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Temporal Power’s flywheel design is
putting the Mississauga-based firm
on the global energy management map
FLYOn
the
14 What’s new in SolidWorks 2015
24 Canadian exhaust designer uses simu-
lation to reduce iterations
45 Canadian ExactFlat CAD
software removes the guesswork from
textile design
1-DES.indd 1 14-10-08 9:35 AM
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5. 5
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IN THE NEWS
8 IMP Aerospace
delivers 100th
Aurora
8 Magna Closures
acquires Ontario-
based Techform
8 3D scanning market
to top $4B by 2018
8 3D bioprinter wins
Canadian 2014
James Dyson Award
10 KUKA Systems
develops robotic
riveting system for
Boeing
10 Canadian DND
awards iRobot
“bomb-sniffing”
robot contract
10 Self-powered water
purifier wins Grand
Challenges Canada
grant
READER SERVICES
Contents | Volume 60, No. 5
14 CAD Report
What’s New in SolidWorks 2015:
SolidWorks receives a major upgrade in
2015, signalling a renewed commitment by
Dassault to its leading MCAD package
22 Hardwire
Home Maker: Dremel’s sub-$1,000
3D Idea Builder takes complexity out of
3D printing at the cost of flexibility and
versatility
34 3D Scanning
Tracking the Path to Success: Quebec’s
Soucy Track leverages Creaform 3D
scanning technology to boost accuracy
of the company’s custom-built farming
machinery rubber track systems
38 Idea Generator
The latest in industrial products including
automation, power transmission, motors,
drives and sensors
45 Canadian Innovator
From CAD to Cutter: Canadian-made
ExactFlat CAD module for SolidWorks and
Rhino removes the guesswork from 3D
textile design
Columns
18 Color Me Awesome
Canadian projection-mapping technology
renders high-definition color textures on
3D printed models
24 Exhaustive Simulation
Canadian exhaust system designer uses
multiphysics simulation to reduce costly
design iterations
28 On the Fly
Temporal Power’s flywheel design is putting
the Mississauga-based firm on the global
energy management map
Features
14
18
22
28
34
45
www.design-engineering.com October | 2014
24
4-5-DES.indd 5 14-10-07 12:42 PM
6. 6 EditorialViewpoint
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October | 2014 www.design-engineering.com
The past couple of months have seen two major milestones in the advancement
of DIY design and manufacturing. At IMTS 2014 in September, crowd-sourced
vehicle design firm, Local Motors, unveiled the Strati, a build-it-yourself car made
largely of additive manufactured components. Over the course of the six-day show,
the company’s crew 3D printed and assembled the finished vehicle for test driving.
Given the media buzz in the Strati’s wake, the company says it will soon sell kits,
including the STL design files, as a limited edition product.
At the opposite end of the spectrum, Cody Wilson and his non-profit, gun ownership
rights group, Texas-based Defense Distributed, made headlines in early October with
the debut of the “Ghost Gunner,” a small sub-US$1,500 desktop CNC machine. Better
known for creating the Liberator—the world’s first 3D printed handgun—Wilson’s
latest venture is specifically designed to create assault rifle parts free of serial numbers.
The machine’s name stems from the fact that such weapons, called “ghost guns,” bypass
background checks and other existing state and federal gun ownership restrictions.
This is possible because, although current U.S. gun laws restrict the sale of firearms
without a serial number, fashioning weapons for personal use has always been legal.
Presumably, the number of unregistered guns in circulation was restricted by the fact
that gunsmithing skill was rare and the equipment needed, formally high-end milling
and lathing machines, cost tens of thousands of dollars.
Today, however, most of the components needed to build the popular AR-15, for
example—including stock, barrel, upper receiver, etc.—can be legally ordered from
Internet-based providers. The only regulated component is a metal part called the
lower receiver. Encompassing the trigger mechanism and clip well, the lower receiver
requires a U.S. Federal Firearms License to sell. It also carries the stamped serial
number and therefore has been a barrier to DIY gunsmiths.
