1. $10.00 | October 2013
PM40069240
Wheels in
Motion
14 An indepth look at Siemens
PLM’s Solid Edge ST6
22 The top four steps to ensure a
successful design technology
implementation
37 Spring-loaded skates leave
conventional blades behind
FLO Cycling’s Canadian
engineers up-end bike
racing equipment industry
armed with CFD and a
competitive drive
1-DES.indd 1 13-10-23 8:26 AM
3. A one day tabletop show highlighting the
latest design and manufacturing technologies
for the OEM market
An effective forum for face-to-face interactions where engineers,
product developers, machine builders and systems integrators
can discuss, network, solicit advice and ‘kick the tires’ on the
latest technologies and applications that drive your business.
Featured technologies include:
• CAD/CAE • additive manufacturing • reverse engineering
• motors • drives • motion control • automation
• fluid power• power transmission • adhesives & fasteners
… and much more
www.DEXEXPO.com
Registration is required:
FREE admission for ALL attendees!
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Alan Macpherson Taebah Khan
Publisher Accounts Manager
416-510-6756 416-510-5230
dex@design-engineering.com tkhan@design-engineering.com
YOU’RE INVITED!
October 30 - Mississauga, Ontario
2-3-DES.indd 3 13-10-07 9:43 AM
5. 5IN THE NEWS
8 Bouchard to lead
Lockheed Martin
Canada
8 Hawk Ridge extends
Canadian territory
8 ATS Automation to
acquire IWK
8 Wainbee purchases
Cowichan Hydraulic
8 Canadian
tech creates
“unbreakable”
hockey stick
8 Canada launches
R&D tech demo
program
10 Valve-less hydraulic
system boosts fuel
efficiency
10 Sauer-Danfoss
changes name
10 Wireless research lab
opens at University
of Waterloo
12 Flex camera takes
panoramas in one
shot
12 Growth slowing in
PT/MC industry
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READER SERVICES
Contents | Volume 59, No. 5
13 DEX 2013
Industrial table-top trade show to feature
Canada’s brightest innovators
18 CAD News
DesignSpark Mechanical offers no-cost
push-pull solid modeling and other 3D
design stories
22 CAD Beat
The top four steps to ensure a successful
technology implementation
30 Motion Control
Modern LVDT linear position sensors
gaining preference in industrial applications
32 Idea Generator
The latest in industrial products including
motion control, fluid power, power
transmission and sensors
Columns
14 Inside Solid Edge ST 6
Is the latest version of Siemens’
Synchronous Technology the best yet?
26 Wheels in Motion
Flo Cycling’s Canadian engineers up-end bike
racing equipment industry armed with CFD
and a competitive drive
37 Canadian Innovator
Spring-loaded Bladetech skates leave
conventional blades behind, in more ways
than one
Features
13
22
26
3037
14
ce
.
es
to
ial
lar
ete
try
our
www.design-engineering.com October | 2013
4-5-DES.indd 5 13-10-10 1:24 PM
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.
@
www.design-engineering.com
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October | 2013 www.design-engineering.com
Although 3D printing has existed for more than 30 years, uptake of the technol-
ogy has been slow in coming. In the last three to five years, however, what was
a curiosity important to a few niche industries has become pervasive in fields as far
flung as food production and bio-medical engineering. And the advent of cheap,
desktop 3D printers has allowed many aspiring inventors to become over-night
crowd-funding site sensations.
Even so, additive manufacturing remains a relatively small industry. In April, IT
research analyst firm, Gartner, pegged the industry’s 2011 market value at $1.7 billion.
Even so, financial analysts expect the industry to explode in the near future. The
same Gartner report anticipated that the 3D printing market value will balloon to
$6.5 billion by 2019. That projection was echoed by Citi Financial analyst, Kenneth
Wong, who predicted in August that the industry will more than triple by 2018.
“We feel the 3D printing and additive manufacturing market is on the cusp of
seeing much broader adoption across more upstream production applications and
the consumer end-market,” Wong wrote in a note to customers that subsequently
sent the stock prices of Stratasys and 3D Systems to 52-week highs.
Wall Street’s bullish take on additive manufacturing is based on the fact that,
beginning in February 2014, core patents now protecting 3D Systems’ selective laser
sintering (SLS) process, will begin to expire. Once those intellectual property restric-
tions are lifted, the expectation is that the cost of SLS printers will follow the same
path as Fused Deposition Modeling machines. Within a few years of Stratasys’ FDM
patents expiring, cheap desktop FDM printers like the RepRap, Solidoodle, Maker-
Bot Replicator and many others brought the technology to within the budgets of
hobbyists and the Maker crowd.
However, the idea that we’ll see cheap SLS machines flood the market soon is
doubtful, say long-time industry watchers. They point out that SLS requires much
more sophisticated machinery than FDM printers, as well as tighter control on build
material quality, to produce the technology’s characteristic high resolution and
durable models. In addition, even though some SLS technology will be open for
adoption, many of the improvements made over the last 30 years are still actively
protected, making for an IP minefield potential competitors may shy away from.
Whatever the case, the industry’s two heavy weights, Stratasys and 3D Systems,
aren’t taking any chances. Over the last couple of years, both companies have been
in a frenzied acquisition mode, buying anything vaguely 3D printing related, to
cement their positions. 3D Systems, for example, has acquired roughly 20 firms since
2011, most notably one-time contender Z Corp. Although not as voracious, Stratasys’
merger with Objet in December 2012 plus its more recent $403 million deal to acquire
MakerBot, have maintained the company in its weight class.
And consolidation in the industry shows no signs of slowing down. As the 3D
printing market ramps up over the coming years, there will always be new up-starts
to take down. Because, as Blackberry painfully discovered, when it comes to emerg-
ing disruptive technology, simply because your company created the field doesn’t
mean a contender can’t land a one-punch knock out.
Mike McLeod
3D Printing Slugfest
6-7-DES.indd 6 13-10-11 11:22 AM
8. 8
Bouchard to lead
Lockheed Martin Canada
Lockheed Martin appointed
retired Lieutenant General
Charles Bouchard to head Lock-
heed Martin Canada. Bouchard
retired in April 2012 after more
than 37 years in the Royal
Canadian Air Force. His military
career includes many senior leadership roles includ-
ing serving as commander of the combined joint
task force that led NATO operations in Libya.
Lockheed Martin Canada today has more than
700 employees at facilities in Ottawa, Montreal,
Dartmouth and Calgary, as well as Department
of National Defence sites across the country.
www.lockheedmartin.com
Hawk Ridge extends Canadian territory
Solidworks reseller Hawk Ridge Systems has extended
its geographic coverage in Canada to include the
provinces of Manitoba and Saskatchewan. Last April,
former SolidWorks Canadian reseller, Automated
Design Systems (ADS) sold a large percentage of its
SolidWorks customer base to Hawk Ridge Systems.
Since then, Hawk Ridge Systems has been providing
sales, training and technical support to SolidWorks
users across Canada.
www.hawkridgesys.ca.
ATS Automation to acquire IWK
ATS Automation Tooling Systems Inc. announced
that it will acquire IWK Verpackungstecknik GmbH
and OYSTAR IWK USA, Inc., a tube filling and
cartoning machinery firm, for approximately
CAD$144 million. Headquartered in Germany,
IWK has 420 employees based at production
facilities near Karlsruhe, Germany and Bangkok,
Thailand, and at sales/services centres in the US,
Europe and Southeast Asia. ATS expects IWK to
contribute approximately $18 million in EBITDA.
www.atsautomation.com
Wainbee purchases Cowichan Hydraulic
Canadian fluid power and automation distributor,
Wainbee Limited, has acquired Cowichan
Hydraulic Equipment Service and Supply Ltd. As a
result, Wainbee now has 15 locations coast-to-coast
servicing customers from Vancouver Island to
Halifax. Founded in 1957, Wainbee Limited is a
100-percent Canadian, employee-owned company.
www.wainbee.com
Up Front Canadian tech creates
“unbreakable” hockey stick
While composite hockey sticks are favored for their light-weight
and performance relative to wood, they tend to break under
competitive play conditions. And at around $300+ a pop, the costs
and annoyance can tally up quickly.
At least it did for Daniel Lucchesi, whose start-up company,
Toronto-based Colt Hockey, is creating a composite stick covered in
nano-tech cladding that’s purported to make the sticks virtually
unbreakable yet without making them heavier or inflexible.
The high-tech cladding comes from Toronto-based Integran
Technologies, which licenses a process called Nanovate CoP
(PowerMetal for its sporting goods clients), originally designed for
coating hydraulic components for the aerospace and defense markets.
