Dng de-01012014

$10.00 | January/February 2014
PM40069240
Open
to
BUSINESS
14 Autodesk’s CAM 360 looks to
disrupt CAM software industry
22 Should Ontario adopt a CPD
program for P.Engs?
45 Canadian engineering spin-outs
take the sting out of winter
Canadian research
facilities embrace
SMEs for commercial
R&D projects.
1-DES.indd 1 14-02-18 7:35 AM

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5Contents | Volume 60, No. 1
20 Rapid Prototyping
SLS additive manufacturing technology
provides low costs, high quality and quick
turnaround times for flow meter parts
22 Shop Talk
Is it time for Ontario to adopt a mandatory
Continuing Professional Development
program for the engineering profession?
30 Motion Control
Variable frequency drives provide many
benefits, but selecting the right one
requires asking the correct questions
34 Automation
Thomson Technology uses SCADA/HMI
software to provide customers advanced
functionality and connectivity while cutting
development time
38 Idea Generator
The latest in industrial products including
automation, power transmission, motors,
fluid power and motion control
Columns
14 Inside Autodesk CAM 360
Autodesk’s CAM in cloud service looks to
disrupt manufacturing software industry
24 Open to Business
Canadian university engineering research
facilities embrace SMEs for commercial R&D
projects
45 Canadian Engineers vs Winter
University of Waterloo’s VeloCity incubator
program spawns two startups determined
to take the sting out of winter.
Features
14
24
30 34 45
20
8
IN THE NEWS
8 Clippard appoints
new president
8 Magellan to
manufacture Airbus
A320 wing ribs
8 MDA awarded
space exploration
contracts
8 Canadian wall-
climbing robot to
aid future space
missions
8 Saskatoon firm
builds world’s
largest EPU
10 U of Waterloo
launches green
energy degree
10 Sherbrooke students
show off electric
concept car at CES
12 Matsuura debuts
hybrid metal 3D
printing and milling
machine
12 Lomiko Metals to
develop graphene
for 3D printing
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6 EditorialViewpoint
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January/February | 2014 www.design-engineering.com
As the cover story this issue illustrates, Canadian universities operate some of the
world’sleadingengineeringresearchfacilities.TheclimacticwindtunnelatUOIT’s
Automotive Centre of Excellence, the Blue Gene/Q super computer at University of
Toronto and the synchrotron particle accelerator at the University of Saskatchewan
represent only a few high profile examples. In total, the length and breadth of engineer-
ing R&D capabilities and expertise in Canada ranks with the best in the world.
That may be a source of nationalistic pride, but it also has profitable implications for
Canadian industry, as well. Considering the enormous costs associated with such
facilities,mostcompanieswouldnevergetthechancetoconductR&Dinone.Fortunately,
Canada’s universities are not only open to private industry but actively seek it out.
Giventhat,you’dthinktheirresearchlabswouldbestrugglingtokeepupwithdemand
from the private sector. However, according to study conducted by École de technologie
supérieure in Montreal, Canadian industry, and particularly Small to Medium-Sized
Enterprises (SMEs), seldom search for, or are even reluctant to form, such partnerships.
In the study, only 10 percent of SMEs with more than $5 million in sales reported an
academic collaboration, and only 1 percent reported a technology transfer.
First and foremost, SMEs’ passivity stems from a simple lack of awareness. Many
businesses don’t know what academic resources are available or who to contact. Other
issues include where the money to fund a short- to long-term R&D project will come
from and how any intellectual property resulting from the research will be shared.
Forassistance,SMEscancontacttheuniversitydirectlytoinvestigatepossibleoppor-
tunities; each typically runs an office of research or innovation that can not only help
match enterprise with researchers but also offer potential funding options as well as
provide the details of its IP policies.
Abetteroptionmaybetoworkthroughathirdparty.Eachprovincehasanon-profit
orcrown-entitythatpromotesindustry/universitypartnershipsand/oroverseesgovern-
ment sponsored funding programs or VC-style investment.
In terms of its scope and available resources, the most sophisticated among them is
the Ontario Centres of Excellence (OCE). The non-profit’s core function is to play
matchmaker between industry and academic researchers. For example, it administers
theprovinciallyfundedIndustryAcademicCollaborationProgram(IACP),aninitiative
designed to help Ontario’s research institutions and technology-based companies com-
mercialize research discoveries.
For funding, OCE offers a range of options including the Collaborate-to-Commer-
cialize(C2C)initiative,atwo-yearprogramdesignedforprojectswithspecialinnovation
challenges and high commercialization potential. Through C2C, OCE invests up to
$250,000withtheparticipatinguniversityinproportiontomatchingfundsfromindus-
trypartners.Inaddition,OCEoffersvoucherprograms,throughwhicheligibleOntario
companies receive a credit that can be applied towards expertise and resources from
Ontario universities.
Considering the breadth of R&D possibilities Canadian universities offer coupled
withtheresourcesavailableandthecontinuous“innovation”mantrachantedbygovern-
ment, there is little reason not to perform at least some preliminary research into what
may be possible.
Mike McLeod
Tech Transferable
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8
Clippard appoints new president
Clippard Instrument Laboratory
announced the appointment of
John Campbell as its new president.
William L. Clippard, III and Robert
L. Clippard will continue to serve as
Clippard’s chairman of the board
and vice chairman, respectively. The
two sons of company founder Leon-
ard Clippard have lead the maker of miniature pneu-
matic components and devices for the past 38 years.
According to the company, John Campbell brings
extensive experience in running small to mid-size
manufacturing companies and has managed all
aspects of their business including sales, marketing,
product development, manufacturing and distribution
as well as key areas of finance, mergers and acquisi-
tions. Through this process, there has been no change
in the company ownership and no change in the
day-to-day operation of the business.
www.clippard.com
Magellan to manufacture
Airbus A320 structural wing ribs
Magellan Aerospace announced that it has reached
an agreement with Airbus S.A.S. to manufacture and
supply complex, 5-axis machined wing ribs for Airbus’
single aisle A320 product family including the A320neo,
in addition to its existing A320 wing ribs work pack-
age. The agreement is expected to generate approx-
imately US$20 million over the next five years. As part
of its commitment, Magellan will invest in a new
high-speed, 5-axis machining centre to be located in
its facility in Greyabbey, Northern Ireland.
www.magellan.aero
MDA awarded space
exploration contracts
MacDonald, Dettwiler and Associates announced
that it has been awarded multiple strategic technol-
ogy development contracts by the Canadian Space
Agency (CSA). The contracts, with a combined value
of approximately CAD$3 million, are funded under
CSA’s Space Technology Development Program.
Several of the contracted projects are expected
to advance technologies which enable more ambi-
tious approaches to robotic spacecraft servicing.
One project is to focus on advancing the develop-
ment of deployable ultra-high frequency (UHF)
antennas that could be folded, resulting in a very
compact size for launch.
www.mdacorporation.com
Up Front Canadian wall-climbing
robot to aid future space
missions
The European Space
Agency (ESA) announced
that it has recently tested a
wall-climbing robot developed
at Simon Frasier University
and found that the gecko-foot
inspired technology may be
suitable for space missions,
potentially leading to hull-
crawling automatons tending
future spacecraft.
The SFU climbing robot,
called Abigaille-III, has six legs
with four degrees of freedom
each, allowing the robot to
transition from vertical to
horizontalandback.Keytothe
robot’s abilities, though, is a dry adhesive, developed at SFU, which
mimics the feet of geckos and allows it to adhere to diverse surfaces.
Geckos “stick” due to microscopic hairs (100–200 nanometres
across) on their feet that take advantage of van der Waals forces,
molecular attractions that operate over very small distances. SFU
engineering scientist Carlo Menon says his team borrowed techniques
from the microelectronics industry to create “footpad terminators”
similar to the a gecko’s nanoscopic hairs.
Interested in assessing the adhesive’s suitability for space, the ESA
tested the adhesive in its Electrical Materials and Process Labs, based
in the Agency’s ESTEC technical centre in Noordwijk, the Netherlands,
with additional support from ESA’s Automation and Robotics Lab.
“A depth-sensing indentation instrument was used inside a vacuum
chamber to precisely assess the dry adhesive’s sticking performance,”
said ESA’s Laurent Pambaguian. “Experimental success means deploy-
ment in space might one day be possible.”
Since joining SFU in 2007, Menon’s research program has focused
on bio-robotics and smart materials. The space research was supported
by the ESA’s Network/Partnering Initiative, enabling it to work with
universities carrying out research with the potential for space appli-
cations.
http://menrva.ensc.sfu.ca
www.esa.int
Saskatoon engineering firm builds world’s
largest EPU for Canadian particle accelerator
Saskatoon-based RMD Engineering has built what it claims is the
world’s largest elliptical polarizing undulator (EPU) for the Canadian
Light Source (CLS) synchrotron, an electron accelerator used to probe
the structure of matter.
Essentially a particle insertion device, the EPU uses powerful rare
earth magnets to cause the synchrotron’s electron beam to generate
DesignNews
C
John Campbell
8-13-DES.indd 8 14-02-07 1:51 PM