However, the U.S Gun Control Act of 1968 does allow companies to sell rough
lower receiver parts that are 80 percent finished. That’s where a machine like the
Ghost Gunner comes in. Using a commonly available steel carbine drill bit for the
spindle, Defense Distributed’s CNC machine mills the few holes and cavities needed
to finish off the remaining 20 percent. Not only is the machine cheap, but it doesn’t
require much skill. According to Defense Distributed, the Ghost Gunner mills wood,
plastic and aluminum, out-of-the-box, without any prior CNC knowledge.
To Canadian ears, the fact that the organization wasn’t shut down within days of
the Ghost Gunner debut may sound like lunacy—the U.S.’s “cowboy,” gun-obsessed
culture run amok. To Wilson and firearm advocates like him, the machine represents
a subversive tool, outmanoeuvring the web of dictatorial regulation obscuring the
Second Amendment.
Whichever side you tend toward, it remains that as most advancement lures us
toward greater dependence on—even addiction to—technology, desktop CNC
machines, entry-level 3D printers and push-pull CAD still hold out the potential for
self-reliance. For most in the gun advocacy crowd, a firearm—like a vehicle—
represents, not unbridled violence, but independence and self-sufficiency. To me,
both should be traceable and require a license to operate, but in an age when the
average Joe can’t fix his own high-tech car, it’s reassuring that he may soon be able
to design, print, machine and assemble one.
Mike McLeod
Ghost in the CNC Machine
6-7-DES.indd 6 14-10-07 2:57 PM
8. 8
IMP Aerospace delivers 100th Aurora
In September, IMP Aerospace delivered its 100th
CP-140 Aurora, a multi-role, long-range patrol
aircraft designed to support Canadian forces and
conduct surveillance domestically.
The Aurora fleet entered service in 1981 and is
now in its sixth Third Level Inspection and Repair
cycle. The company says it has incrementally modern-
ized the aircraft — replacing the wings and horizon-
tal stabilizers, as well as installing state-of-the-art
navigation and flight instruments, communications
and mission systems — to extend the Aurora fleet’s
operation beyond 2030.
www.impaerospaceanddefence.com
Magna acquires Techform
Magna International Inc. announced that its sub-
sidiary, Magna Closures, will acquire Ontario-based
Techform Group of Companies, an automotive
supplier of hinges, door locking rods and other
closure products. On completion of the transaction,
Magna will acquire Techform’s facilities in Pene-
tanguishene, ON; Portland, Tennessee; and Hefei,
Anhui China. The transaction is scheduled to close
in early October 2014.
www.magna.com
www.techform.com
3D Scanning Market to top $4B by 2018
Industry analyst firm, ReportsnReports.com, esti-
mates the global 3D scanning market will grow to
$4.08 billion by 2018, at an estimated CAGR of
14.6% from 2013 to 2018.
According to the firm’s report (3D Scanning Mar-
ket Worldwide Market Forecasts and Analysis 2013
– 2018), there has been an accelerated growth in
3D scanning adoption because the conversion of
point clouds to CAD data is becoming easier, prices
are lower and hardware and software used is more
efficient.
Major 3D scanning market players include Faro
Technologies, Konica Minolta, Creaform, Surphaser,
Autodesk, 3D Systems and 3D Digital Corp.
ReportsnReports.com
UP FRONT 3D bioprinter wins
Canadian 2014 James
Dyson Award
The PrintAlive Bioprinter, a 3D printer that produces artificial
skin grafts for burn victims, has been awarded the top prize in
the Canadian leg of the 2014 James Dyson Award, an international
student product design contest.
Developed by University of Toronto mechanical and biomedical
engineering graduate students, Arianna McAllister and Lian Leng,
the PrintAlive represents a major step forward in producing “high-
resolution human microtissue arrays,” the printer’s creators say and
could significantly speed burn victim recovery time.
Similarinconcepttoaconventional3Dprinter,thePrintAlivedoesn’t
create a skin graft in the traditional sense, but instead produces a kind
of “living bandage” hydrogel. As its build material, the system extrudes
a biopolymer infused with human keratinocytes and fibroblasts in a 3D
structure that mimics epidermal and dermal skin layers.
