutions, and our customers appreciate this. Festo has been focused on this worldwide, so that customers will see us as a partner instead of just a supplier. Kevin O’Doherty, Regional Manager, Hydraulic Systems and Services, Wajax Industrial Components: From our perspective, 2012 is definitely going to be a more robust year than 2011, which was better than 2010. Through the first quarter, sales are up across both industrial and mobile seg- ments and we’re hopeful the trend continues. The rebound is being led by the resource businesses, whether its oil and gas in Western Canada or metals and minerals here in Ontario. FluidPower: Roundtable Fluid PowerRoundtable 2012 38-41 DES.indd 38 12-04-13 2:22 PM
  39. 39. Steve Apps For the mobile hydraulic market, emission control is probably the biggest consideration. Meeting the Tier 4 emission standard will affect performance, costs, physical design and a number of other things. — Steve Apps, Sales Product Manager for Mobile Markets, Bosch Rexroth As well, I think a lot of companies, through the belt tighten- ing years, performed a bit less maintenance on their machin- ery in plant. Now that production is beginning to ramp back up, they do have to put those investment dollars back into their machinery. DE: At the NFPA annual conference in March, the prevailing themewasglobalization.AreyourCanadiancustomerslook- ing beyond the U.S. market? Monaghan-Gates: Absolutely. We have Canadian distributors who supply mines in North Africa, as well as agriculture equip- mentinRussia,EuropeandAsia.Forthepasttwodecades,Gates hasbeenonfivecontinents.Whatwe’vedonetohelpdistributors is develop a global product. Any OEM, across the globe, can purchase our products so they don’t have to import the product from a specific country of origin. We’ve also re-named most of our hose and fittings to include the letter “G” for global, which means that no matter where you buy it, it will be manufactured to the same specifications and standards. Apps -Bosch Rexroth: From my perspective, this has always been there. When the demand for domestic machines was higher, maybe globalization wasn’t as prevalent because cus- tomers could concentrate on their own backyard. With the change in the Canadian economy, the factors that influence production or harvesting of natural resources has dropped. As a result, to stay in business, people are looking for markets other than Canada and the U.S. One of the advantages we have is that we are able to draw on the applications and expe- 39FluidPower: Roundtable www.design-engineering.com March/April | 2012 38-41 DES.indd 39 12-04-13 2:22 PM
  40. 40. March/April | 2012 www.design-engineering.com 40 FluidPower: Roundtable Andreas Sobotta We aren’t just selling products; we sell solutions, and our customers appreciate it. Festo has been focused on this worldwide, so that customers see us as a partner instead of just a supplier. —Andreas Sobotta, Vice President, Product and Market Management, Festo Canada rience of companies from around the world. Also, people want to know that what we are supplying is going to be sup- ported if it is shipped, for example, to Eastern Europe. That has a certain attractiveness to local Canadian companies. Sobotta-Festo: About 75 percent of Canadian exports still go to the U.S., but I know that a lot of customers are looking to expand into new markets. For example, some of our Canadian customers are exporting into South America and some pulp and paper companies into Europe. Yet, it will take some time for some to look beyond the U.S. The difficulty is in the require- ments and the expectation in Europe. They are used to a more sophisticated level of product. For example, in Europe, they use more bus systems and smaller products with better per- formance. For a lot of U.S. companies, if something isn’t big, it can’t be good. It’s important for some of our customers to re-think their approach into new markets. O’Doherty-Wajax: Our customers are definitely looking at the export markets. For example, a lot of the mining machin- ery OEMs we work with are doing more business in South America and Africa as well as parts of Russia and Asia. So, we definitely see customers taking a much more globalized approach to their sales channels versus just Canada and the U.S., the way it was a few years ago. Wajax is very much a Canadian-based company, so we don’t sell directly into other countries, but we do support the after-market for products that we manufacture here in Canada. DE:Technicallyspeaking,whattrendsaredrivingyourcom- pany’s new product development? Monaghan-Gates: For 2012, Gates has budgeted nearly double the industry standard for product growth to create products designed for specific regions. For example, in Canada we are coming out with a low-temperature product— an arctic version of a hydraulic hose. We are also re-releasing global products with improved pressure ratings and minimum bend radius. The product capabilities gaining