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10
X-rays of controllable polarization. Scientists can then use
the information obtained to help design new drugs, develop
more effective motor oils and build more powerful computer
chips, among many other applications.
Currently, CLS has two EPUs in operation but the new
device is unique not only for its size but its ability to switch
between high and low energy experiments. The RMD Engi-
neering-built EPU measures 4.17 x 2.69 x 2.8m, weighs
approximately 13,500 kg and can produce anywhere from
15-200 eV to 200 – 1000 eV.
“This allows researchers using the synchrotron to study
and develop state-of-the art technology, from supercon-
ductors to car batteries,” said Mike McKibben, Canadian
Light Source’s director of technical support.
RMD Engineering owner Jim Boire said that turn-
ing the design of the EPU into a cutting-edge machine
was a considerable challenge. His company spent over
9,500 work-hours of engineering, machining and
assembly to put together the nearly 1,100 parts, includ-
ing 865 manufactured components.
Now that the RMD-built structure has arrived at
the synchrotron, CLS engineers will calibrate the machine
and position 1,560 rare earth magnets onto the EPU. Once
testing and calibration is complete, the EPU will be moved
into the storage ring area of the synchrotron for use in
experiments on a new beamline called QMSC, an experi-
mental station that will be operational in 2015.
www.lightsource.ca
www.rmd-engineering.com
Waterloo Engineering launches
green energy graduate degree
The University of Waterloo’s Faculty of Engineering will
launch a graduate diploma in green energy to provide profes-
sional development for working engineers through real-time
online learning. The ﬁrst of its kind in Canada, the Green
Energy Graduate Diploma was developed through collabora-
tion of Waterloo’s network of private sector partners, utilities,
government and the non-proﬁt sector in partnership with
the Waterloo Institute for Sustainable Energy.
Diploma courses are designed to enhance technical knowl-
edge and training in green energy systems such as bioenergy,
fuel cells, air pollution and greenhouse gas management, solar
and wind energy, and building energy performance. A Bach-
elor’s degree in engineering or a related area of study is required
and students must complete the program within two years.
The Green Energy Graduate Diploma will be delivered
from an interactive instruction facility called Live-Link, a
remote learning environment, enabled through the use of
smart boards and multi-point interactive video conferencing.
www.uwaterloo.ca
Sherbrooke engineering students
show off electric concept car at CES
Engineering students from Universite de Sherbrooke rolled
out their urban electric concept vehicle – Project VUE
(Vehicle Urbain Electrique) – at the Consumer Electronics
Show (CES) 2014 in Las Vegas in January. Based on a 2006-
model Smart Fortwo Coupe chassis, Project VUE is an ongo-
ing senior project for engineering students.
Initiated two years ago, the initial conversion of the Fortwo
focused on improving reliability of the battery, power supply
and other electrical systems. The all electric vehicle sports a
top speed of 75 mph and a range of about 40 miles. The cur-
rent VUE concept vehicle weighs 1,741
pounds with a 77-inch wheelbase.
In its latest incarnation, on
display at CES, the VUE
features semi-auton-
omous driver-
assistance
systems and
improved all-
digital instru-
ment,
infotainment
and vehicle diag-
nostic displays.
It’s radar- and
camera-based obstacle
and road-sign detection
systems enable automatic speed adjustment and are designed
to help drivers safely react to obstacles and dangerous driving
conditions.
Project VUE also partnered with Finish automotive embed-
ded hardware and software development company, Elektro-
bit, to create the car’s HMI systems. The Sherbrooke team
used the company’s GUIDE 5.5 development platform to
create the VUE’s fully digital instrument cluster, an infotain-
ment system based on the QNX Neutrino Realtime Operating
System and vehicle diagnostic displays.
Future development objectives will include the extension
of driver-assistance functions for completely autonomous
driving and voice controls.
http://vue2013.gel.usherbrooke.ca
www.elektrobit.com
DesignNews
“This allows researchers using the synchrotron to study
and develop state-of-the art technology, from supercon-
ductors to car batteries,” said Mike McKibben, Canadian
the synchrotron, CLS engineers will calibrate the machine
and position 1,560 rare earth magnets onto the EPU. Once
testing and calibration is complete, the EPU will be moved
into the storage ring area of the synchrotron for use in
rent VUE concept vehicle weighs 1,741
pounds with a 77-inch wheelbase.
In its latest incarnation, on
display at CES, the VUE
features semi-auton-
omous driver-
assistance
systems and
improved all-
digital instru-
ment,
infotainment
and vehicle diag-
nostic displays.
It’s radar- and
camera-based obstacle
8-13-DES.indd 10 14-02-07 1:51 PM

8-13-DES.indd 11 14-02-07 1:51 PM

12
Matsuura debuts hybrid metal
3D printing and
milling machine to
North American
Matsuura Machinery Corpora-
tion announced that its LUMEX
Avance-25 Metal Laser Sintering
Hybrid Milling Machine has
entered the North American
market (U.S. and Canada) start-
ing January 1. Sold through a
distribution agreement with
Mitsubishi, the hybrid machine
is the result of five years of R&D and is
the only machine to offer a one-machine
process for complex molds and parts.
Like other laser sintering machines,
the LUMEX Avance-25 binds thin lay-
ers of metal powder using a laser. How-
ever, during the additive manufacturing
process, the machine also mills partially finished parts to
provide higher accuracy as well as complex geometry that
isn’t possible using traditional methods.
The machine accommodates a maximum workpiece size
of 250 x 250 x 180mm, a feed rate of 60/60/30 m/min and a
maximum spindle speed of 45,000 min-1. With a price tag of
just under US$846,000, the company says it hopes to sell 10
in its first year on the North American market.
www.matsuura.co.jp
Graphene Laboratories, Lomiko Metals to
develop graphene for 3D printing
Graphene Laboratories Inc. announced it will partner with
Vancouver-based Lomiko Metals Inc. to develop graphene-
enhanced materials for 3D printing. To commercialize their
research, the companies have formed Graphene 3D Labs Inc.,
a spinoff of Graphene Labs, to work toward integrating gra-
phene-based products into end-user goods.
Heralded as a strong, ultra-light, ultra-conductive material,
graphene is a one-atom thick sliver of graphite that could have
applications in everything from super-sensitive sensors to
thin flexible touch displays to high-efficiency solar panels.
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ket, a supplier of nanocarbon and graphene products. Lomiko
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14
By Mike McLeod
Throughout its history, Autodesk’s soft-
ware has almost exclusively played on
the engineering and design side of the
product development fence, leaving the
shop floor, the actual manufacturing, to
CAM software developers. And it was the
only major CAD software developer to do
so. PTC, Siemens and Dasault Systemes all
have CAM software in-house that tightly
integrates with their respective CAD suites.
That changed in 2012 when Autodesk
acquired HSMWorks, a company that made
integrated CAM software exclusively for
SolidWorks. Since then, Autodesk has been
working on bringing the same seamless
2.5-, 3- and 5-axis CAM integration to
Inventor with Inventor HSM. It has also
released a no-charge 2.5-axis plug-in
(Inventor HSM Express) that, for the most
part, mirrors the free HSMXpress plug-in
for SolidWorks.
Autodesk took their CAM strategy a step
further at Autodesk University 2013 with
the announcement of CAM 360. Utilizing
the same HSMWorks CAM kernel, the
online NC programming and toolpath
creation/simulation service is the latest
addition to Autodesk’s growing stable of
cloud-enabled engineering software. It joins
the “push-pull” direct modeler, Fusion 360,
released last year, as well as AutoCAD 360,
PLM 360, Sim 360 and Mockup 360, all of
which are linked to the Autodesk 360 cloud
file storage and collaboration service.
The first of its kind, CAM 360 is designed
to split its CAM functions between the
user’s local computer and Autodesk’s cloud
computing service, using a server/client
model. A relatively small executable is
installed locally, which ties, via the Internet
(and an account login), to Autodesk’s cloud
service. According to Anthony Graves,
Autodesk Product Manager for CAM, CAM
360 will dynamically shift processing duties
from the local thin client to the cloud or
vice versa depending on which is faster.
“Let’s say, for example, you’re at home
with a computer without a lot of horsepower,
you will be able to login to CAM 360, grab
your CAM project and choose to have it
CADReport
Inside
Autodesk
CAM 360
As CAM 360 opens for Beta testing, Autodesk positions its
CAM in the cloud service to shake up the manufacturing
software industry.
14-19-DES.indd 14 14-02-07 1:54 PM