According to its inventors, the PrintAlive has the potential to
overcome the limitations of existing severe burn treatments. For
example, traditional skin grafts are limited in size and can introduce
infection or rejection issues, while techniques that grow skin cells to
be applied over a larger area take weeks for cultivation. By contrast,
the UofT technology could produce large custom-built hydrogel
sheets rapidly using the patient’s own skin cells.
For winning the Canadian stage of the award, the UofT team will
receive $3,500 to further develop the technology. Currently, the Print-
Alive is in the process of clinic testing and pre-commercialization.
In addition to the winner, four runner-ups will go on to compete
in the international award. Runners-up include:
EcoSat: A small CubeSat that will test the diamagnetic properties
of pyrolytic graphite in low gravity.
EyeCheck: A camera and smartphone app system that can quickly
diagnose vision problems, as well as provide eyeglass prescriptions.
The Skorpion Rock Drill: A mobile mining drill carrier designed
to replace heavy “jackleg” hand-drills that account for nearly one-third
of all underground injury claims.
Suncayr: A pen-like marker containing UV sensitive dyes that
DesignNews
October | 2014 www.design-engineering.com
8-13-DES.indd 8 14-10-07 12:43 PM
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10. 10
change color when the sunscreen washes or wears off.
According to the award’s organizer, the James Dyson Foun-
dation, 600 entries were received for the international prize
from 18 countries. The international winner, announced Novem-
ber 6th, 2014, will receive CAD$50,000 plus another CAD$18,000
for the student’s university department.
The judges for the Canadian 2014 James Dyson Awards
included Lucas Cochran, technology correspondent on Discov-
ery’s DAILY PLANET; Mario Gagnon, founder of ALTO Design,
Canada’s largest design engineering firm; and this article’s
author, Mike McLeod, editor of Design Engineering magazine.
www.jamesdysonaward.org
Self-powered water purifier wins Grand
Challenges Canada grant
In September, Canadian engineering start-up, Formarum,
received a $112,000 grant from Grand Challenges Canada (GCC)
for its self-powering water purification device. The Toronto-based
company was one of 22 Canadian projects to receive backing
by the Government of Canada-funded organization, which
supports sustainable technology, social and business solutions
to health challenges in developing nations.
Requiring no outside power source, the company’s Dive puri-
fier incorporates a small turbine generator that produces electric-
ity internally from the water flowing through the device. The
electricity powers Dive’s automated copper–silver ionization
process, which treats the water as it flows. The system also auto-
matically adjusts the disinfection rate based on water flow rate.
Once connected to a pipeline, the device functions without
technical expertise or a dedicated power supply.
Invented by Ryerson University chemical engineering
graduate and Formarum’s CEO and founder, Seyed Nour-
bakhsh, Dive is currently also in development as a recreational
pool water purifier. According to Nourbakhsh, the system not
only removes the labour intensiveness of pool maintenance
but also offers an alternative to chlorine for control algae and
fungus growth.
www.formarum.com
KUKA Systems develops robotic riveting
system for Boeing
When the Boeing 777X twin-aisle passenger jet goes into full
production for its debut in 2020, each fuselage will be built using
KUKA Systems Aerospace Group’s robotic pulse production
line, known as the Fuselage Automated Upright Build (FAUB)
system. According to the company, the system will assemble
fuselages for the current 777 models and then become the base-
line manufacturing process for the wide-body 777X.
The pulse line uses guided KUKA robots equipped with end
effectors manufactured by another KUKA company, Alema
Automation, to do the riveting currently performed by workers
using handheld tools. The robots will work on the forward and
aft sections, installing up to 60,000 fasteners per 777 fuselage.
For KUKA Systems, the project is one of the largest it has
undertaken in the aerospace sector. The FAUB system, which
was pre-assembled and integrated at KUKA Systems in Sterling
Heights, MI, is undergoing the final phase of testing and produc-
tion readiness in a Boeing facility in Anacortes, WA.
www.kukanao.com
Canadian DND awards iRobot
“bomb-sniffing” robot contract
Canadian Department of National Defence
(DND) announced that it has awarded iRobot
Corp. multi-year contracts worth $9.6
million for 20 of the U.S.-
based robotics firm’s 510
PackBot CBRN Recce
Systems, plus training and
product support.