the most trac- tion have to do with safety, which is always a concern in the fluid power industry. For example, our Lifeguard line of sight hydraulic hose sleeves protects against catastrophic failure. If the hose were to burst or there were a pin hole, the sleeve protects the operator. Safety is more of a concern for OEMs now, and it’s a selling feature for them as well. Apps-BoschRexroth:Forthemobilehydraulicmarket,emission control is probably the biggest consideration. Meeting the Tier 4 emission standards, which come into play at the beginning of 2014,willaffectperformance,costs,physicaldesignandanum- ber of other things. That single point has played a large role in shaping, not only the components themselves, but the system concepts. The trick is to find ways to improve a machine’s operation or performance such that it’s emissions are reduced. Bosch Rexroth saw this coming because there is an internal connection between the automotive and hydraulics sectors. So, we have some access to the technologies and concepts used in the automotive industry, which was hit with these emission standards well before the off-road industry. Sobotta -Festo: The new trend coming from Europe is that products need to be more efficient. As a German company, we aretryingtoconvinceourcustomerstojumponthatbandwagon and be more productive. In terms of product, what we see is smaller, faster and more energy efficient. In terms of products that are gaining traction, customers want to have more flexibil- ity so we have a single form factor product series that allows differentsizevalvestodrivedifferentapplicationsoverdifferent distances, all in one control panel. Additionally, you have the abilitytoconnecttoanytypeofbussystem.Whetheracustomer has an Allen Bradley, Siemens or Omron system, they can take advantage of their existing software to drive our modules. O’Doherty -Wajax: We see a lot going on with electronics and with the quest for higher pressures. For example, the marriage between high-pressure hydraulics and electronic systems on mobileequipmentisbecomingmuchmoreofatrend—anything that helps with emissions and fuel consumption but increases payloads. If you fill your car each week, you know it isn’t getting any cheaper. Of course, the bigger the equipment, the more fuel they burn, so if they can get something as miniscule as a five or 10percentfuelsavings,thattranslatesintosomefairlybigdollars for these guys at the end of the year. DE: Which strategies or initiatives are you finding most suc- cessful in developing tomorrow’s fluid power professionals? Monaghan-Gates: Recruitment is definitely an issue and has been for a number of years. We combat that through the high schools and colleges. To get the fluid power name out there, it’s usually best to find a high school senior who hasn’t made 38-41 DES.indd 40 12-04-11 12:20 PM
  41. 41. 7PLNT15928.indd 1 3/20/07 12:32:48 PM Kevin O’Doherty Most people in fluid power have to be built from within. It is really incumbent upon us to take the lead in their development such that we can hone their skills and turn them into a value player. —Kevin O’Doherty, Regional Manager, Hydraulic Systems and Services, Wajax Industrial Components up his mind yet. Specifically, Gates provides a lot of product and equipment to high schools and we give out six scholar- ship awards every year to high school seniors. We also put on training courses at colleges and offer engineering services to FIRST Robotics, where a large number of participants go on to pursue a career in engineering. Sobotta-Festo: Festo is one of the largest sponsors of Skills Canada competitions for colleges and universities. The last World Skills competition was held in Calgary, Alberta two years ago and we got a lot of interest from Alberta colleges and universities, which not only generated business for us, but they have now incorporated our equipment into their curriculum. As a result, students become familiar and ben- efit from this advanced learning technology. We also have a unique product offering for high schools that is at the begin- ning of the implementation phase, which is well underway. We just have to work on the curriculum so that high schools move toward a more automation and pneumatic focus. O’Doherty – Wajax: As an industry, I think this is one of our biggest collective challenges. There is very little talent walking out of schools ready to go these days. Most people in fluid power have to be built from within. It’s really incum- bent upon us to take the lead in their development such that we can hone their skills and turn them into a value player. A lot of companies have backed off the throttle a bit, especially through the recent recession. But as business starts to ramp back up, we definitely see the need to train, develop and build our own. DE 41FluidPower: Roundtable www.design-engineering.com March/April | 2012 38-41 DES.indd 41 12-04-13 2:22 PM

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