Similar in concept to chrome plating, Nanovate CoP elecroplating
can coat most materials with a thin layer of nanocrystalline Cobalt that
imparts steel-like durability to nearly any material. Its strength, the
company says, comes from the nanoscale of the metal’s grains (10-100
nanometres as opposed to 10 microns for polycrystalline metals).
At the same time, Integran says Nanovate CoP boasts a high
elastic limit (1.5 percent) that allows equipment, like a hockey stick,
to remain flexible. To date, Integran’s technology, through its spin-off
firm PowerMetal Technologies, has been incorporated into True
Temper “Epic Shaft”, Ping “IN” series putters, Anderson “NanoTek”
series bats and the forks of Cervelo’s $10,000 RCA racing bike.
www.colthockey.com
www.integran.com
Canada launches R&D tech demo program
The Canadian Ministry of Industry launched the Technology
Demonstration Program to help large-scale technology demonstration
projects move from the lab to real-world testing. According to the
ministry, the Technology Demonstration Program will cover up to
50 percent of eligible project costs. In total, the program will provide
up to $54 million in non-repayable funding annually.
To qualify, projects must be led by an OEM or Tier 1 integrator with
a large scale R&D project in the aerospace, defense, or security sectors
andmustbefor-profit,incorporatedandconductingbusinessinCanada.
http://ito.ic.gc.ca/eic
DesignNews
October | 2013 www.design-engineering.com
Charles Bouchard
8-13-DES.indd 8 13-10-10 1:25 PM
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10. 10
Magellan awarded $110
million MDA contract
Magellan Aerospace announced
the award of a CAD$110 million
contract from MacDonald,
Dettwiler and Associates for the
RADARSAT Constellation Mission
(RCM) satellite bus manufacture.
RCM is a Canadian Space
Agency mission to support mari-
time surveillance, disaster man-
agement and ecosystem
monitoring. The primary areas of
coverage are Canada and its sur-
rounding Arctic, Pacific and
Atlantic maritime areas. The
launch is planned in 2018.
www.magellan.aero
Sauer-Danfoss changes
name
Sauer-Danfoss announced that it
has officially changed its name to
Danfoss and now operates as a
new business segment called
Danfoss Power Solutions within
the Danfoss Group. The company
says it will continue to provide
mobile hydraulic solutions but will
benefit from the wider global
network and broader technology
base that Danfoss has to offer.
powersolutions.danfoss.com
SKF named among most
sustainable companies
For the 14th year in a row, SKF
has been listed as one of the
world’s most sustainable compa-
nies by both the Dow Jones
Sustainability World Index (DJSI)
and the Dow Jones Sustainability
Index for Europe. DJSI rated SKF
as best in class for the company’s
approach to environmental man-
agement. SKF BeyondZero is the
company’s strategy to reduce its
environmental impact from
operations and provide products
and solutions with improved
environmental performance.
www.skf.com
Up Front Off-road valve-less hydraulic system boosts
fuel efficiency
Researchers at Purdue Univer-
sity’s School of Mechanical
Engineering have developed a
hydraulic steering system for
heavy construction equipment
they say significantly reduces
fuel consumption and improves
efficiency.
In essence, the new approach
eliminates the wasted energy
introduced by the valves com-
mon in most heavy off-road
equipment’s hydraulic systems.
Instead, a pump precisely con-
trols each actuator’s motion by
adjusting the pump displacement. This, in turn, allows the diesel engine to run at
optimal fuel saving speeds.
According to the Perdue researchers, their “electro-hydraulic power steering
system” showed a 15 percent fuel savings and 23 percent increase in machine pro-
ductivity during tests performed on a front loader. In total, the test resulted in fuel
efficiency increase of 43 percent during steering maneuvers.
In previous projects, Maha researchers have shown that valveless systems could
reduce fuel consumption by 40 percent in an excavator and a 70 percent productiv-
ity improvement in terms of tons of soil removed per kilogram of fuel consumed.
The Maha Fluid Power Research Center is part of the Engineering Research Center
for Compact and Efficient Fluid Power, funded by the National Science Foundation.
www.purdue.edu
Wireless research lab opens at University of Waterloo
The University of Waterloo opened its 5,000 square-foot, $15-million Centre for
Intelligent Antenna and Radio Systems (CIARS), considered one of the best in the
world for testing electromagnetic devices. According to the university, the facility
and its instruments can measure electromagnetic fields radiated by anything from
a human hair to a two-ton truck, with the highest precision over the widest range of
frequency possible in any academic facility in the world.
CIARS features a unique multi-configuration electromagnetic radiation lab, includ-
ing an anechoic chamber and terahertz measurement facilities. The centre is expected
to help academic and industry researchers who specialize in everything from next-
generation wireless com-
munications, to mobile
health, car radar, satellite
communication,futuristic
nano-sensors and smart
devices.
Researchers hope the
facility will help them
learn more about tera-
hertz, a part of the elec-
tromagnetic spectrum
between radar and fibre
optics that is not yet fully
understood.
www.uwaterloo.ca
DesignNews
October | 2013 www.design-engineering.com
DMR_
Monika Ivantysynova, Maha Fluid Power Systems
Professor at Purdue’s School of Mechanical Engineering
The University of Waterloo CIARS lab houses a world class
anechoic chamber to measures electromagnetic fields.
8-13-DES.indd 10 13-10-10 1:25 PM
12. 12
Flex camera takes panoramas in one shot
Researchers at Queen’s University’s Human Media Lab have
developed the FlexCam, a bendable camera that can capture
panoramic photos in one shot. Typically, such pictures require
a special lens or stitching together a series of standard photos.
Using a Flexible Organic Light Emitting Diode (FOLED) as the
viewfinder display, the FlexCam goes one better by allowing
photographers to broaden or narrow the camera’s field of view
(FOV) on the fly.
The FlexCam’s integrated bend sensors measure the amount
of flex in the display, which is then used by the camera’s software
to adjust the viewfinder virtual FOV display. In addition, the
flex input dynamically stitches images captured by an array of
camera lenses on the back of the handheld device.
At present the FlexCam is a prototype and the panoramic
pictures aren’t always seamless but Queen’s researchers envision
the device becoming one aggregate flexible, thin-film device.
www.hml.queensu.ca
Growth slowing in PT/MC industry
According to the Power Transmission Distributors Association’s
(PTDA) 2Q13 Business Index, the power transmission / motion
control (PT/MC) industry expanded for the 13th consecutive
quarter but at a slower pace compared with 1Q13. The report’s
index showed a reading of 54.7, which represents a decrease
over last quarter’s reading of 61.1. When comparing this read-
ing to 2Q12, this is a slight increase to the reading of 54.2.
To put the numbers in perspective, the index reading indi-
cates the rate of change compared with the previous period.
For example, a reading of 50 indicates no change from the prior
period while readings above 50 indicate growth and below 50
indicate contraction. The further the index is above or below
50 suggests a faster or slower rate of change.
www.ptda.org/Index
DesignNews
October | 2013 www.design-engineering.com
8-13-DES.indd 12 13-10-10 1:25 PM
13. www.design-engineering.com October | 2013
13DesignNews
Dr. Todd Reichert (left) and Cameron Robertson, the engineering team behind the Sikorsky Prize
winning human-powered helicopter, will keynote the 2013 Design Engineering Expo on October 30.
Design Engineering magazine, Canada’s
leading B2B publication for Canadian
mechanical engineers and OEMs,
announced that it will showcase some of
Canada’s most creative, young engineering
minds at the Design Engineering Expo
(DEX) 2013, in Mississauga, ON.
Scheduled for October 30, 2013 at the
MississaugaConventionCentre,theone-day
showprovidesaforumforface-to-faceinter-
actionswhereengineers,productdevelopers,
machine builders and systems integrators
candiscuss,network,solicitadviceand‘kick
the tires’ on the latest technologies.
Those on hand to present and talk about
their engineering innovations include:
AeroVelo Human-Powered Helicopter
Dr. Todd Reichert and Cameron Robert-
son— aerospace engineers and design lead-
ers of the Canadian human-powered
helicopter, Atlas, that recently claimed the
33-year-old AHS Sikorsky Prize—will key-
noteDEX2013.Atthekeynote,Reichertand
Robertson will talk about innovation, the
design of the prize-winning helicopter and
AeroVelo’s next “impossible” project.
Bladetech Hockey Skates
Canadian engineer and hockey player,
Jeffrey Azzolin, will display his spring-
loaded Bladetech hockey skates. Azzolin’s
innovative approach to the classic ice
skate not only reduces stress-related
injuries but helps skaters speed down the
ice faster.
University of Waterloo EcoCar 2 Entry
Engineering students from the University
of Waterloo will showcase their entry in
General Motors’ EcoCar 2 competition.
The team’s modified Chevy Malibu fea-
tures a plug-in hybrid electric architec-
ture that delivers 260 HP and an
all-electric range of 60 km plus a 2.4L
engine to provide power and extend
vehicle range.