The iRobot system is a
modular expansion
to the company’s
510 PackBot Multi-
Mission robot platform
modified to meet the spe-
cific requirements of the Cana-
dian DND. It includes a CBRN suite that
integrates five primary sensors to detect, alert and report on
chemical warfare agents, toxic industrial chemicals, volatile gases,
explosives and radiation. The robot also features enhanced mobil-
ity through the addition of rear flippers.
The robot is designed for missions including explosive ord-
nance disposal, reconnaissance, route clearance and data col-
lection in industrial settings. All systems under the contract
are expected to be delivered by April 2015.
www.irobot.com
Canadian researchers develop nano-sensors
for smartphone glass
Researchers at Polytechnique Montréal say they have created
3D light-guiding systems, laser-written into a smartphone’s
protective glass, that could one day be used for sensing everything
from temperature to blood sugar levels.
“We’re opening Pandora’s box at the moment,” says Raman
DesignNews
October | 2014 www.design-engineering.com
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12. 12
Kashyap, professor of electrical engineering and engineering
physics at Polytechnique Montréal. “Now that this technique is
viable, what remains is to invent new uses for it. This is why we
are actively looking to partner with industry to develop this
technology.”
To create these nano-sized, transparent systems, the research
team used an infrared laser to etch three-axis transparent light
pathways, or waveguides, within Corning Gorilla Glass, a strong,
dense glass currently used in most smartphones.
Measuring only a few microns in diameter, but up to a meter
long, the channels are imperceptible to the naked eye but act as
conduits for the light given off by the smartphone display. Ana-
lyzing shifts in the light as it passes through the waveguides
allows for novel sensor applications.
As a proof of concept, the research team created a heat sen-
sor composed of two waveguides, one straight and one curved.
As the glass heats up, the waveguides get longer as the glass
expands. By measuring how the light that emerges from one
waveguide interferes with light from the other, the device can
measure the temperature of anything it touches.
The team also created a smartphone authentication system
by employing waveguides with patterns of tiny holes. Using this
method, each smartphone could have a unique photonic fin-
gerprint to add another layer of security in, for example, finan-
cial transactions.
“It’s easy to imagine how the technology could also eventu-
ally allow computing devices to be embedded into any glass
surface, such as windows, tabletops, telephone screens, creating
totally transparent tactile surfaces,” says Jérôme Lapointe, lead
researcher and doctoral student at Polytechnique Montréal. “It
would be like adding a new dimension to the real world that
our eyes can see.”
www.polymtl.ca/en
DesignNews
October | 2014 www.design-engineering.com
8-13-DES.indd 12 14-10-07 12:43 PM
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14. SolidWorks receives a major upgrade in 2015, signalling
a renewed commitment by Dassault to its leading MCAD
package.
By Ralph Grabowski
Four years after Dassault Systems
announced the successor to SolidWorks
(a badly flubbed PR move that led to a
frenzy of speculation as its dedicated users
debated the future of the company’s mid-
level CAD package), its future is now
secure. At the September launch of Solid-
Works 2015, Dassault executives reassured
the assembled media that the MCAD
program would be updated and supported
for another 15 years, at least.
The uncertainty primarily affected the
chattering classes because, at 2.3 million
users, SolidWorks continues to sell briskly,
keeping its position as the #1 MCAD pro-
gram. Now, the bulk of these sales are to
educational institutions; subtract them out
and there appears to be around 650,000
commercial seats. Dassault trumpets the
number as often as it can, because arch
competitor Siemens PLM only occasionally
provides vague guidelines for second-place
Solid Edge, such as “over 500,000” com-
mercial seats, while Autodesk stopped
reporting licenses of apparent third-place
Inventor years ago.
What’s New in SolidWorks 2015
And so, in this light, Dassault imbued
SolidWorks 2015 with a bevy of new and
enhanced functions. After all, nothing says
“We’re there for you” like lots and lots of
enhancements from a software company.
Let me highlight a few that caught my eye.