15
solved in the cloud instead of locally,” he
says. “Computing in CAM 360 will be done
on the desktop or on the cloud, depending
on which is more appropriate. What this
does is give people the flexibility to use
whatever hardware they have available.”
From the user’s point of view, Graves
says the experience is the same as with
purely locally installed software, but the
online model opens up a number of unique
opportunities typically not offered by tra-
ditional CAM software.
The first is CAM 360’s all-inclusive offer-
ing. Initially, the CAM 360 version open
to beta testing will provide capabilities
similar to that of Inventor HSM or
HSMWorks for SolidWorks: 3-axis CAM
with a range of toolpath strategies — for
generating milling, drilling, counterboring
and tapping operations — as well as adap-
tive roughing or clearing strategies and
toolpath simulation.
What’s unique is that CAM 360 does
not require a license of a pricey CAD pack-
age. Instead, it borrows the direct modeling
tools from Fusion 360 that CAM users need
to feature, de-feature, modify or patch a
model to prep it for machining. In addition,
it also includes cloud-based translators that
import CAD data formats from major CAD
packages (Pro-E, Catia, SolidWorks, Solid
Edge, NX, etc) plus most neutral formats
(STEP, IGUS, STL, etc).
Lastly, and perhaps most importantly,
Autodesk says it will continue to offer 2.5-
axis CAM at no charge after the full com-
mercial release of CAM 360 in early 2014.
For those who need more, the 3-axis CAM
360 version will cost $75 per user per month
on a 12-month contract while 5-axis (3+2)
will run $150 a month.
According to Graves, it’s this combina-
tion of no-cost or pay-as-you-go 2.5 to
5-axis CAM plus free CAD file translation
and intuitive modeling tools that makes
CAM 360 a disruptive and compelling entry
in the CAM software industry.
“What’s important about CAM 360 is
that it includes the kind of modeling and
patching tools that CNC programmers
dream of to quickly prep models for
machining,” he says. “But, at the same time,
they get all the CAM functionality and
performance of HSM technology. With
CAM 360, you will get 2.5-axis CAM for
free and by the end of next year, I can’t
imagine anyone spending money on 2.5-
axis CAM ever again.”
In addition, he says that, since all design
data including revision history, is stored in
the cloud, all of Autodesk 360 tools (includ-
ing CAM 360) allow users to share and
collaborate on projects. For example, an
engineer could model a part in one location
using Fusion 360 and invite a job shop in
another location into the project. The
machinist, through his Autodesk 360
account, could then access the most current
CADReport
CAM 360 combines CNC programming, simulation and design with real-time collaboration and
online project and data management.
14-19-DES.indd 15 14-02-07 1:54 PM

16
design revision and produce the toolpaths
to manufacture the part using CAM 360.
The Post Problem
Of course, toolpaths are all well and good
but without a reliable post processor, CAM
is just a pretty, but purely virtual, animation.
Similar to a printer driver’s function between
a word processor and a laser printer, a post
processor translates the binary toolpaths
generated by CAM software into the mul-
tiple lines of human-readable G-code that
systematically instructs the CNC machine
how to cut a part.
The problem is that G-code, while tech-
nically an international standard, is unique
to each brand and speciﬁc model of CNC
machine. The syntax of the language (G0,
G1, etc) is largely the same, but CNC mak-
ers like Fanuc, Heidenhain, Haas, Hurco, Mazak and many
others tweak the standard language to suit their products unique
capabilities. On the other side of the equation, post processors
also have to be matched to each CAM package since each gener-
ates and encodes toolpaths in a unique way.
As a result, there is no single post processor to rule them all,
much like there isn’t a single universally accepted CAD data ﬁle
format. But unlike faulty BREP geometry, bad G-code isn’t
simply a matter of a non-manifold solid or a reversed normal.
A malformed G-code block can gouge a workholding setup or
CADReport
To generate toolpaths, CAM 360 is built with the same CAM kernel that drives HSMWorks and
Inventor HSM.
14-19-DES.indd 16 14-02-07 1:54 PM

17
thrash a $200,000 machine, which is why many machinists still
prefer to manually write 2.5-axes code from scratch or at least
edit code produced by software.
To confront this challenge, HSMWorks, and now Autodesk,
has adapted an open source model for post processors develop-
ment. Like many CAM developers, HSMWorks/Autodesk offers
its own generic post processors, which it refines to suit specific
customers at no charge. Beyond this, the company writes its
post in relatively accessible Javascript instead of a heavy-handed
programming language like C++ or Java that is compiled.
Autodesk’s approach eliminates the “black box” aspect of
some post processors that force customers to go back to the
CNC manufacturer, reseller or a 3rd party for customization.
More importantly, it makes the code available to a community
of post developers who can refine the code to suit any CNC
machine or machinist’s preference. Autodesk is taking advantage
of the unique setup through its CAM website (cam.autodesk.
com) with a post development forum where members can share
their customizations.
“One of the frustrating things about a lot different industries,
and particularly in the metalworking community, is that people
feel like they are getting nickel-and-dimed at every turn,” Graves
says. “We just want to create an open solution that’s going to
produce good parts. And since we are not trying to generate
revenue from post, our architecture gives us complete flexibil-
ity to be as open as possible.”
CAM in the Cloud
Autodesk bills its 360 spectrum of cloud products as a complete
design to manufacture solution, and in many ways it succeeds.
Parts and assemblies can either be modeled or imported to
Fusion 360, run through FEA and/or CFD analysis in Sim 360,
photo rendered in Autodesk 360 and now, potentially, physically
manufactured via CAM 360.
But for all its capabilities, Autodesk’s cloud toolbox lacks one
crucial manufacturing component: Drawing creation and/or
PMI data. For any machinist or job shop, simply getting a CAD
file isn’t enough to produce an accurate or even acceptable part.
While it may sometimes be possible to drill down on specific
properties within a design file, this only holds true when the
file is open in its native CAD environment.
However, Fusion 360 (and therefore CAM 360) doesn’t retain
this information for imported models. Being history free, it
strips parametric and build order data from the model. While
dimension remain intact, precise GD&T or PMI data (e.g. sur-
face finish and material specifications) isn’t included.
It should be noted that at Autodesk University 2013, the
company strongly hinted that manufacturing drawing creation
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18
or some form of Model Based Definition capability would be
added to the 360 line in the near future.
Another potential challenge for Autodesk’s cloud strategy in
general is that companies doing work for government agencies,
at least in the U.S., are contractually restricted from storing
digital design data on third party computers, including the cloud
storage on which the 360 service depends.
Although Autodesk emphasizes that 360
customers will always be able to access their
files, even in the case of a billing dispute,
purely private entities may also baulk at
having their design data stored with a third
party.
Finally, CAM 360 represents a radical
shift. Concepts like storing files off site
and using software that one rents rather
than “owns” may be hard to accept for
machinists who’ve spent years producing
quality parts with a stand-alone CAM
package.
Still, given CAM 360’s aggressive free-
mium and/or low-cost model, Autodesk is
hoping potential customers will at least
“kick the tires” on the new service and come
to prefer the ability to scale their software expenditures up or
down at will. And even if entrenched machinists give CAM 360
a pass, the company is betting the next generation on the shop
floor will embrace the mobility, platform independence and social
media-like advantages the 360 approach affords. DE
http://cam.autodesk.com
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20
SLS additive manufacturing technology
provides low costs, high quality and quick
turnaround times for flow meter parts.
For nearly a decade, Mississauga-based firm, Anubis Manu-
facturing Consultants, has provided engineering services,
equipment development and manufacturing for the pharma-
ceutical, chemical, consumer goods, and food and beverage
industries.
Recently, Anubis developed, patented, and commercialized
a mass flow meter for particulates. Called the ARBOmeter, the
device can operate either as a strictly volumetric device or, with
the addition of a hopper and tray, a meter that can measure the
variable bulk density of materials. The device is primarily used
in the mining, plastics, recycling and food processing industries,
and it can measure flow of everything from pellets to powder
to potato chips.
Inside the meter’s stainless steel enclosure are a number of
delicate electronic components, several of which require a
framework that reduces vibration and keeps it in place. The
individual frames need to hold each part firmly and accurately
at a fixed angle. Components to be supported include two cam-
eras and an LED light that have different shapes and require
unique frames.
Because of prior experience with EOS additive manufactur-
ing technology and materials, Anubis selected laser sintering as
the process to make seven of the frameworks, including those
for the cameras and LED light. There were several reasons for
the choice: Frame complexity (incorporating such features as
built-in hinges and quick-release snap fits), small production
runs and—most important—continuing evolution of the frame
designs. In addition, the company operates an AM division
in-house, that includes an EOS FORMIGA P 100 plastic laser-
sintering system.
“Several of the plastic parts went through extensive redesign,”
says Anubis owner, says Tharwat Fouad, “and we chose to revise
the flow meter at least 15 times.”
With so many changes, traditional plastics processes such
as molding would be far too costly and would slow down
product development. By contrast, using laser-sintered nylon
(PA 2200, a Nylon 12 material), it was possible to manufacture
the frames inexpensively and produce new versions overnight.
The ability to make multiple revisions within tight turnaround
times allowed Anubis to create optimal frames for each com-
ponent.
A Cool Alternative
Laser sintering’s capabilities also prompted Anubis to consider
an additional functionality for the frames: Integrated cooling
channels. The ARBOmeter employs an internal CPU that gives
off heat. To protect electronic components, the temperature inside
the stainless steel enclosure should not exceed 42C/108F.
That presented a challenge. Standard practice might be to
cut a hole in the enclosure and mount a fan. But in this instance,
the device is IP 65 rated, so neither dust nor water can enter the
enclosure—and that means no holes at all. Any cooling system
would need to be internal.
“We searched extensively and consulted electrical manufac-
turers,” Tharwat says, “but we didn’t find an inexpensive way
to cool an enclosure and keep the IP rating we wanted.”
As a result, Anubis considered incorporating channels inside
the nylon frames so that air could flow through to cool the
electrical parts. Since laser-sintering systems can create nearly
any shape, a thin layer of nylon isolating the components from
the channels would ensure that the meter could still earn its IP
rating.
Designing the cooling channels involved a number of con-
siderations and revisions. Engineers calculated the volume of
airflow needed to remove the heat and the size of the air conduit
to carry that volume. Adding an impeller provided additional
forced-air. By making the channels longer and narrower, air
velocity accelerated even more.
Taking advantage of the geometric complexity possible with
laser sintering, the designers added fins and baffles to maximize
heat transference. With each new modification, they quickly
RapidPrototyping
Designed and manufactured by Mississauga-based Anubis
Manufacturing Consulting Corp., the ARBOmeter flow meter is
designed to measure the variable bulk density of everything from pellets
to powder to potato chips.
Gowith the
Flow...Meter
20-21-DES.indd 20 14-02-07 2:57 PM