U of T FSAE Racing Team
A Formula-style race car—designed, built
and raced by the University of Toronto’s
FSAE Racing Team—will show off the
engineering skills of the university’s
undergrad-run club.
www.dexexpo.com
2013 showcases
Canadian innovators
8-13-DES.indd 13 13-10-10 1:25 PM
14. October | 2013 www.design-engineering.com
14
By Ralph Grabowski
Every software vendor likes to think
the newest release of its software is
the best ever, and so Siemens PLM Soft-
ware was no different last May introduc-
ing Solid Edge ST6 to users at Solid Edge
University 2013. We heard phrases like
“greatest version ever,” “sixfold perfor-
mance increase” (on some tasks), and
“1,300 new features” — although that list
never was distributed.
ST 6 is not the sixth release of Solid
Edge, as the software was first released
nearly 20 years ago. When in 2008 it added
Synchronous Technology to Solid Edge,
Siemens PLM reset the numbering system,
and so this is the sixth release since then.
(ST is short for “Synchronous Technol-
ogy,” the name given to the hybrid of
direct editing and parametric modeling
used by Solid Edge, as well as in bigger
brother NX.)
It’s a nice change to see a software
company show new software first to its
users, rather than the usual industry
practice of previewing it to the media
under an embargo. Here are some of the
highlights of the new release, which
shipped in July.
Surfacing with SynchTech
Solid Edge had a surfacing component
that it called “BlueSurf,” but it was in seri-
ous need of upgrading, because it did not
employ Synchronous Technology. So in
Solid Edge ST 6, surfacing becomes part
of the history-free SychTech environment.
This feature is aimed at industrial design-
ers, who like to make consumer products
with swoopy curves (See figure 1).
Surfacing differs from solid modeling
Inside Solid Edge
ST6
CADReport
Figure 1: An example of surface modeling in Solid Edge ST6.
Is the latest version
of Siemens’ Synchronous
Technology the best yet?
14-17-DES.indd 14 13-10-10 1:26 PM
15. www.design-engineering.com October | 2013
15
inthatwemanipulatepointsonthesurfaces
of3Dobjects,ratherthantheobjectsthem-
selves; the CAD program fills in the rest
visually to make the objects look solid.
To ensure swoopiness, Siemens added
C2 curvature in all areas. (C0 positions,
C1 ensures tangency, C2 ensures con-
tinuous curvature; these are visually
similar to the more general G0-G2 cur-
vature used by other CAD systems and
differ only mathematically.) C2 means
that any two adjacent surfaces will meet
smoothly, with no kinks.
Siemens also added a whole wack of
new functions to create and edit surfaces.
These include in-place curvature edits,
bounded surfaces, 3D control handles
(instead of just 2D), ruled surfaces, user-
defined UV curve densities, curvature
combs, symmetrical reflection, trimming
and extending multiple faces at once, and
defining replacement faces.
This last one is useful for imported
surfaces. It replaces many “dumb” sur-
faces with intelligent ones (i.e., ones that
use SynchTech). The replaced faces can
then be interactively edited once key
point curves are added, and transitions
between faces made smooth through C2.
Integrated CAM
For the first time with ST6, a CAM
(computer-aided manufacturing) system
runs inside Solid Edge. While this capa-
bility is not new to other MCAD systems,
it serves to illustrate how Siemens PLM
does not have a strong third-party devel-
oper community, as do competitors
Inventor and SolidWorks.
To make this happen, Siemens PLM
worked specifically with Geometric Soft-
ware Solutions and its CAMWorks soft-
ware. The advantage to integration is that
when the CAD model is updated, the
CAM tool paths are updated automati-
cally. (The reverse does not occur.) It
becomes a single click to switch between
CAM and CAD modes. CAMWorks
provides 2.5- and 3-axis milling, and
2- and 4-axis turning.
As an added bonus, CAMworks has
automated feature recognition that lets
it treat imported CAD models from
Inventor, SolidWorks, CATIA, Pro/E,
NX, CADKEY, Rhino and standard for-
mats as native Solid Edge files. All CAM
data is stored in the Solid Edge drawing
file, but can be exported if necessary.
There are, however, some drawbacks:
You need to upgrade to ST6, and you have
to like CAMWorks. Some users I spoke
with at SE University were not keen on
how CAMWorks handles certain opera-
tions. In that case, you’ll have to continue
to use your preferred CAM software
external to Solid Edge.
Drafting Enhancements
The biggest cheer from users was reserved
for one feature in particular: After num-
CADReport
Figure 2: Dimensions laid out automatically by Solid Edge ST6.
14-17-DES.indd 15 13-10-10 1:26 PM
16. October | 2013 www.design-engineering.com
16
bered balloons were placed along an
aligned shape, the demo jock dragged the
shape to smoothly repositioned all con-
nected balloons. The same happens with
dimensions: select a drawing view, and
dimensions are arranged automatically.
(See figure 2.)
These automatic alignment functions
serve to emphasize how important Sie-
mens PLM considers 2D drafting to be:
More important than 3D modeling and
surfacing. “[2D] drawings are still king
of the product development world,” the
company insists.
Here are some more enhancements ST
6 upgraders can expect to see: Center
marks and callouts are placed automati-
cally for slots. It’s easier to draw circles
that define bolt holes.
Parts lists (BOMs) are generated auto-
matically by selecting objects and linked
balloons are created automatically as well.
BOM tables can be edited directly, and
the formatting of individual cells can be
overridden.
The drawing view wizard previews
proposed views and view settings can
then be saved for later reuse in new draw-
ings. Any two views can be aligned by
relating a point in each view, or by using
the center of each view. Broken (detail)
views are associative, so they update when
the source view changes.
Schematic blocks can be edited in-
place, kind of like the RefEdit command
in AutoCAD. Similarly, embedded objects
like spreadsheets and images can be edited
inside Solid Edge through the OLE
mechanism, which displays the source
program’s user interface and editing tools.
Finally, the display speed of drawings
is improved, with zooms, pans and
hatches redrawing more quickly.
Other New Functions
When there are 1,300 new features, it’s
hard to fit them into a single article. Let
me run quickly through a few more sig-
nificant improvements:
ST6 now deforms sheet metal parts with
dimples, louvers, drawn cutouts, and beads.
Contour flanges can be added along edges.
Sheet metal features can be placed on
ordered parts. A body can stamp a target
body. Flatten operations preserve chamfers,
bends, and holes across bends.
The online video service YouTube runs
inadockablepaneforviewinginstructional
videos; a new dialog box lets ST6 record
design sessions for upload to YouTube,
creating instant tutorials for other users.
Goal-seeking is available for 3D, instead
of just in 2D. Physical properties in a table
are used for iterative solving; significantly,
this analysis now works in synchronous
and ordered (a.k.a. history) modes.
The Simplify Assembly Environment
makes use of all ordered (history) part
modeling commands. The new Enclose
Components command replaces selected
items with simplified representations.
The Duplicate Body command copies
and patterns (arrays) solid bodies—
single or multiple.
Targeting the uncertainty over the
future of SolidWorks, Siemens PLM
makes it possible to bulk-import parts
and assemblies. The user interface of Solid
Edge can be adjusted to better suit ex-
SolidWorks users. (See figure 3.)
Solid Edge Insight XT is renamed
Solid Edge SP, where SP is short for
Microsoft’s SharePoint online file man-
agement system. And, as for the cloud,
company executives emphasized that
there would be no cloud version of Solid
Edge itself, although drawings can be
accessed through TeamCenter servers
and portable apps running on Android
and iOS.
Greatest Ever?
This is a rare occasion when a software
release actually can be described as “the
greatest ever.” While CAD vendors typi-
cally improve one area in a new release
significantly, Solid Edge ST 6 makes
strong advances in four important areas:
C2 surfacing and editing, CAM integra-
tion, SolidWorks compatibility, and
greater automation in 2D drawings.
But just how well is Solid Edge doing?
Siemens PLM is secretive about sales
figures, unfortunately. We know only
that Solid Edge grew 25 percent in USA
licenses in the second quarter of this
year—a cherry-picked statistic, clearly.
The question is, 25 percent on what? We
don’t know, other that before it was pur-
chased in 2007 by Siemens, UGS reported
revenuesthatmadeitthethirdlargestCAD
vendor, ahead of PTC but behind Autodesk
and Dassault Systemes.
Being a small part of the $100 billion-a-
year Siemens AG, Solid Edge didn’t get
sufficient attention marketing-wise for the
first few years. This, however, is changing
forthebetter,asweseewiththenew,annual
SolidEdgeUniversity.SolidEdgeisinagood
position to become the strongest MCAD
packagetoprovidehybridhistoryanddirect
editing. DE
www.solidedge.com
Ralph Grabowski is a CAD journalist and
blogger at worldcadaccess.typepad.com
CADReport
Figure 3: Options for importing SolidWorks assembly and part files.