Intended for building assemblies
graphically, Treehouse is not so much new
functionality as reintroduced since it was
previewed years ago. Using its flowchart-
October | 2014 www.design-engineering.com
14 CADReport
What’s New in
SOLIDWORKS
Figure 1: Creating assemblies by dragging and dropping parts in Treehouse.
14-17-DES.indd 14 14-10-07 12:44 PM
15. like interface (See figure 1), we build
assembly structures by dragging and drop-
ping parts and assemblies into the inter-
face—or by opening an existing assembly
into Treehouse. After this, we can edit the
parts to specify things like configurations,
quantities and custom properties. The
data can then be linked to SolidWorks
Enterprise PDM.
Chain patterns are a new type of assem-
bly. Here, we pattern (array) parts along a
path that can be opened or closed—think
tank-treads or even gantry cable guides—
in three modes: Distance, distance linkage
or connected linkage. Once the assembly
is complete, SolidWorks simulates the
motion of the chains so that we can be sure
it’ll operate correctly.
Something we saw introduced to Solid
Edge ST7 this year, SolidWorks also auto-
matically flattens 3D models to see how
much material is needed. With an eye on
the fashion industry into which Dassault
sells specialty software, this flattening can
be used towards clothing, footwear and
upholstery design.
Over in the area of surfacing, surface
curvature combs let us see how well sur-
faces connect. This is important for ensur-
ing smooth transitions from one surface
to the next.
Asymmetrical fillets means that we can
specify two radii (instead of just one, as for
traditional fillets), like two distances for
chamfers. In this case, the resulting fillet
looks like a quarter ellipse.
Patterns (arrays) no longer need to be
regularly spaced; they can have variable
distances defined by formulae. (I first saw
this in the Russian KOMPAS MCAD pro-
gram earlier this year, and so it’s interest-
ing how quickly the function appeared
elsewhere.) To make variable patterns, we
first create a pattern table that defines the
distances, which can be pasted into Solid-
Works from a spreadsheet. The table defines
distances between features (extrudes,
revolves, fillets, domes, drafts and so on),
as well which instances to skip for non-
continuous patterns. The values can be
static, or calculated using mathematical
functions, like sum, sine, log, pi and square
root. I can see this one function needing
an entire course to learn!
To make it easier to find references in
2D drawings, sheets can now be divided
into zones. As a result, annotation notes,
balloons and revisions tables refer to zone
numbers, which are updated automatically
should parts be moved to another zone.
Other new items that caught my eye are
touch-ups that probably should have been
added to SolidWorks years ago. These
include drawing lines symmetrical to the
midpoint; saving selection sets by name
for reuse; customizing toolbars; drawing
spline-shaped leaders; and setting word
wrapping, paragraph spacing, and line
spacing in paragraph text.
SolidWorks Links to MBD
Along with adding functions to SolidWorks,
Dassault continues on a parallel path, slowly
writing modules that are independent of
the MCAD program, yet help out designers
using SolidWorks. The modules are inde-
pendent because they are written with Das-
sault’s proprietary CAD platform — Enovia
database (for the “file” system) and CGM
kernel (for the modeling).
Consequently, they are inherently
incompatible with the Parasolid kernel
employed by SolidWorks. Being external
modules also allows Dassault to charge
extra for each, typically $2,000 apiece with
a $500/yr subscription.
The newest module is SolidWorks MBD
(Model-Based Definition). The idea is that
3Dmodelsshouldcontainalltheinformation
needed to build the design, forsaking 2D
www.design-engineering.com October | 2014
15CADReport
n
S 2015
14-17-DES.indd 15 14-10-07 12:44 PM
16. 16
entirely. (See figure 2.) Now, MBD is
the hot new term that isn’t as sexy as
“social”or“cloud,”butismuchmore
important; well, it has the potential
to be that, but only now is getting
attention along with slowly getting
needed traction among design firms.
MBD is driven by government
agencies, such as the U.S. Military’s
MIL-STD-31000A specification, a
3D data format required for parts
manufactured for military use.
Traditional 3D models contain
onlyinformationthatisinherent,such
as the lengths of edges and volumes.