21
laser sintered and thermodynamically lab-tested the part.
Although time constraints prevented Anubis from finalizing
the cooling channel design on the ARBOmeter (the company
has implemented a vortex cooling system instead), they are
currently considering such a feature for several other applications.
Production and Predictions
Presently in full production, the ARBOmeter’s laser-sintered
frames are built in batches of four nested sets, seven to a set,
over about twenty hours. Each part is made of 100-micron
layers, one on top of the other.
“The quality, repeatability and durability of the parts are
very satisfactory,” Tharwat says. “Laser sintering is uniquely
suited to our needs on this project.”
Anubis has minimized the frames to optimize set sizes and
plans to run five sets at once in the FORMIGA P 100. The com-
pany produced between 100 and 200 ARBOmeters in 2013.
“I believe that additive manufacturing will close the com-
petitive gap between larger corporations and small businesses,
or even individual inventors, for bringing new products to
market,” Tharwat says. “It will have a major impact on speed
to market and will provide more manufacturing choices to
end users. I don’t think it will eliminate traditional manu-
facturing—at least in the foreseeable future. But for low-
volume applications, it is filling a valuable niche in which it
is more cost-effective, and offers greater design freedom, than
traditional processes.” DE
www.anubiscorp.com
RapidPrototyping
In the Anubis ARBOmeter, white nylon frameworks are custom
designed for individual components and manufactured in a FORMIGA P
100 plastic laser-sintering system from EOS
20-21-DES.indd 21 14-02-07 1:54 PM

22
Is it time for Ontario to adopt a mandatory Continuing Professional Development program
for the engineering profession?
By Paul Acchione, P.Eng.
Professional competency and quality assurance are an integral
part of engineering work. Continuing Professional Develop-
ment (CPD) is a part of maintaining competency. Having no
CPD guidelines in Ontario leaves the profession vulnerable to
criticism by the public.
Ontario is currently the only Canadian jurisdiction that does
not have any defined (CPD) regime for its licensed professional
engineers. In fact, eight of the provinces have mandatory CPD
programs. Many engineers are concerned that, without a formal
program in place, Ontario’s licensed engineers will not maintain
the same level of credibility in the eyes of industry and the
public compared with engineers in the other jurisdictions that
have established programs.
Furthermore many large engineering firms and industrial
engineering departments have adopted quality assurance pro-
grams that include CPD because of demands from their clients
or owners. Simply put, by not having a provincial program in
place, we are only delaying the inevitable.
Last year, the Ontario Society of Professional Engineers
(OSPE), the advocacy and member services body for the prov-
ince’s engineers, formed a Continuing Education Working Group
to study and recommend best CPD practices for professional
engineers in Ontario from a practicing engineer’s perspective.
Based on our findings, we developed a report proposing a system
based primarily on Alberta’s APEGA program, modified to
provide greater flexibility for engineers, to respect employers’
workload demands and to keep costs down.
Our proposal, for example, suggests that a random sample
of engineers be selected to report each year versus requiring
every individual to report. We also include provisions to reduce
CPD requirements for individuals who are employed only part
time and for those who do no engineering work at all.
Before finalizing our report, we presented a draft to our
membership, which resulted in some lively discussions. One
question centred on whether our recommendations represented
a conflict of interest for OSPE, as a provider of professional
development programming.
The appearance of such a conflict is understandable, but two
points must be kept in mind. First, only Professional Engineers
Ontario (PEO) can make the decision on a CPD program for
Ontario engineers, not OSPE. Second, PEO is aware of OSPE’s
conflicted position. We are confident PEO will carefully look
at the proposed rules to make sure OSPE is not building a train-
ing empire for itself.
Regarding whether the CPD program should be voluntary or
mandatory remains an ongoing debate among engineers. Perhaps
10 or 15 years ago, we could have made a valid case for a voluntary
program because there was little experience with how such pro-
grams work in the context of Canadian engineering practice.
However, almost all the other provinces have since moved over
from voluntary to mandatory CPD programs. At this late date,
there is little reason to recommend a voluntary program.
Also,OSPEismindfulthatnoteveryoneneedstocomply.There
are exemptions in the OSPE recommended CPD program for
individuals who want to retain their “P. Eng.” title but do not
practiceengineeringandforengineerswhoareunderthedirection
of an engineer who conforms to the CPD requirements. So a
simpleannualdeclarationduringfeerenewalwillexemptaperson
fromcomplianceiftheydon’tpracticeengineeringindependently.
OSPE’s report, including feedback and recommendations
from OSPE members, has been submitted by OSPE to PEO for
consideration. Implementation of OSPE’s recommendations
would bring Ontario into alignment with Engineers Canada’s
Framework for Licensure with respect to CPD programs.
In response to concerns about the effectiveness of current
Canadian CPD programs in terms of public risk mitigation and
the cost of compliance, OSPE’s Continuing Education Working
Group is undertaking a second phase of research and analysis
to determine whether additional recommendations can be made
to better mitigate public risk at a lower cost of compliance and
regulatory enforcement.
Of course, as professionals, we should remember that CPD
is only one component of an effective engineering quality assur-
ance program. Equally important are the checks that are built
in to engineering work processes to make sure honest mistakes
by even our best engineers do not reach the public. DE
www.ospe.on.ca
This article was originally published in the Fall 2013 edition of
The Voice, OSPE’s official member magazine. Paul Acchione,
P.Eng., is President and Chair of OSPE. He can be reached at
chair@ospe.ca.
Maintaining Canadian
Engineering Credibility
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Canadian university research facilities embrace SMEs for commercial R&D projects.
By Mike McLeod
For Canadian small-to-medium-sized enterprises (SMEs),
gaining access to cutting edge research facilities would seem
out of reach. Multi-million dollar wind tunnels, supercomput-
ers, particle accelerators and other such high-tech facilities seem
to be the sole province of blue-sky research academics or multi-
national corporations that use them exclusively for their own
product development.
And in many parts of the world, that may be true. But at
Canadian universities, and the cutting edge engineering
research facilities they house, public/private ventures are not
only welcome but core to their mandate. According to Dr. Ted
Sargent, vice-dean of research for the faculty of applied science
and engineering at the University of Toronto, the era of defined
lines between purely academic and commercially-oriented
research have blurred.
“To the extent that there has ever been a perception that
universities can be a bit “ivory tower,” I feel that, within the
faculty of engineering, we are moving away from any such
perception,” Sargent says. “As engineering researchers, we
know our friends in industry have their finger on the pulse of
what society wants and needs. And of course we have a great
deal to offer in terms of advanced technologies and capabili-
ties. So we feel it’s really core to our mission to partner with
industry.”
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24-29-DES.indd 24 14-02-07 1:55 PM