AD-116
14-17-DES.indd 16 13-10-10 1:26 PM
18. October | 2013 www.design-engineering.com
18
DesignSpark Mechanical offers
no-cost push-pull solid modeling
Typically, learning to use 3D CAD software efficiently
requires a sizeable investment in time and money—
two factors that keep many drafters rooted to their famil-
iar 2D packages and many would-be designers at arms
length from complex 3D applications.
To help spread the use of 3D CAD design, electronics
distributors, Allied Electronics and RS Components, in
partnership with SpaceClaim, released DesignSpark
Mechanical, a no-cost direct modeling 3D solid
geometry creation tool.
Based on SpaceClaim Engineer code, DesignSpark
Mechanicalisn’tsomucha“dumbed-down”versionofthe
comprehensive modeling package but a rearrangement of
the interface to simplify it for new and/or casual users, say
SpaceClaimreps.Forexample,usingMechanicalissimilar
toSketchup’ssketchandextrudetechnique,butfocuseson
four basic modeling commands: Pull, Move, Fill and Combine.
Within each of those commands, however, reside many of
the functions experienced CAD users would be familiar with.
For example, Pull is used to extrude, fillet, sweep, shell, and
scale geometry, while Move can be used to reposition, rotate,
pattern or mirror 3D features or 2D sketch components.
Similarly, Fill is used to create surface patches and Combine
contains all the common boolean functions.
WhileMechanicalisn’t“ToyCAD”andfeaturesmanyofitsbig
brother’s modeling capabilities, it doesn’t include the extras of
commercial applications such as industry specific tools or render-
ing. The biggest distinction between Mechanical and SpaceClaim
Engineer is the former’s lack of import and export capabilities.
WhileSpaceClaimisaveritable“universaltranslator”ofCADdata,
DesignSpark Mechanical is limited to only a few options.
Forexample,itimportsonlyopenformatssuchasOBJ,SketchUp,
STEP, STL and notably, ECAD files (IDF) like those created by the
company’sfreeelectricalCADapplication,DesignSparkPCB.This,
the company says, allows electrical and mechanical engineers to
collaborate easily on the creation of circuit boards and the larger
enclosures and/or assemblies to house them.
Similarly, Mechanical exports AutoCAD (DXF), OBJ, STL,
XAML, JPEG, and PNG file formats, along with 3DPDFs. This
fact somewhat limits its use beyond 3D printing, CNC preparation
and early-on design conceptualization. However, solids can be
exported individually or combined (internalized) into assemblies
or “components” which can be packaged as a single file.
Even so, Mechanical users do have access to approximately
38,000 3D models in DesignSpark’s online component library as
well as TraceParts’ extensive CAD portal in DesignSpark Mechan-
ical format. In addition, the modeling application also acts as a
sort of e-commerce portal, in that a tab within the interface allows
users to order components, in the automatically populated BOM,
directly from Allied Electronics/RS Components.
DesignSpark Mechanical is compatible with Windows XP
through 8 in either 32- or 64-bit versions. The application is
available for download on the DesignSpark website.
www.designspark.com/eng/page/mechanical
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18-21-DES.indd 18 13-10-10 1:43 PM
20. 20
Autodesk integrates
CAM into Inventor
After two months in beta development, Autodesk announced
the release of its free CAM add-on, Autodesk Inventor HSM
Express. The software is the result of the company’s acquisition
a year ago of HSMWorks. Although the CAM developer was
closely associated with Solidworks, Autodesk has repeatedly
assured Dassault Systemes customers that it will continue to
refine the package in parallel for both platforms.
While free, HSM Express includes many of the functions of
its approximately $10,000 stand-alone product, Inventor HSM,
which won’t ship until 2014. Besides its integration into the Inven-
tor interface—allowing for full associativity between model and
generated toolpaths—HSM Express supports 2 and 2.5-axis CAM
operations, representing a sizeable portion of CAM work being
done. In addition, Express fully exploits the advantages of
modern 64-bit processors, allowing it to address more system
memory and harness multiple cores simultaneously.
HSM Express also includes toolpath strategies for generating
milling, drilling, counterboring and tapping operations as well
as adaptive clearing or roughing that generates roughing/clear-
ing toolpaths inside closed curves both with and without islands.
It also includes a backplot simulation tool and a CNC program
editor for NC functions, file-compare, CNC templates, backplot-
ting, and serial communications for RS232 DNC transfers. The
CAM add-on also includes generic post processors for CNC
machines from Fanuc, Heidenhain, Haas, Hurco, Mazak, Mill-
Plus, Okuma, Siemens and Yasnak, among others.
Although free to download from Autodesk’s CAM website,
Inventor HSM Express does requires an active license of Autodesk
Inventor or Inventor LT 2014.
http://cam.autodesk.com
CADNews
Autodesk’s Inventor HSM Express offers 2.5-axis machining, toolpath
strategies, adaptive roughing and backplot simulation at no cost.
18-21-DES.indd 20 13-10-10 1:43 PM
21. 21
3DConnexion releases
wireless 3D mouse
3Dconnexion announced a wire-
less version of its popular 3D
mouse, appropriately dubbed the
SpaceMouse Wireless. Similar
to its other products, the
SpaceMouse features
6-degrees-of-freedom to
manipulate the view of 3D
models quickly without
having to look at a keyboard.
For this version, however, the
3D mouse cuts the cord and
includes a 2.4GHz bluetooth
dongle that operates at a range
up to 10 meters. The mouse
also has an lithium-ion battery,
charged through a micro-USB port, that lasts up to one month,
the company says. The 3Dconnexion SpaceMouse Wireless is
compatible with Windows, OS X and Linux and is available for
order from the company’s web site for US$129.
www.3Dconnexion.com
CAD MicroSolutions adds
Electronics Design Software
Canadian Solidworks reseller CAD MicroSolutions announced
that it has added products from electronics design software
company, Altium, for clients expanding into the electronic
design automation market. Altium’s product line will be added
to CAD MicroSolutions existing line of design tools including
SolidWorks, DriveWorks, Boxx and Dell hardware. Altium
products span the domains of PCB implementation, FPGA
design, embedded software development and design data
management.
www.cadmicro.com
CADNews
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18-21-DES.indd 21 13-10-10 1:43 PM
22. October | 2013 www.design-engineering.com
22
Design software is great but it isn’t auto-magical and can even be counter-productive if not
implemented intelligently.
By Scott Hale
Much has been said about the Canadian manufacturing
industry’s productivity. There are highly educated profes-
sionals in both technical and business fields. Capital markets
are healthy and capable of funding infrastructure requirements.
Why then is productivity notably lower than capacity?
One area that holds promise for big productivity improve-
ments—and that is regularly exploited—is buying into manu-
facturing software. But, as many have discovered, software isn’t
a magic bullet. A poor implementation can lead to large work
backlogs, missed deadlines, budget overruns, and outright
rejection. Technology may lie at the heart of productivity and
innovation, but it must be coupled to great process design.
Manufacturers looking to realize productivity improvements
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24. October | 2013 www.design-engineering.com
24
1Define what you want to achieve and assign champions
You can’t get anywhere if you don’t know where you are
going. Establish a solid foundation for the implementation
project by identifying what you would like to achieve. For
example, do you want to reduce staffing requirements? Slash
time to project delivery by 50 percent? Optimize workflow
processes? Establish product specifications once and have those
retained downstream? Integrate sales orders with the shop floor’s
production schedule? The possibilities are endless, but your
organization will have a top three list specific to your business
and based on how you currently work.
A great way to narrow down the list of business objectives is
to survey staff. Compile their feedback to identify the top areas
for improvement. This stage results in a business case for the
project, a plan that outlines the specific milestones required to
complete the project and builds consensus amongst the various
stakeholders.
To ensure success, identify a core team of people in your orga-
nization who will be champions for the project. Look for the
people who will be most impacted by change, but least resistant,
and assign a clear project leader to ensure proper oversight.
2Develop data and workflow standards and train staff
During the development phase, identify design and workflow
standards, styles, settings, preferences and any software con-
figuration requirements. By creating and maintaining design
standards, you ensure consistency and relieve people of redun-
dant tasks that need not be repeated every time a new project
hits their desktop.
At this stage, you can start training your people on the newly
defined standards, so they understand the basics and how they
apply it to their workflows and environment. Where applicable,
get them involved in the creation of any standards to gain the
benefit of their expertise and to ensure buy-in.