Design details are left to stacks of 2D
drawings,whichdocument3Dmod-
els through flattened views, dimen-
sions and geometric tolerances,
welding instructions plus embedded bills of material and their
accompanying balloons, all topped off with index sheets. This is
why marketing departments make a big fuss over how well their
MCAD programs generate linked 2D drawings from 3D models,
automatically. Because that’s the way it’s done, currently.
MBD promises to jettison all the 2D generation, automation
and linking for a purely 3D deliverable that is loaded up with
all the information that today is relegated to drawing sheets.
But this means updating MCAD systems to embed 3D PMI
(product and manufacturing information) and metadata into
CADReport
Absolut
zuverlässig!(Absolutely dependable!)
1 . 8 0 0 . 6 6 8 . 4 3 7 8 • w w w . n o r d . c o m
Figure 2: Model-based definitions embed all information needed to manufacture 3D models
14-17-DES.indd 16 14-10-07 12:44 PM
17. 17
3D models—information like design intent, GD&T, BOMs,
material definitions, and all this stuff that used to be external
to the pure 3D model.
Clearly, generating self-contained 3D models requires a big
switch in thinking and a big programming job by MCAD soft-
ware developers.
This is not a simple transition, and
so SolidWorks doesn’t do it. Instead,
the new, separate module does it.
SolidWorks MBD attaches all that
PMI data directly onto 3D models.
Output templates generate mod-
els and data suitable for different
departments, such as procurement,
request for quotations and manu-
facturing. And, in a tip of the hat
the current practice, MBD also
outputs drawings in 2D.
With SolidWorks 2015, users will
berelievedtoseetheirfavoriteMCAD
systemimbuedwithnewlifethrough
an impressive set of new functions.
For those firms who need it, MBD
will allow them to use a mid-level
MCAD system for high-end aircraft and military contracts. DE
www.solidworks.com
Ralph Grabowski is a CAD journalist and blogger at
worldaccess.typepad.com
CADReport
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18. October | 2014 www.design-engineering.com
18
Canadian projection-mapping technology
renders high-definition color textures on
3D printed models.
By Mark Barfoot, Hyphen
Recently, additive manufacturing/3D printing has been get-
ting a lot of attention with its benefit of producing prototypes
quickly to try out designs; creating fixtures to aid in production
of components in a fast; and efficient matter and producing
production parts for a variety of industries, from aerospace to
medical to commercial and consumer products. More recently,
with the advent of the lower cost “home-use” based machines,
the power of 3D printing has now entered everyday life.
One complaint about additive manufacturing technologies,
however, is that they are limited to a single color in the build.
Three current technologies, however, allow for color:
• Stratasys’ Polyjet technology in its Connex 3 machine uses
inkjet print heads to lay up primary colored photopolymers in a
mixture to create a range of color parts. The resulting parts are
hard and durable but have a limited color palette.
• 3D Systems’ Color Jet Printing (CJP) process spreads a layer
of starch based powder and then sprays out a colored binder to
harden the part. This provides full color models, but they require
infiltrating with cyanoacrylate after printing to get them hard
enough to handle. Even once infiltrated, their strength is only
similar to a cured ceramic part.
• Paper 3DP by Mcor, the newest technology to offer color,
takes regular full color printed paper sheets and glues them in a
stack and cuts away the excess to create full color models.
If you don’t have any of these technologies, you have to resort
to painting the parts manually to achieve the colors you need.
If companies want to compare different color versions to choose
final color, distinct individual models have to be created.
A New Color Concept
Christie Digital Systems Canada and its subsidiary, Kitchener-
based service rapid prototyping and environmental testing
center Hyphen, have come up with a proof of concept for a new
application, called the Christie Interactive Design Studio. With
this system, you can take a standard gray 3D printed part and
have projectors instantly provide the color and texture through
projection mapping. A video display wall composed of Christie
MicroTiles as a backdrop lets you “place” the part in any envi-
ronment.
The result is a system that allows you to dynamically change
the color, texture and style of your part on the fly, while further
offering the opportunity to see how that part looks in different
settings. This can save the time and cost of printing multiple,
different color versions or laboriously hand painting various
color options on different models.