25
Wind Tunnel
Increasingly, Dr. Sargent sentiments are
being echoed at Canada’s leading engineer-
ing research universities. Nowhere is that
more evident than at the University of
Ontario Institute of Technology’s (UOIT)
Automotive Centre of Excellence (ACE) in
Oshawa. Best known for its climactic wind
tunnel—that can generate wind speeds
beyond 240 kph, temperatures from -40 to
+60°C and relative humidity ranges from
5 to 95 per cent—the one-of-a-kind facility
also offers a number of smaller chambers
designed for structural durability and
lifecycle testing.
The most striking thing about ACE,
however, may be that it’s run as much like
a business as an academic facility. While
owned by the university, ACE emphasizes
that it is fully independent, available for
rent on an hourly basis and has served
customers as far ranging as small sports
equipment makers to Hollywood-style film
productions. In fact, says John Komar,
director for engineering and operations at
ACE, approximately 90 percent of the facil-
ity’s time since it opened in 2011 has been
taken by commercial ventures.
“Automotive is a good portion of our
business but we also cater to aerospace,
architectural, consumer products, defense,
energy development, athletics and other
human factors as well as media produc-
tion,” he says.
ACE’s real value, Komar adds, lies in the
facility’s close tie-in with the university.
For smaller and less research-savvy start-
ups and SMEs, having world-class academic
researchers on hand can prove invaluable.
“All our clients like the fact that they
can validate their products using a $100
million tool that’s independent, highly
secure and operated by team of top notch
engineers and technicians,” Komar says.
“We are all about getting the science off
the bookshelf and into proof of concept
and proof of concept to market.”
Anechoic Chamber
While ACE provides highly targeted
research that could last for only the hour
or two the facility is needed, other Canadian
universities tend more toward collaborative
research. At the University of Waterloo, for
instance, partnerships with companies of
any size still play a key role but for longer-
term projects.
“We don’t engage in research here unless
we have an industry partner,” says Ross
McKenzie, managing director of the Water-
loo Centre for Automotive Research
(WATCAR) at the University of Waterloo.
“And, in many instances, we are the lab for
hire, but ultimately we exist to educate and
train. We are more of a medium- to long-
term option for industry.”
To help foster commercial partnerships,
the University of Waterloo opened the
Centre for Intelligent Antenna and Radio
Systems (CIARS) lab last year. Like the
UOIT wind tunnel, CIARS’ anechoic cham-
ber is unparalleled. According to McKenzie,
it is the only publicly available facility in
the world that can generate and measure a
broad spectrum of near-field radio wave
frequencies and transmission types (e.g.
planar, spherical and conical). It’s also the
only wireless research lab that can simulate
far-field transmission as well.
Antennas may seem a niche field, but
McKenzie points out that, as the Internet
CoverStory
Available to rent on an hourly basis, the climactic
wind tunnel at UOIT’s Automotive Centre of
Excellence generates wind speeds beyond 240
kph and temperatures down to -40°C.
24-29-DES.indd 25 14-02-07 1:55 PM

26
of Things concept takes hold and more radio frequencies become
available, nearly every electronic device, from household appli-
ances to McKenzie’s own automotive focus, will incorporate
antennas to broadcast and receive cellular, Wi-Fi, GPS and/or
Bluetooth signals.
“To give an automotive example, in the next 10 years, the car
will become its own hotspot with a unique IP address,” he says.
“Antenna manufacturers, whose products provide that con-
nectivity, will need to make sure the new spectrum and band-
width out there doesn’t cause interference with its antennas. So
even existing products will need to be tested and validated.”
In addition to the CIARS lab, McKenzie says the University
of Waterloo is unique in the way it handles intellectual property
agreements. At most North American universities, he says, the
first thing that follows a research proposal is the signing of a
non-disclosure and research contract between the industry
partner, the research team and the university.
“Any intellectual property that comes out of that project is
shared by all three parties,” he says. “At Waterloo, however, the
university doesn’t seek to retain ownership of any resulting IP.
That simplifies the conversation from the start since there are
only two parties.”
Particle Accelerator
Making an academic research facility like a wind tunnel or
anechoic chamber open to commercial R&D is an easy argument
to make but something as complex and esoteric as a particle
accelerator would seem beyond the means of even large corpo-
rations, let alone SMEs.
And nearly anywhere else in the world and you’d be right.
Not so in Canada, says Jeff Cutler, deputy director of the Cana-
dian Light Source (CLS) in Saskatoon. In fact, CLS is the only
such facility in North America and one of handful in the world
open to commercial research.
“One of the things we have tried to do is make this facility
more available to SMEs,” says Cutler, who also serves as the CLS
director of industrial science. “In other places in the world, you
would have to be a Boeing or 3M and have huge research pro-
grams and lots of money to spend, whereas we see that a lot of
innovation comes out of small companies with 40 people.”
Opened in 2004 on the University of Saskatchewan campus,
CLS is a 2.9 GeV high-energy synchrotron that uses electromag-
nets to accelerate a particle beam around a toroid-shaped vacuum
tube. As the electrons approach the speed of light, they give off
photons that can be focused and separated into its component
wavelengths, from infra-red to high-energy x-rays. Those wave-
lengths are then tightly focused into beamlines that researchers
can use to observe matter down to the atomic level.
According to Cutler, the spectrographic data collected can
be used for a wide range of applications including advanced
material science, nanotechnology, pharmaceutical development
and the detection of environmental pollutants. But while CLS
presents a unique research opportunity for Canadian SMEs,
the challenge Cutler says is that many don’t know how or if it
could help further their R&D efforts.
“That’s a problem for large multinationals as well,” he says.
“Historically, the issue for a company looking at a synchrotron
was that they would also need expertise in how to use it. What
CoverStory
The only facility of its kind open to industry,
the Canadian Light Source synchrotron at the
University of Saskatchewan allows researchers
to observe matter down to the atomic level.
24-29-DES.indd 26 14-02-07 1:55 PM