3 Deploy a pilot project
Piloting a new workflow or design process allows for test-
ing and validation before rollout to the rest of the team. In
addition, a pilot reveals unforeseen components of your plan
that may need revision. Pilot project selection is key to success
and should take into consideration three things.
One: Pick a project that your team is used to working on. So,
for example, if your shop works mostly on custom products,
then select a custom project. If you manufacture product lines
that have variable specifications, choose a product line that has
a few variations, but not a million. Really, this is about right-
sizing your choice to allow for initial success and can act as a
model for other products.
Two: Consider a project with liberal timelines, not one with
looming deadlines. Rushing to make a deadline while imple-
CADBeat
7PLNT15928.indd 1 3/20/07 12:32:48 PM
22-25-DES.indd 24 13-10-10 1:44 PM
25. www.design-engineering.com October | 2013
25
menting new technology, workflows and processes is a recipe
for disaster – especially when staff needs to learn the new pro-
cesses and software skills.
Three, pick a project that’s reasonable in size. If it is too small,
you can’t fully understand the value of the new process. If the
project is too large or complex, the learning curve may be too
steep. The idea behind pilot project selection is that you are
trying to minimize the number of curveballs thrown at your
team all at once.
Often at this stage you will need to provide additional train-
ing because people will identify gaps in their knowledge. This
is very useful for the next stage when everyone will adopt the
new system, because you can tune the training to address the
most common gaps.
4Deliver across your entire organization
Once you have optimized your workflow, standards and
configuration based on the pilot, you can start rolling out the
new processes and technology to the entire company. Make sure
you provide both technical and workflow training for all users.
Assigning mentors for different roles gives people the support
they need to work at their own speed and receive guidance when
they run into difficulties – whether technical or interpersonal.
Provide feedback to everyone regarding their progress and
encourage them to make improvements as they learn. Getting
your whole team up and running with more efficient and opti-
mized processes is exciting to watch and the results should be
evident in massive productivity improvements.
Keep your antennae up and be ready to adopt new tech-
nologies and approaches that will improve productivity and
your ability to innovate. Recognize though, that every manu-
facturing operation is unique and will require a unique solution.
Make sure your software implementation goes beyond instal-
lation and delves deep into the heart of how you work. DE
www.imaginit.com
Scott Hale is the Director of Consulting Services for the Manu-
facturing Solutions Group of IMAGINiT Technologies. The
team provides a wide range of customized services to meet the
needs of manufacturing focused organizations. Scott can be
reached at shale@rand.com
CADBeat
22-25-DES.indd 25 13-10-10 1:44 PM
26. October | 2013 www.design-engineering.com
26
By Mike McLeod
It’s somewhat rare that a small entrepreneurial player not only
breaks into an established industry but also beats its long-time
incumbents at their own game. However, for Jon and Chris
Thornham—FLO Cycling’s twin mechanical engineering duo
from Dartmouth, Nova Scotia—the transition from “audacious”
idea to entrepreneurial success has been nearly as quick as the
high-end, aerodynamic, yet affordable, bike racing wheels their
young company is known for.
“There is no single component you can change on a bike that
will give you better aerodynamic performance than a set of
wheels,” says Jon Thornham, who founded FLO Cycling in Las
Vegas with his twin brother Chris in 2010.
In contests where speed is the deciding factor, competitors
will search for any advantage, no matter how seemingly small.
For example, in bike racing, hundreds of a second can add up
to a commanding lead or relegate less streamlined racers to
footnote status. Consequently, competitors will bear nearly any
price to assure their aerodynamic superiority.
At least that was the case for Chris Thornham, a competitive
triathlete himself, when he told his twin brother Jon in 2010
how much he’d just paid for a set of high-end racing wheels for
his road bike.
“He told me what he’d paid for them and I said, ‘You’ve got
to be kidding me!’” relates Jon Thornham, adding that such
wheels commonly cost anywhere from $1,800 to $3,500. “He
asked me if I thought we could make them cheaper and I said,
um, yeah. So, I asked him if he thought we could make them
with the same performance and he said yes. So we just started.”
Although both Jon and Chris had worked as mechanical
engineers for several years after graduating from University of
New Brunswick, neither had experience in manufacturing or
sports-related product development. Added to that, they were
facing an industry dominated by big name companies that had
spent years—and untold amounts of R&D money—in expen-
sive wind tunnel testing to refine and prove the aerodynamic
efficacy of their products.
Against this headwind, the self-funded start-up leveraged a
few key advantages. The first was an appreciation of the real
world conditions racers face. According to Thornham, the
aerodynamics of an aero wheel primarily comes down to the
depth and shape of its fairings, the strip of material that spans
from the tire rim inward toward the hub. During straight-on
headwinds, fairings have little influence on aerodynamics, but
such conditions rarely happen during competition.
However, when hit by off-center winds, the leading edges of
both the front and back of the wheel split the air and the fairings
help maintain attachment of the airflow, thereby reducing tur-
bulence and drag. The challenge, then, became designing a
wheel that performed consistently over the most common range
of side-wind angles, or degrees of yaw, that riders encounter,
Thornham says.
“What we did was create what we call a net reduction drag
FLO Cycling’s Canadian engineers up-end bike racing equipment industry
armed with CFD and a competitive drive.
CoverStory
Wheels
in Motion
Canadian engineer and FLO Cycling
co-founder, Jon Thornham inspects
one of his company’s high-end,
CFD-designed bike racing wheels.
26-29-DES.indd 26 13-10-10 2:01 PM
27. www.design-engineering.com October | 2013
27
value,” Thornham explains. “We know that 80 percent of a
rider’s time is spent between 10 and 20 degrees of yaw so we
looked for specific shapes that were aerodynamically efficient
over that whole range and not just at one very specific yaw angle.”
To optimize for that broad range, Jon and Chris devised a
distinctive wide fairing design that deviates significantly from
the industry standard. Most fairings have either a V-notch or
teardrop toroid cross-section that taper to a point. While aero-
dynamic, they can introduce instability when hit by a gusting
crosswind. The asymmetry between the leading edge of the wheel’s
front half (rounded tire) and the leading edge of the wheel’s back
half (the sharp edge of the V or toroid) creates uneven wind
resistance that can cause the front tire twist suddenly.
By contrast, FLO’s wide and rounded fairing mirrors the
shape of the tire, providing even aerodynamics at the first and
back half of the wheel. At the same time, the rounded shape
enhances boundary layer attachment while the fairing’s depth
takes advantage of the off-angle airflow to propel the bike for-
ward, similar to a sailboat tacking into the wind.
“We designed our wheel to create a smooth transition from
the tire to the rim to the wide toroidal fairing, which allows the
boundary layer of airflow to stay attached longer,” Thornham
says. “At the same time, we were looking to balance forces in a
way that reduced drag by pushing the bike forward to some
extent while not creating a wheel that is rough to ride”
With a number of prototypes modeled in CAD, the brothers
still had to narrow their candidate designs down to one. Even
today, Thornham says industry practice is to run multiple
physical prototypes though hours of wind tunnel testing to the
tune of approximately $500 to $900 per hour, well beyond the
means of a small start-up.
To sidestep this cost, Jon and Chris leveraged their other key
advantage: Computational Fluid Dynamics (CFD). They turned
to friend and consulting engineer, Justin Smothers, founder of
JSC Engineers, who ran each potential design through a com-
paratively inexpensive seat of CD-Adapco’s STAR-CCM+
simulation software.
“I ran all the model variations in wind speeds from 5-30 mph
in intervals of 5 and from 0-20 degrees of yaw,” says Smothers.
CoverStory
The rounded profile of FLO Cycling’s Wide Ride fairings provide
greater stability and aerodynamic airflow than designs common in
other racing wheels.
V-NOTCH WHEEL EARLY TOROIDAL WHEEL FLO WIDE TOROIDAL WHEEL
26-29-DES.indd 27 13-10-10 2:01 PM
28. October | 2013 www.design-engineering.com
28
“Since we only had a license for one processor, it took us 28 days
to run through all the variation, but if we had more processors
it would have taken a lot less.”
Using a k-epsilon turbulence model, Smothers says the wheel
designs were simulated in changing wind speeds and yaw angles
to optimize the geometry across a wide range of conditions. Each
prototype model was composed of a polyhedral mesh with 1.5
million cells, including a prism layer to capture boundary layer
flow as well as refinement zones near the wheel to analyze wake.
After a number of tweaks, the end result was a single wheel design
that performed as well in the wind tunnel as competitors’ prod-
ucts but at a fraction of the development cost.
“CFD drastically saves time and money because we’re not
having to manufacture a rough shape and then spend time in
the wind tunnel,” Thornham says. “Other companies claim that
they’ve spent half a million dollars developing one wheel. We
developed four wheels for not anywhere close to that.”