The first iteration of this unique projection mapping system
for 3D printing was shown at Infocomm 2013 and consisted of
RapidPrototyping
COLOR Me
AWESOME
Above: A 3D printed C7 Corvette model, created by Hyphen, sits on a
video display platform composed of Christie Digital Systems’ MicroTiles.
Below: The Christie Interactive Design Studio projects a dynamic
background and HD color textures onto the grey Corvette model.
18-21-DES.indd 18 14-10-07 12:47 PM
19. The RSM2800 Magnetic Encoder counts turns,
measures angles down to the last degree, and
remembers shaft positions without power
Don’t try this with other encoders: imagine your machine
with the RSM2800 inside both lose power and are still
turning without power; when power is restored, the
RSM2800 reports the correct position including the
counts that occurred with no power!
RSM2800 magnetic encoders provide the level of reliability
and accuracy sought in demanding applications like:
• Material Handling • Agricultural Machines
• Forklifts • Cable Extension Transducers
• Overhead Doors • Medical Equipment
The RSM2800 is based on Novotechnik’s proprietary
non-contact, multi-turn technology for absolute
5,760° (16 turns) measurement.
This new wear-free device
combines advanced capabilities
with mechanical simplicity in a
very compact and sturdy housing to
provide for longer life and lower cost
than optical encoders.
Novotechnik U.S., Inc. • 155 Northboro Road • Southborough, MA 01772
Tel: 508-485-2244 Fax: 508-485-2430
RSM2800 Specifications:
Absolute multi-turn
Up to 16 turns
Up to 0.1° resolution
Up to 0.1%
independent linearity
Outputs: 0.1 to 10V
or 4 to 20 mA
or 0.25 to 4.75V
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IP rating options:
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24. October | 2014 www.design-engineering.com
24
Canadian exhaust system designer uses multiphysics simulation to reduce
costly iterations.
By Matt Butson and Ning Cao,
Active Exhaust Corp.
Designing exhaust systems is complicated by the
number of different physical phenomena involved.
Designers must consider airflow inside the exhaust system and
its impact on back pressure experienced by the engine. The flow
of gas through the exhaust manifold produces vibrations and
noise that the design must mitigate. The system’s temperature
must be maintained to maximize exhaust after-treatment per-
formance and to minimize impact on both the environment
and adjacent vehicle components. Active Exhaust uses multiphys-
ics simulation to reduce costly iterations by validating designs
before testing.
Active Exhaust is a world-class provider of exhaust manage-
ment systems for industrial engine and vehicle applications.
The company specializes in sound, emissions and thermal
management solutions for mobile and stationary engine appli-
cations ranging from 5 HP to 700 HP.
Headquarters in Toronto, the company’s facility houses RD,
product engineering and customer support, as well as its North
American manufacturing center. It has a staff of approximately
275 employees along with two off-shore joint ventures in China
and India, and warehouse locations in the United States. Active
Exhaust caters its technologies to markets that include consumer
and commercial lawn care equipment, construction and farm-
ing machinery, welders and generators, as well as all-terrain,
recreation and utility vehicles.
Design Validation by Testing
In the past, the company utilized 2D design tools
that were developed internally based on exist-
ing tube and muffler elements. The design
engineer approximated the design
performance using these tools,
but the accuracy, documenta-
tion and scope of design-ready
geometries were limited.
Engine manufacturers must
adhere to stringent regulations
including those set forth by the U.S.
Environmental Protection Agency and
Department of Agriculture.
As a value-added service, Active Exhaust
directly collaborates with various approving bodies
to simplify the process for its customer base. As a
result of uncertainty in design performance, all new
exhaust systems have to undergo lab validation of cri-
teria such as pressure drop, horsepower, torque, thermals,
vibrations, acoustics, emissions, cleanliness, particulates
and leak testing.
This process relied heavily on physical testing to vali-
date design performance. Active Exhaust’s extensive test
facility has provided the final validation before products are
shipped to customers. The million-dollar test facility includes
five eddy current dynamometers with capacity of up to 10,000
rpm, 400 Nm and 160 kW. When the engines are instrumented,
Exhaustive
SIMULATION
CADBeat
ANSYS FEA results show deformation of this
manifold headerpipe designed by Toronto-based
Active Exhaust Corp.