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28
we’re saying to SMEs is, you are the expert in your problem, we
are the experts in the tools. So they explain what they want to
understand and we point them toward the right tool, help them
do the experiments and then make sense of the results.”
Super Computer
Making sense of the results can be half the battle in any R&D
project, especially when there’s too much data for mere humans
to dig through. That’s where a super computer like the IBM Blue
Gene/Q on the University of Toronto campus can lend a hand.
Operated by the Southern Ontario Smart Computing Inno-
vation Platform (SOSCIP), a consortium of seven universities
including UofT and Western University, the Blue Gene/Q con-
tains nearly 33,000 water-cooled processor cores, making it the
fastest super computer in Canada and
among the top 100 “Big Iron” machines
in the world.
As impressive and potentially overkill
as that sounds, most of the private enter-
prises that make use of the Blue Gene/Q
fall into the SMEs category, says Laura
Philippe, research communications man-
ager with SOSCIP.
“All of our projects fall under five focus
areas: Health, energy, cities, water and agile
computing,” she explains. “Some of the
companies we deal with already have a
relationship with an academic researcher.
But if a company had an idea for research
in one of those areas but didn’t have an
academic partner, they can still apply and
we’ll help them find someone.”
Since the super computer officially came online in 2012 at
the UofT’s SciNet HPC facility, Philippe says it has run big data
projects in all its focus areas, but the facility hasn’t yet reached
full capacity. And, once a project is approved by SOSCIP’s advi-
sory committee, the super computer’s resources come at essen-
tially no up front costs.
“SOSCIP donates the resources so, other than the manpower
costs, there is no other money expected from commercial part-
ners,” she says. “We also work in the background with partners
on IP agreements and those kinds of issues.”
While it’s easy to focus on eye-catching, cutting-edge facil-
ities, Canadian universities offer many other specialized engi-
neering research labs and faculty expertise. For example, in
addition to the Blue Gene/Q, UofT is home to the Centre for
Advanced Nanotechnology and the University of Toronto Insti-
tute of Aerospace Studies (UTIAS).
However, combing through all the available opportunities
can become a research project in itself. For those companies
looking to form relationships with academic researchers, a good
place to start is with organizations like the Ontario Centres of
Excellence (OCE). Among its other directives, the non-profit
organization specializes in brokering partnerships between
academia and industry.
Comparable organizations to OCE across Canada (e.g. Brit-
ish Columbia Innovation Council (BCIC); Alberta Innovates;
and Innovacorp in Halifax, to name only a few) keep close tabs
on the research opportunities at the universities in their respec-
tive provinces. As such, they can play matchmaker between
academic experts and promising Canadian companies looking
to take their R&D to the next level. In many cases, they can also
help explore the various financial options, whether through
research grants, government-sponsored programs or splitting
costs with the university itself. DE
ace.uoit.ca
ciars.uwaterloo.ca
www.lightsource.ca
soscip.org
CoverStory
Top: The University of Waterloo’s CIARS lab houses one of the world’s
most sensitive anechoic chambers, capable of measuring a broad spectrum
of near-field and far-field radio wave frequencies and transmission types.
Bottom: With nearly 33,000 processor cores, the Blue Gene/Q at the
University of Toronto is the fastest super computer in Canada.
24-29-DES.indd 28 14-02-07 1:56 PM

1
2 3 4
30
Variable frequency drives provide many benefits, but selecting the right one requires asking
the correct questions.
By Joe Kimbrell
The primary function of a variable
frequency drive (VFD) is to vary the
speed of a three-phase AC induction
motor. VFDs also provide non-emergency
start and stop control, acceleration and
deceleration and overload protection. In
addition, VFDs can reduce the amount of
motor start-up inrush current by accel-
erating the motor gradually. For these
reasons, VFDs are suitable for conveyors,
fans, pumps and other applications that
benefit from reduced and controlled
motor operating speed.
Determine if a VFD is right for your
application
A VFD converts incoming AC power to
DC, which is inverted back into three-phase
output power. Based on speed setpoints,
the VFD directly varies the voltage and
frequency of the inverted output power to
control motor speed. There is one caveat:
Converting AC power to a DC bus — and
then back to a simulated AC sine wave —
can use up to 4 percent of the power that
would be directly supplied to a motor if a
VFD were not used. For this reason, VFDs
may not be cost-effective for motors run
at full speed in normal operation. That
said, if a motor must output variable speed
part of the time, and full speed only some-
times, a bypass contactor used with a VFD
can maximize efficiency.
Consider your reasons for choosing
a VFD
Typical reasons for considering VFDs
include energy savings, controlled starting
current, adjustable operating speed and
torque, controlled stopping and reverse
operation. VFDs cut energy consumption,
especially with centrifugal fan and pump
loads. Halving fan speed with a VFD low-
ers the required horsepower by a factor of
eight, as fan power is proportional to the
cube of fan speed. Depending on motor
size, the energy savings could pay for the
cost of the VFD in less than two years.
Starting an AC motor across the line
requires starting current that can be more
than eight times the full load amps (FLA)
of the motor. Depending on motor size,
this could place a significant drain on the
power distribution system, and the result-
ing voltage dip could affect sensitive
equipment. Using a VFD can eliminate
the voltage sag associated with motor
starting, and cut motor starting current
to reduce utility demand charges.
Controlling starting current can also
extend motor life because across-the-line
inrush current shortens life expectancy
of AC motors. Shortened life cycles are
particularly prominent in applications
that require frequent starting and stop-
ping. VFDs substantially reduce starting
current, which extends motor life, and
minimizes the necessity of motor rewinds.
The ability to vary operating speed
allows optimization of controlled pro-
cesses. Many VFDs allow remote speed
adjustment using a potentiometer, keypad,
PLC or a process loop controller. VFDs
can also limit applied torque to protect
machinery and the final product from
damage. Because the output phases can
be switched electronically, VFDs also
eliminate the need for a reversing starter.
Select the Proper Size for The Load
When specifying VFD size and power
ratings, consider the operating profile of
the load it will drive. Will the loading be
constant or variable? Will there be fre-
quent starts and stops, or will operation
be continuous?
Consider both torque and peak current.
Obtain the highest peak current under
the worst operating conditions. Check the
motor FLA, which is located on the motor’s
nameplate. Note that if a motor has been
rewound, its FLA may be higher than
what’s indicated on the nameplate.
Don’t size the VFD according to horse-
power ratings. Instead, size the VFD to
the motor at its maximum current
requirements at peak torque demand. The
VFD must satisfy the maximum demands
placed on the motor.
Consider the possibility that VFD
oversizing may be necessary. Motor per-
formance is based on the amount of cur-
rent the VFD can produce. For example,
a fully-loaded conveyor may require extra
breakaway torque, and consequently
increased power from the VFD. Many
VFDs are designed to operate at 150 per-
cent overload for 60 seconds. An applica-
tion that requires an overload greater than
150 percent, or for longer than 60 seconds,
requires an oversized VFD.
Altitude also influences VFD sizing,
because VFDs are air-cooled. Air thins at
high altitudes, which decreases its cooling
properties. Most VFDs are designed to
operate at 100 percent capacity up to an
altitude of 1,000 meters; beyond that, the
drive must be derated or oversized.
Be Aware of Braking Requirements
With moderate inertia loads, overvoltage
during deceleration typically won’t occur.
For applications with high-inertia loads,
the VFD automatically extends decelera-
tion time. However, if a heavy load must
be quickly decelerated, a dynamic braking
resistor should be used.
MotionControl
Top
for Specifying VFDs
10 TIPS
30-33-DES1.indd 30 14-02-07 1:56 PM

5
6
7
31
When motors decelerate, they act as
generators, and dynamic braking allows the
VFD to produce additional braking or stop-
ping torque. VFDs can typically produce
between 15 and 20 percent braking torque
without external components. When neces-
sary, adding an external braking resistor
increases the VFD’s braking control torque
— to quicken the deceleration of large iner-
tia loads and frequent start-stop cycles.
Determine I/O Requirements
MostVFDscanintegrateintocontrolsystems
andprocesses.Motorspeedcanbemanually
set by adjusting a potentiometer or via the
keypadincorporatedinsomeVFDs.Inaddi-
tion, virtually every VFD has some I/O, and
higher-end VFDs have multiple I/Os and
full-feature communications ports.
Most VFDs include several discrete
inputs and outputs, and at least one analog
input and one analog output. Discrete
inputs interface the VFD with control
devices such as pushbuttons, selector
switches, and PLC discrete output modules.
These signals are typically used for func-
tions such as start/stop, forward/reverse,
external fault, preset speed selection, fault
reset and PID enable/disable.
Discrete outputs can be transistor, relay
or frequency pulse types. Typically, transis-
tor outputs drive interfaces to PLCs, motion
controllers, pilot lights and auxiliary relays.
Relay outputs usually drive AC devices
and other equipment with its own ground
point, as the relay contacts isolate the exter-
nal equipment ground. The frequency
output is typically used to send a speed
reference signal to a PLC’s analog input, or
to another VFD running in follower mode.
Typically, general-purpose outputs of
most VFDs are transistors. Sometimes one
or more relay outputs are included for
isolation of higher-current devices.
Frequency pulse outputs are usually
reserved for higher-end VFDs.
Analog inputs are used to interface the
VFD with external 0 to 10VDC or 4 to
20mA signals. These signals can represent
a speed setpoint and/or closed loop control
feedback. An analog output can be used as
a feedforward to provide setpoints for other
VFDs so other equipment will follow the
master VFD’s speed; otherwise, it can
transmit speed, torque or current measure-
ment signals back to a PLC or controller.
Select the Proper Control Mode
VFD control mode choice greatly depends
on the application. The three VFD control
modes are volts-per-Hertz (V/Hz), sensor-
less vector (sometimes called open-loop
vector) and closed-loop.
V/Hz-type VFDs use the ratio between
voltage and frequency to develop the oper-
ating flux to supply operating torque to the
motor. Sensorless-vector VFDs have accu-
rate torque control over a wide speed range
without having to use encoder feedback.
Closed-loop VFDs use encoder feedback
to obtain motor speed and slip information.
V/Hz control is adequate for many appli-
cations such as fans and pumps. However,
for applications that require greater degrees
of speed regulation, sensorless vector or
closed-loop control types may be necessary.
Understand Your Control Profile
Requirements
Selecting the proper VFD control profiles
is critical and depends greatly on the appli-
cation. Control profiles to consider include
acceleration, deceleration, ramp linearity,
torque control, braking and PID. Most of
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30-33-DES1.indd 31 14-02-07 1:56 PM