Those lower costs, Thornham says, allowed the company to
price their four wheels (the FLO Climber, FLO 60, FLO 90 and
FLO Disc) at a fraction of their competition. Sold directly from
the company’s web site, a set of FLO Cycling’s high-end
aluminium and carbon fibre wheels, for example, cost US$898.
That compared to the $1,800 and up Chris had paid two years
previous. Not surprisingly, customer enthusiasm was immedi-
ate and almost overwhelming, Thornham says.
“In our first pre-order in 2012, we ended up selling 750 wheels
in an hour even though the web site crashed the minute we
opened up due to the traffic,” he says. “This year, we’ve had four
pre-orders and all of them have sold out within 15 minutes. In
2012, we shipped 1,500 wheels and this year, we’re on track to
ship 3,600 wheels to 38 countries. Even though we’ve experienced
140 percent growth, demand for our product continues to spread
quickly. Luckily for us, people like it.” DE
www.flocycling.com
CoverStory
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CFD flow visualization showing pressure and velocity around FLO
Cycling’s FLO 60 wheel.
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30. October | 2013 www.design-engineering.com
30
By Lee Hudson
Today’s industrial process control applications increasingly use
automated systems to optimize operations and ensure a safer,
more productive process. Linear position sensors used in these
automated systems provide highly accurate feedback on product
parameters, control states and outputs to machine controllers.
Whether implemented as a standalone component or as part
of a control or safety system, the linear position sensor—also
known as an LVDT—is capable of providing linear displacement
measurements from micro inches to several feet, under various
operating and environmental conditions with high accuracy
and reliability. Essentially, the LVDT linear position sensor plays
an important role in machine control by providing feedback
about product location.
Mechanics of an LVDT
In basic terms, an LVDT linear position sensor is an electro-
mechanical device that converts linear position or motion to
a proportional electrical output (see Figure 1). More specifically,
the LVDT position sensor produces an electrical output signal
directly proportional to the displacement of a separate movable
core. Typically, the ferrous core within the LVDT is attached
to the moving element on the piece of equipment requiring
position feedback.
In operation, the LVDT’s primary winding is energized by
alternating current of appropriate amplitude and frequency,
known as the primary excitation. The LVDT linear position
sensors’ electrical output signal is the differential AC voltage
between two secondary windings, which varies with the axial
position of the core within the LVDT coil. Usually, this AC
output voltage is converted by suitable electronic circuitry to
high level DC voltage or current for convenient use by a computer
or other digital output device.
Because there is normally no contact between the LVDT’s
core and coil structure, no parts can rub together or wear out.
This means that an LVDT linear position sensor features unlim-
ited mechanical life. This factor is highly desirable in many
industrial process control and factory automation systems.
LVDT Use in Process Control Apps
Recent innovations in construction materials and manufactur-
ing techniques, as well as low-cost microelectronics, have revo-
lutionized the LVDT linear position sensors into a more reliable
and cost-effective technology for process control applications.
In the past, the electronics necessary to operate LVDT linear
position sensors properly were complicated and expensive,
prohibiting its wide use in process control applications for
displacement measurement.
Modern ASIC and microprocessors give LVDT technology
more complex processing functions and enable signal condition-
ing within the sensor housing. As a result, LVDTs generate
digital outputs directly compatible with computer–based systems
and standardized digital buses. In addition, today’s linear posi-
tion sensors can provide more accurate and precise measurement
of dimensions in a wider variety of quality control, inspection
equipment and industrial metrology applications.
For applications where sensors must operate in extreme
environments, the sensing element can be segregated from the
electronic circuitry. Connected by long cables up to 31 meters
(100 feet), AC-operated LVDTs can work with remotely-located
electronics that power the sensors, amplify and demodulate
their output. Output is then displayed on a suitable readout
and/or inputted into a computer-based data acquisition system
for statistical process control. This ability to transmit data to a
remote computer has made linear position sensors popular in
quality assurance schemes.
Tight Places with Harsh Conditions
While linear position sensors were once considered too long for
applications with limited space, new winding techniques and
computer-based winding machines allow the linear position
sensor body to be reduced while maintaining or increasing
stroke length. With the improved stroke to length ratio (now
up to 80 percent), the LVDT linear position sensor becomes a
viable position measurement device for machine tool position-
ing, hydraulic cylinder positioning and valve position sensing.
Smaller, contactless linear position sensors also feature a
Positive Feedback
Modern LVDT linear position sensors gaining preference in industrial applications.
MotionControl
30-31-DES.indd 30 13-10-10 2:02 PM
31. www.design-engineering.com October | 2013
31
lightweight low mass core that is ideal for process control appli-
cations having high dynamic response requirements.
LVDTs are also configurable in a variety of mechanical and
electrical designs to meet the measurement and environmental
requirements of various process control application. New corro-
sion-resistance/high-temperature materials such as Monel or
Inconel enable the LVDT linear position sensor to operate in more
hostile environments. For applications where sensors must with-
stand exposure to flammable or corrosive vapors and liquids, or
operate in pressurized fluid, its case and coil assembly can be
hermetically sealed using a variety of welding processes.
For example, in power generation applications, linear posi-
tion sensors designed for high temperature and mild radiation
resistance can perform in power plants to provide feedback on
the position of nuclear steam and gas turbine control valves for
increased plant efficiency and reduced operating costs.
In a typical power plant, steam turbines contain a number of
control valves . Typically, plants have very precise control schemes
for valve position to increase operating efficiency and save fuel.
Operating within the harsh environment of a power or steam
plant, linear position sensors can determine if valves are fully
opened or closed to within a thousandth of an inch, providing
output to remote electronics that can be monitored by operators
if something is not working properly.
Sensors also play an important role in the predictive main-
tenance of gas turbines as part of process control systems used
to monitor shell expansion and bearing vibration. Installed on
turbine shells, hermetically-sealed LVDT position sensors mea-
sure shell expansion, providing linear output that operators can
utilize to determine proper thermal growth of a turbine shell
during startup, operation and shutdown.
LVDTs designed to withstand shocks and heavy pounding
are used in the press and dye industry for the mechanical con-
trol of machine operations as improper operation can lead to
broken dyes while ambiguous force of presses can lead to mis-
shapen and out-of-spec parts. Spring-loaded LVDT position
sensors are installed on presses so that the plunger of the sensor
is compressed as the punch press comes in contact with the
metal being shaped. The output of the LVDT is fed back into
the machine’s control system, providing feedback on how far a
press has moved and when to stop.
For more than six decades, LVDT linear position sensors have
served as part of measurement and control systems, providing
essentialinformationwithoutwhichmanyprocesscontrolsystems
couldn’t function. DE
www.macrosensors.com
Lee Hudson is an application engineer with Macro Sensors.
MotionControl
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30-31-DES.indd 31 13-10-10 2:02 PM
32. To advertise your solution in this section call Alan Macpherson at 416.510.6756
DesignSolutions
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
October | 2013 www.design-engineering.com
32
Motion Control
Safe Motion Modules
Kollmorgen launched its KSM Safety Module
line, which combines Safety PLC functionality
with safe motion functions when paired with
the company’s AKD drives and automation
controllers. KSM can also connect to Ether-
CAT, Profinet, and CANopen devices. KSM is
capable of fifteen different Safe Motion func-
tions, including Safe Torque Off (STO), Safe
Stops (SSX), Safe Limited Speed (SLS), Safe
Limited Position (SLP), and Safe Brake Control
(SBC), among other functions. The safety
system can simultaneously monitor up to twelve axes in a single
system. KSM Safety Controllers are TUV certified for machines that
require ISO 13849 PLe and IEC 61508 SIL3 level functionality.
www.Kollmorgen.com/KSM
Stepper Motor Controller
Haydon Kerk Motion Solutions
added the PCM4806E to its
IDEA Drive line of stepper motor
controllers. The RoHS-compliant
drive allows an encoder input to
the controller for closed-loop
position correction capability.
The encoder interface is
designed to accept single-
ended, 2-channel quadrature encoder input and an index signal.
The 90 degree offset of Channel A and B allows the system to
determine motor direction. A 1000 line encoder will be translated
by the firmware as a 2000 pulse signal for use in position correction.
Other features include programmable current control; a single
supply voltage of 12 to 48VDC; 0.6Arms (0.84Apeak) max rated
current per phase; and 8 opto-isolated general purpose I/O. Each
input is rated for 5 to 24VDC, 8mA maximum per input.
www.idea-drive.com
Motors and Drives
ECPM Motor
NovaTorque Inc. announced that
its Gen2.0 PremiumPlus+ Elec-
tronically Commutated Permanent
Magnet (ECPM) motors are now
available in 3hp and 5hp 2400
rpm (maximum speed 3600 rpm)
models. Driven by variable fre-
quency drives (VFD), the line possesses motor-only rated point
efficiencies of 93 and 92 percent for 3hp and 5hp versions respec-
tively. Additionally, the motors maintain high efficiency and torque
over a broad speed and load range, the company says. NovaTorque
PremiumPlus+ motors are packaged in standard NEMA frame sizes
and mounting dimensions and compatible with VFDs from most
leading manufacturers.
www.novatorque.com
IdeaGenerator
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
32-36-DES.indd 32 13-10-10 2:03 PM
33. www.design-engineering.com October | 2013
33
Spindle Drive
Maxon Motor released a ceramic spindle with the
launch of its GP8S and GP16S spindle drives. The
GP 16 S metric M6 ceramic spindle transmits up to
315 N in short-term operation. It also features axial ball bearings and an integrated
planetary gearhead. Similarly, the company’s 8mm GP 8 S spindle drives come
standard equipped with metric steel spindles or ceramic spindles. The M3 x 0.5mm
spindle is designed for feed forces of up to 32 N in short-term operation. Two pre-
loaded ball bearings serve as the axial bearing. Due to the extremely compact design,
the GP 8 S spindle drives achieve a very high force/volume ratio, a characteristic highly
desirable for collimators, dosing pumps, and many other applications.
www.maxonmotorusa.com
Insulated Motor Cable
HELUKABEL introduced its TOPFLEX
620 VFD, a flexible-PVC, XLPE-insu-
lated power cable built for on/off or
slow down/speed up VFD motor
applications. The special PVC jacket is resistant to oils (Oil Res I & II), coolants and
solvents and is also double-shielded to resist electrical noise. The power cable is
available in a four conductor configuration ranging in sizes from 16 – 2 AWG. It has
been rated for both 600V and 1000V applications, and can operate in varying
temperature environments from -25°C to 105°C, having passed both the -25°C cold
impact and -40°C cold bend tests. In addition to UL (1277 and 2277 Flexible Motor
Supply Cable) and CSA (AWM I/II A/B), the TOPFLEX 620 VFD is CE approved for
machine builders exporting to Europe.
www.helukabel.ca
Fluid Power
Pneumatic Cylinders
AutomationDirect’s NITRA pneumatic product line
now includes D-Series double-acting heavy-duty
air cylinders with a 250 psi operating pressure and
adjustable cushions to provide end-of-stroke decel-
eration at both ends. All D-Series cylinders are
constructed with aluminum components and a
magnetic piston fitted with a PTFE wear band; all
cylinders can be used along with solid state or reed
switches for rod position sensing. The series
includes bore sizes from 1 ½-inch to four inches and stroke lengths from one inch
to 24 inches to meet a broad range of applications. Models feature flange, rear clevis
and rear pivot, side and rod clevis mounting options.
www.automationdirect.com
Slurry Pump
KSB introduced its heavy-duty KWPK series pumps,
designed to handle slurries and aggressive fluids.
The KWPK family is based on a modular design so
that individual pumps can be customized to meet
specific application requirements. Five standard
material combinations are available, each with
different characteristics with respect to corrosion
resistance and wear resistance and cost. Seals and
IdeaGenerator
32-36-DES.indd 33 13-10-10 2:03 PM
34. October | 2013 www.design-engineering.com
34
bearings have been designed to withstand the effects of corrosive
or abrasive media. This series of pumps feature KSB’s K-type non-
clogging impeller design and are available in a range of sizes, with
inlet diameters from 40mm to 900mm. Maximum flow rate is
15,000 m3/hour, while the discharge head is up to 100m.
www.ksb.com
Ball Valve
AALBORG Instruments released
its Three-Way PTFE Ball Valve. The
manually operated valve is con-
structed of PTFE wetted parts and
Polypropylene structural compo-
nents. Four separate handle posi-
tions facilitate ¼ turn selectable
flow patterns.
The valve targets corrosive
and ultra-pure fluid applications
in laboratories and industrial
processing applications. The valve
features ½-inch Female NPT Inlet and Outlet Ports; a Flow
Coefficient (CV value) of 6 and maximum operating pressure of
4.1 bar (60 psig).
www.Aalborg.com
Power Transmission
Hinged Shaft Collars
Stafford Manufacturing Corp.
introduced a line of hinged shaft
collars that feature a triple-link
hinge and a captive clamping
screw but provide the same hold-
ing power as standard two-piece
collars. Available with square, hex,
round and threaded bores, the
shaft collars are available in 25
sizes from 3/8-inch to 4-inch I.D.
and 16 metric sizes from 6 mm to
50 mm. Offered in steel and two
grades of stainless steel, the col-
lars can be modified with tapped holes for attaching sensors.
www.staffordmfg.com
Endless Timing Belts
BRECOflex Co. announced a line of seamless timing belts avail-
able with Nylon facing (PAZ, PAR) and a large variety of backing
materials. Tension members are available in steel, stainless steel
and Kevlar. Polyurethane materials are offered in 92 Shore A,
IdeaGenerator
GTC Falcon Mini-Joints feature
Zero-Backlash and all stainless steel
construction. Suitable for instrumentation
and control systems. Mini-Joint universal
joints available as single, double &
telescoping versions. Bore sizes of .031”
to 1”/ 1mm to 30mm.
Also now available:
NEW Mini-Joint Ball Splines, featuring Zero-Backlash.
Also available:
Precision Mini-Joint Couplings for angular,
parallel & axial misalgnment, with operating
speeds to 30,000 RPM
Our Experienced engineering staff invite all
U-Joint and Shaft Coupling inquiries, as we
design our product to YOUR application.
Tel: (508) 746-0200, 888-309-0646
Fax: (508) 746-6494
E-mail: sales@gtcfalcon.com
URL: www.gtcfalcon.com
ZERO BACKLASH
UNIVERSAL JOINTS
32-36-DES.indd 34 13-10-10 2:03 PM
35. www.design-engineering.com October | 2013
35
85 Shore A, in FDA food grade, as well as with a
high ambient temperature PU-material. All BRECO-
flex endless timing belts incorporate the com-
pany’s bifilar tension member technology as well
as Standard Plus manufacturing technology.
According to the company, the belts feature length
tolerances down to 0.05 mm per meter as well
as tensile strength twice that of welded “V”
timing belts.
www.brecoflex.com
Spring-Engaged Brake
Nexen released its dual faced brakes (DFB) and quad
faced brakes (QFB) with torque capacities that range
from 9,000 to 164,800 inch-pounds. The brakes feature
a piston and cylinder actuator sealed with O-rings, as
well as non-asbestos friction facings and low-inertia
friction discs. The dual-faced brakes are engineered with
a single-disc assembly, and the quad-faced brakes have
a double-disc assembly. The brake housing is flange
mounted to machinery, and the hub is keyed to the shaft.
Cylinder inlet ports provide direct air supply.
www.nexengroup.com
Transformer Disconnect Terminal Blocks
WAGO Corporation introduced its 2007 Series TOPJOB
current transformer disconnect terminal blocks that
feature an orange three-position (Operating, Shorting
and Measuring) disconnect lever. Engaging the lever
fully automatically short-circuits the transformer when
using the required adjacent push-in jumper. Measur-
ing 99mm long and 8mm wide, the series’ touch-proof
design does not require a separate cover to be installed
which eases access to test plugs and meter
connections. Available in through- or ground-con-
nection versions, the 2007 series employ CAGE
CLAMP Spring Pressure Technology for conductor sizes 20-8 AWG. This eliminates lugs,
crimps and torquing.
www.wago.us
Washdown shaft collars
Ruland unveiled a line of washdown shaft
collars that feature a patent pending assem-
bly containing a type 303 stainless steel shaft
collar, a two-piece housing made from FDA
compliant materials and three O-rings with
NSF H1 registered lubricant. The collars offer
holding power comparable to clamp style
shaft collars and allow for simple adjustments
without marring the shaft. Ruland’s exclusive
design is pending an IP69K rating against the
ingress of dust and water up to 80°C and 8 to 10 MPa of pressure. Washdown shaft
collars are supplied with a zinc-plated forged alloy screw and are available for shaft sizes
ranging from 1/4 to 1 inch or 6 mm to 25 mm.
www.ruland.com
IdeaGenerator
Vision1210™ PLC + HMI
Starting at: $1,676
PLC + HMI
FREE Remote Access
FREE Programming Software
FREETechnical Support
Complete Control in ONE Unit
32-36-DES.indd 35 13-10-10 2:23 PM
36. October | 2013 www.design-engineering.com
36
Sensors
Ethernet Camera
Imaging Development Systems (IDS) released its
Gigabit-Ethernet board-level GigE uEye LE camera
series, which feature a 5 Megapixel CMOS sensor.
With a 2560 x1920 pixel resolution, the sensor’s A-Pix
technology provides enhanced sensitivity and can be
used in low to moderate light conditions.