8
32
these parameters are available on nearly every VFD type on the
market, but PID may not be offered on very basic models.
These parameters are programmable and can be selected
using the operator keypad or by digital communications. Under-
standing these parameters (and how they affect integration of
the VFD into the process) is imperative. To this end, VFD user
manuals typically provide the information required to select
and program the right control profiles.
Know Your Communication Options
Many VFDs have one or more built-in digital communication
interfaces. Even the most economical models typically include
a serial interface such as Modbus RS-232/RS-485. Ethernet and
fieldbus communication are options offered with many VFDs.
A digital communication interface can be used to connect
the VFD to other devices that can function as a master device
such as a PLC or PC-based controller. The master device can
control the VFD with this interface instead of using the discrete
and analog I/O. The master can also use this interface to
monitor the status of various VFD parameters such as speed,
current and fault status.
An RS-232 connection is somewhat limited as the maximum
RS-232 network cable length is 50 feet. Also, the RS-232 inter-
face is one-to-one, allowing connection of only one VFD to one
controller. An RS-485 network cable can span up to 4,000 feet
and allows connection of multiple devices. Extra adapters may
be required to make this type of connection.
AnEthernetInterfaceprovidesahigh-performancelinkbetween
the control system and multiple VFDs. Some VFD Ethernet inter-
faces are even available with a web server that allows users to
configure and control the VFD from any web browser. Ethernet
protocols such as Modbus TCP/IP and EtherNet/IP take the
guesswork out of VFD control over Ethernet and make setup easy
for non-IT users.
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In addition to varying speeds, conveyor applications typically require
frequent starting and stopping. Here, VFDs substantially reduce starting
current to extend motor life.
30-33-DES1.indd 32 14-02-07 2:05 PM

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Don’t Overlook Thermal Require-
ments
VFDs generate a significant amount of heat.
This heat can cause the internal tempera-
ture of an enclosure to exceed the VFD’s
thermal rating. Enclosure ventilation or
cooling may be necessary to keep enclosure
temperature within specified limits. Ambi-
ent temperature measurements and calcu-
lations should also be made to determine
the maximum expected temperature.
Operating precautions must also be
considered. One should avoid running a
standard induction motor at low speed for
an extended period of time, as this can
cause the motor temperature to exceed its
rating due to limited airflow produced by
the motor’s fan. When a standard motor
operates at low speed, output load must be
decreased. If 100 percent output torque is
desired at low speed, it may be necessary
to use an inverter-duty rated motor.
Don’t use a contactor or disconnect
switch for run/stop control of the VFD and
motor, as this reduces VFD life. Cycling
the input-power switching device while the
VFD is operating should be done only in
emergency situations.
Beware of Harmonics
Any non-linear load, which includes any-
thing with rectifiers, generates harmonics
— including VFDs. If excessive, harmon-
ics can overheat and damage equipment,
transformers and even power distribution
wiring.
Two types of filters can mitigate the
harmonics associated with VFDs. Passive
harmonic filters include AC line reactors
and chokes. Reactors and chokes reduce
VFD-related harmonics and line notching,
and are recommended for all installations.
They also protect the VFD from transient
overvoltages, typically caused by utility
capacitor switching. Active harmonic filters
sample the harmonic current waveform,
invert it and feed the inverted waveform
back to the line to counteract harmonics.
Some active filters also have dynamic brak-
ing circuits that allow motor deceleration
to place regenerative current back on the
AC supply line.
Output line, or load, reactors protect
motor and cable insulation from VFD short
circuits and insulated gate bipolar transis-
tor (IGBT) reflective wave damage. They
also allow the motor to run cooler by
smoothing the current waveform. Output
line reactors are recommended for operat-
ing non-inverter duty motors and applica-
tions in which VFD-to-motor wiring
exceeds 75 feet. DE
www.automationdirect.com
Joe Kimbrell is a product manager,
Drives, Motors, and Motion Control at
AutomationDirect. This article is adapted
from his white paper—Top 10 Tips:
Specifying VFDs.
Using VFDs to operate fans and pumps can
significantly reduce energy consumption,
because they can tailor fan speed to the
application. Fan horsepower is proportional to
the cube of fan speed, so depending on motor
size, energy savings can compensate for the
initial VFD purchase price in less than two years.
Web printing presses, paper mills, and material
converting applications require the precise
speed regulation of closed-loop control available
in higher-end VFDs. Elsewhere, volts-per-Hertz
(V/Hz) and sensorless (or open-loop vector)
modes are used.
30-33-DES1.indd 33 14-02-07 2:03 PM

34
Thomson Technology uses SCADA/HMI software to provide customers
advanced functionality and connectivity while cutting development time.
By Blake DeBiasio
Any manufacturing or industrial facility is only as reliable
as its power source, as much of the equipment in those
facilities must have a robust supply of electrical power. Thom-
son Technology is based in Vancouver, B.C. and has been devel-
oping, designing and manufacturing power generation controls
and switchgear since 1973. We provide systems for critical
applications such as health care, data centers, water/wastewater
treatment plants, and oil and gas exploration. Our wide variety
of customers presents challenging and ever changing demands,
and we needed an SCADA/HMI capable of meetings these
mandates.
When Thomson Technology began to research a better
Supervisory Control and Data Acquisition (SCADA) and Human
Machine Interface (HMI) solution for our flagship Series 2400
switchgear, we needed to find a product that would be as reliable
as the equipment we produce. As the SCADA/HMI is the win-
automation
Switchgear Manufacturer
Cuts SCADA/HMI
Development time
Vancouver-based Thomson Technology provides modular
switchgear and other power systems equipment to a
wide variety of customers.
34-37-DES.indd 34 14-02-07 1:56 PM