With a footprint of 45mm x 45mm, the
camera also features GigE interface and
can be connected with maximum cable
lengths of up to 100 meters. The uEye also
integrates two general purpose I/Os, an
I2C-Bus and 60 MB of internal image
memory.
www.ids-imaging.com
Rotary Sensor
Novotechnik U.S. introduced
its Vert-X 31E Series of pro-
grammable rotary angle
sensors with a permanent
magnet that can be secured
to a rotating shaft to prevent
wear. Key specifications for
sensor include 31mm profile;
0 to 360° measurement
range; resolution to 14-bit;
repeatability of 0.1° or bet-
ter; and maximum hysteresis of 0.1°. Eight
output options are available: 0.1 to 10V, 0.5 to
4.5V, 4 to 20mA, 10 to 90 percent of power
supply, SSI, PWM, Incremental and SPI. The
series includes 5 and 24 V supply models. Vert-
X 31E 5V versions have a MTBF of 668 years
and 24V versions are 240 years MTBF. All mod-
els feature an ingress protection rating of IP 68
and operating range of -40 to +85°C.
www.novotechnik.com
Photoelectric Sensor
Baumer has expanded its range of NextGen
sensors with a O300 Series designed for 1-inch
mounting sizes. The sensor’s touchless qTeach
method allows the O300 series to be programed
by any ferromagnetic tool, such as a screwdriver.
A blue LED light provides clear visual feedback,
which thanks to its
exposed position
atop the sensor is
clearly visible from
all sides. The com-
pany says this class
of optical sensor
employs three sen-
sor principles: The
light sensor has
background sup-
pression while the retro-reflective sensor works
reliably with reflective surfaces but without any
separate reflector.
www.baumer.com
IdeaGenerator
Cutouts & Modifications – in days
Custom cut-outs in stock enclosures in 5 days or less
Full assembly of Rittal components
Enclosure suiting
Custom painting
www.rittal.ca
Go to www.rittal.ca or scan the code below for more
information about our modification services.
32-36-DES.indd 36 13-10-10 2:03 PM
37. www.design-engineering.com October | 2013
37
By Treena Hein
Athletes, just like the rest of us, are always looking for a
competitive edge. A good advantage to have in hockey is
extra speed, and in this case, it’s delivered by the players’ literal
edge on the ice – their skates.
It’s part of a revolutionary trend in engineering all over the
world: different sources of wasted energy are being noticed, cap-
tured and made available for use afterwards. Whether it’s a flywheel
in a bus braking system or solar energy being captured and stored
in a jacket as a person walks down the street, the idea makes
enormous sense. Last year, it was the energy wasted throughout
hockey games that came to the attention of University of Water-
loo Mechanical Engineering grad Jeffrey Azzolin.
During his undergrad degree and now at his start-up called
Bladetech Hockey, he developed a skate that captures some of the
wasted energy produced by a player through the normal motion
of a skating stride. They then make that
energy available moments later, again and
again, throughout the game.
When a Bladetech skate hits the ice,
Azzolin’s patent-pending spring mecha-
nism compresses, absorbing some of the
energy of the player’s movement. When
the player pushes forward off the ice
afterwards, the energy in the spring is
released as it returns to its original posi-
tion, providing a boost of power. Azzolin,
who has played recreational hockey for
many years, says that even a slight
increase in speed and agility gives a player
a significant advantage.
Spring Loaded
But these skates aren’t only about better
performance on the ice. Their design also
has the potential to prevent injuries to
their users’ hips, knees and ankles.
“As the springs compress, they capture
impactloadswhichotherwisewouldhave
traveledthroughthebonesandintojoints,
into cartilage, meniscus and synovial flu-
ids,” Azzolin explains. “So, not only does
thespringmechanismcaptureandharness
energy which otherwise would have been
wasted,italsoprovidesacushioningeffect
on the body, decreasing joint damage and
reducing the probability of injury.”
In addition, the design provides play-
ers with the ability to move smoothly
from a flat-footed to a forward-angled
stance, which reduces the chances of getting shin-splints.
“Pro players skate many hours a day, most days of the year,
for years at a time,” Azzolin notes, “so it’s important to protect
the body as much as possible. Having technology which can
reduce the likelihood of developing injuries provides is an enor-
mous benefit over a professional career.”
The main challenges of the design process all related directly
to a modern skate’s plastic blade holders. Their thin and tapered
shape limits the options for housing an internal spring-loaded
mechanism, making it tough to figure out which components
and geometries would work. Azzolin and his team found some
help, however, in the fact that as player weight increases, so does
foot size and blade holder size.
“We were able to create a spring-loaded mechanism that can
provide customized stiffness, depending on player weight, foot
Game
Changer
Bladetech skates leave conventional blades behind,
in more ways than one.
CanadianInnovator
University of Waterloo Engineering graduate,
Jeffrey Azzolin, who developed Bladetech
hockey skates.
photo credit: cNW Group/uNiversity of Waterloo
37-40-DES.indd 37 13-10-10 2:03 PM
38. Advertiser Website Page
Automation Direct www.automationdirect.com 7
Baldor Electric Company www.baldor.com 40
Brecoflex Corp. LLC www.brecoflex.com 32
Century Spring Corp. www.centuryspring.com 38
Clippard Instrument Laboratory, Inc. www.clippard.com 9
Daemar, Inc. www.daemar.com 11
Design Fusion www.designfusion.ca 14-15
Ellsworth Adhesives www.ellsworthadhesives.ca 18
Exair Corporation. www.exair.com 23
GTC Falcon, Inc www.gtcfalcon.com 34
Harting Canada, Inc. www.harting.ca 28
HELUKABEL Canada www.helukabel.ca 13
Henkel Canada Corporation www.loctite.com 17
igus Inc. www.igus.com 33
Karsh Precision Machine www.karshprecision.com 31
Master Bond, Inc. www.masterbond.com 31
Mersen Canada www.mersen.com 29
Myostat Motion Control, Inc. www.myostat.ca 12
NORD DriveSystems www.nord.com 20-21
Proto Labs, Inc. www.protolabs.com 19
Rittal Systems Ltd. www.rittal.ca 36
Rosta, Inc. www.rostainc.com 24
RotoPrecision, Inc. www.rotoprecision.ca 27
Rotor Clip Company, Inc. www.rotorclip.com 25
Schaeffler Canada, Inc. www.ina.com 4
SEW Eurodrive www.sew-eurodrive.ca 39
Unitronics Inc. www.unitronics.com 35
Yaskawa America, Inc. www.yaskawaamerica.com 2
Advertisers Index
October | 2013 www.design-engineering.com
38
size and preference,” he says. “After
several iterations, we came up with a
working solution, which we later rede-
signed to minimize the number of
components. This made the design not
only simpler to assemble, but more
reliable as well.”
The biggest hurdle of the whole
process, he says, was ensuring the
assemblyfitintheallottedpackagesize.
“No measurements were available
for each different size of blade holder
in terms of their cavities and unique
shapes,” says Azzolin. “It meant that
designing the assembly to fit into each
compartment took a nightmarish
amount of time.”
Scoring Opportunities
The Bladetech team has conducted a
number of tests to determine how
much the skates increase player speed,
agility and turning capabilities.
“We’re adding to our data to help
strengthen our analysis, but we’re sure
the increased performance will be a
game-changer,” Azzolin says. “Users
will be able to develop more scoring
opportunities or defensively stop
more scoring opportunities. In the
elite leagues where fractions of a sec-
ond can affect the entire outcome of
a game, this technology will more
than prove its worth.” Tests to better
quantify the reduction in impact loads
that the body will experience with
these skates are also underway.
Azzolin and his team are hoping to
have the product ready by this coming
spring or summer, so that they can
take part in 2014/2015 pro season
action. With endorsement by one NHL
player already, Bladetech’s future is
looking as slick as a sheet of ice. DE
www.bladetechhockey.ca
Treena Hein is a Pembrook, Ont.-
based frelance writer.
CanadianInnovator
222 East 16th Street
Los Angeles, CA 90015 USA
Ph: 800.237.5225
Fx: 213.749.3802
info@centuryspring.com
www.centuryspring.com
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In addition to our extensive
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Metric and standard sizes
One order =
one shipment + one invoice
Made in the USA
When your next project calls for
springs, call us, visit us on
the Web, or email inquiries to
info@centuryspring.com.
Request a copy of
our FREE 400+ page
product catalog!
Visit us at DEX Expo this Oct. 30th in Mississauga!
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Azzolin’s spring-loaded skates help prevent injuries to
their users’ hips, knees and ankles and return stored
energy to boost skaters’ speed from a standing start.
37-40-DES.indd 38 13-10-10 2:03 PM