35
dow that switchgear operators use to access information and control operation, it was
a particularly critical component.
Searching for a Solution
No OEM likes to switch critical components, but Thomson Technology realized the
time spent in development of our SCADA/HMI screens and related functionality for
our switchgear systems was preventing us from meeting our objectives.
For several years, we custom programmed our SCADA/HMIs using many of the
well-known software products and related development platforms. While these products
allowed us to create acceptable SCADA/HMI solutions, we couldn’t find what we really
wanted—a software product that offered both the reliability of a hardware-based
platform and the flexibility of a hardware-independent solution. In addition, we spent
too much time and effort in application development because the software products we
were using were cumbersome and hard to program.
Once we made the decision to find a solution to our SCADA/HMI problem, we started
with a list of requirements that had to be met. In order to cut development time, we
required flexibility, easy customization, seamless scheduling and extensive communica-
tion capabilities.
We needed to create new projects based on a basic template that would let us quickly
customize the SCADA/HMI for each switchgear product based on its intended applica-
tion. The new SCADA/HMI development platform had to let us customize a new
project by selecting options during the configuration process, as opposed to performing
custom programming.
The same standard SCADA/HMI program also had to be able to perform different
tasks based on the features selected. The SCADA/HMI configuration process had to
include automatic screen layout changes based on information entered. It also needed
to include a built-in simulator that would allow Thomson Technology to test new features
or troubleshoot existing projects.
The ability to save and load the project configurations in our own file structures was
critical. This feature, in combination with the simulator, would enable us to quickly
load a site configuration without changing the basic program. We also needed to run
tests to offer support to the service department, or to simply develop a new project
quickly.
To keep the HMI intuitive, Thomson Technology needed complete control over the
design of the interfaces. To include advanced information to operators, we would need
the functionality to develop HMI solutions with pop-up help screens, messages and
indicator lights that would detail the meaning of each individual set point in the appli-
cation. Any conflicts or illegal operations, and the status of communication with field
devices, would also have to be diagnosed and depicted on the screens.
Customers in Control
We also wanted our customers to have control over their SCADA/HMI, so we looked
for a development platform that would enable changes to be made during runtime
without stopping program execution. Our customers needed the ability to add or remove
users, edit communication parameters, configure their own web server for remote
monitoring, generate reports from history files, and configure the application to send
automatic emails when the system triggered alarms—all without taking the SCADA/
HMI off-line.
Because the scheduler implemented by Thomson Technology can use hundreds of
setpoints, a good display that enabled the user to edit in a visually intuitive way was
important. Just as significant was the ability to save and load all the scheduler setpoints
to a file to save time when entering hundreds of setpoints. Furthermore, it had to be
easy to deploy these setpoints at multiple sites.
Finally, it was imperative that our new SCADA/HMI software serve as a communi-
cation gateway between devices. It should be able to acquire data from engine control-
automation
Our Fit Will
Impress.
LOCTITE®
Retaining
Compounds for
strong cylindrical
assemblies
■ New primerless, oil
tolerant & higher
temperature-resistant
formulas
■ Increase strength &
reliability
■ Reduce weight & cost
■ Prevent fretting,
oxidation & corrosion
■ Precision LOCTITE®
RotoSpray™
applicator
■ Disassemble like standard
press fits
Impress.
Compounds for
strong cylindrical
New primerless, oil
tolerant & higher
temperature-resistant
Increase strength &
Reduce weight & cost
Prevent fretting,
■ Precision LOCTITE
RotoSpray™
■
press fits
applicator
Disassemble like standard
LOCTITE®
applicator
Disassemble like standard
www.loctiteretaining.com
(1-855-436-5354)
AD-166-14.
®
34-37-DES.indd 35 14-02-07 1:56 PM

36
lers, meters, protection relays and other devices. It also had to
provide a central monitoring and logging platform to send the
information further up the chain in order to integrate with
other SCADA systems.
The Right Fit
The solution that we found to this challenging set of require-
ments was the InduSoft Web Studio SCADA/HMI software
and development platform. The software’s Rapid Application
Configuration Environment development
platform, displayed as a ribbon interface,
helped us cut development time by 60 percent.
This in turn cut our costs, and reduced lead
times for delivery of switchgear systems to our
customers.
Using InduSoft, Thomson Technology
designed a custom application template for use
in our Series 2400 switchgear. Each system in
this series is delivered with an integrated
SCADA/HMI that offers options for commu-
nication with the Building Automation System,
the Building Management System, the plant
monitoring system and other customer systems.
Thomson Technology’s application offers
standard communications through Modbus
Serial, Modbus TCP and OPC. Virtually any
protocol is available through InduSoft’s native
drivers, from DNP 3.0 to BACnet.
By finding a better SCADA/HMI solution,
we were soon able to incorporate other features
as well. We could now make minor changes
on-site with only the runtime license installed.
This saved us the time, trouble and expense of
taking a PC, with the InduSoft development
system software installed, to the site.
We can now also provide our customers with
the option of multiple remote stations delivered
using the InduSoft Web Thin Client, which is
important for our oil and gas as well as water/
wastewater customers.
In addition, Thomson Technology now offers
a “Virtual Technician” that enables us to
remotely connect to the local switchgear
SCADA/HMI over the Internet, allowing us to
diagnose problems and make adjustments
without traveling to the site. This saves us time
and, more importantly, lets us help customers
faster and more economically since we no lon-
ger need to send a technician to the site.
By switching to InduSoft Web Studio, we’ve
cut down on SCADA/HMI programming time
by 60 percent per project. We’re also able to
offer a much more feature-rich application
with many more communication options,
along with a standardized and easily service-
able installation. Data logging and remote maintenance features
are now also offered, both of which didn’t exist in previous
applications. DE
www.thomsontechnology.com
Blake DeBiasio is an engineering manager at Thomson Technol-
ogy who oversees the team dedicated to designing the company’s
power generation switchgear systems. He graduated from the
British Columbia Institute of Technology in 1986.
automation
Thomson’s SCADA/HMI Scheduler is capable of reading hundreds of setpoints, and
displaying them all in a visually intuitive manner.
Energy management is easy to track and control using the Thomson switchgear’s intuitive
SCADA/HMI.
34-37-DES.indd 36 14-02-07 1:56 PM

Answers for industry.
www.siemens.ca/mechanical-drives
Many couplings are suitable for an app-
lication, but only one can be precisely
right. For this reason, it is no longer
enough just to have the best couplings:
you also need a complete portfolio to
be able to advise objectively and inde-
pendently.
We are the only manufacturer of mechan-
ical couplings with comprehensive, cross-
industrial know-how in drive technology
and decades of experience in many appli-
cations. With us, it is expertise, quality
and a particularly high standard that
make a coupling the right solution for
your requirements.
Our coupling standard
offers you:
◾ High reliability
◾ High flexibility
◾ Fast availability worldwide
◾ High security and safety
◾ A very good price-
performance ratio
With FLENDER couplings, we offer you
maximum flexibility. With their wide
range of types and sizes, they are always
the right choice, including for potentially
explosive environments.
The right coupling is reliable, because
it is carefully manufactured from high-
quality materials. The right coupling is
available, because it has proved itself in
a thousand individual cases and is manu-
factured as a standard part on the basis
of many years of development. Above
all, therefore, the right coupling offers
you security and safety – for your drive
train, for your entire production and for
your own peace of mind.
The right coupling
The entire coupling range for torques
between 10 and 10,000,000 Nm
34-37-DES.indd 37 14-02-07 1:57 PM

38
Automation
Multi-touch Panel PC
Beckhoff Automation introduced its
CP26xx Panel PC series. The fanless Panel
PCs feature an ARM Cortex A8 processor
with a hardware-based floating point
unit to speed up floating point opera-
tions. Subsequently, the series can be
used for motion control applications in
addition to running HMI software.
In addition to its 1 GHz ARM Cortex
A8 CPU, the series features 1 GB internal DDR3 RAM memory plus an 256 MB Micro SD
card (up to 4 GB are optionally available). Additionally, a 128 kbyte NOVRAM ensures
fail-safe storage of TwinCAT process data. Also available is an on-board 10/100BASE-T
Ethernet adapter, an EtherCAT adapter with RJ-45 connector and an RS-232 interface with
two USB-2.0 ports. The standard operating system is Microsoft Windows Embedded
Compact 7.
The aluminum panel housing offers IP 65 protection at the front and IP 20 in the back.
Users have a choice of eight different multi-touch TFT displays in sizes between 7” and
24”, as well as 4:3, widescreen, landscape or portrait formats. The operating temperature
range for the panels is 0 to 55 °C.
www.beckhoffautomation.com
Panel PC HMI
B&R has added two new series to its Power Panel HMI family:
Power Panel T-Series terminals and Power Panel C-Series con-
trollers – both featuring touch screens. The Power Panel T30
terminal can also be used as a VNC client
and the series comes in four TFT display
sizes ranging from 4.3” to 10.1”. It also
features two Ethernet interfaces and two
USB ports. The Power Panel C70 controller
is equipped with a 333 MHz Intel Atom
CPU, 256 MB DDRAM, 16 kB FRAM and 2 GB
flash EEPROM memory, as well as touch screen display sizes ranging from 5.7” to 10.1”.
With cycle times down to 1ms, the Power Panel C70 also features POWERLINK and standard
Ethernet, USB 2.0 and X2X Link technology as well as optional RS232, RS485 and CAN
connections.
www.br-automation.com
Linear Controller
Steinmeyer, Inc. released its FMC200 series, a small point-to-point controller that supports
a range of motors including linear brushless, DC brush and stepper motors. Up to three
axes can be controlled from a single unit that measures 100x100x25mm. Input power,
ranging from 9 to 36VDC, depends on the motors to be controlled. Open loop and closed
loop control is possible. Maximum input quadrature encoder frequency is 10 MHz. The
FMC200 series controller comes with a software package that includes LabView libraries,
as well as C++, C#, Visual Basic, Delphi and other
libraries. Stand alone operation is possible
with stored motion sequences. The control-
ler, able to interface with an external joy-
stick and limit switches, also includes extra
I/O ports.
www.steinmeyer.com
IdeaGenerator
38-44-DES.indd 38 14-02-07 1:57 PM

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