Simulation, such as this temperature distribution of gas inside an exhaust diffuser, allows
Active Exhaust to virtually validate designs, and thereby reduce costly physical testing.
24-27-DES.indd 24 14-10-07 1:27 PM
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Available in Industrial PVC, CPVC, ABS and Natural
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Leader in Thermoplastic Piping Systems
IPEX Inc. designs and manufactures one of the world’s most diverse lines
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26. October | 2014 www.design-engineering.com
26
these state-of-the-art data acquisition systems collect flow,
pressure, noise, acceleration, temperature and other measure-
ments at frequencies to distinguish exhaust pulsations with
high resolution.
Recently, however, the company entered markets with engines
so large that they exceed the capacity of internal dynamometers.
Third-party testing would have been required, driving costs to
uncompetitive levels. The additional costs related to building
prototypes and the outside manpower required to perform
analyses made it too expensive to continue designing these
larger systems employing the physical testing method.
Active Exhaust recognized several other limitations in their
test-based design process. Whenever a design did not meet
requirements, the team had to react quickly to redesign, rebuild
the prototype, and repeat the tests at considerable expense.
Additional design iterations took substantial amounts of
time, running the risk of delaying product introduction. The
measurements that were captured by physical testing were
constrained by the physical limitations of
sensor technology: Information
generated by the tests was often
insufficient to diagnose the
root cause of a problem. For
example, physical testing is
unable to detect flow recircula-
tion, which can significantly
increase exhaust pressure drop.
Further, the high cost of testing
meant that the team had only limited
opportunities to evaluate design alternatives
that might optimize performance and cost.
Simulation-Based Design Process
Active Exhaust considered a number of different simulation
options. With fluid flow crucial to the design, the company first
focused on computational fluid dynamics (CFD) solutions.
Engineers found several software packages that met the com-
pany’s needs, but ANSYS software was distinguished by its
ability to solve the additional physics involved in the design,
including mechanical, thermal and acoustics.
Active Exhaust selected ANSYS CFD-Flo for fluids simulation
along with ANSYS Mechanical, which provides structural,
thermal and acoustics capabilities. These and other ANSYS
tools reside within the ANSYS Workbench environment, provid-
ing bidirectional data transfer with CAD systems, a common
user interface and integration between the different physics,
among other capabilities.
Simulation now is at the heart of the design process at Active
Exhaust. The first step typically is to open a file containing the
CAD geometry that has been created in PTC Creo software.
Active Exhaust then extracts the fluid volume from the solid
model and adds boundary conditions to it, such as the mass
flow rate at the exhaust inlet, exhaust outlet pressure and other
parameters arising from the engine operating conditions.
ANSYS CFD is then used to perform a flow simulation
through the exhaust system. This simulation calculates the
exhaust system pressure drop and resulting back pressure at the
inlet. Since the flow is now being simulated in the actual exhaust
geometry, the results usually correlate quite closely with phys-
ical measurements.
The CFD software provides diagnostic capabilities far beyond
what is obtainable from test results, including velocity and
pressure at every point in the flow path. For example, an engi-
neer running a flow simulation of a new exhaust system might
see a recirculation zone in the flow path. Aware that recircula-
tion generally increases the system pressure drop, he would then
make changes to the geometry of the CFD model, such as reduc-
ing any obstruction or excess curvature in the main flow path.
The engineer would then rerun the simulation to see if the
change eliminated the recirculation zone. If not, the engineer
would continue modifying the model geometry until the recir-
culation zone was eliminated. This process often leads to a
significant reduction in back pressure. The benefit of using the
analysis software is that, as the geometry changes, the mesh,
setup and solution are automatically updated, saving time in
the development process.
In conjunction with using CFD simulation, Active Exhaust
engineers apply ANSYS Mechanical to analyze the exhaust
system from thermal, structural and acoustics perspectives. The
integration between ANSYS CFD and ANSYS structural mechan-
ics software makes it easy to transfer the internal temperatures
calculated using CFD to ANSYS Mechanical, where they
become inputs for a thermal analysis that deter-
mines the temperatures on the exterior of
the exhaust system and identifies the
stresses generated by thermal
expansion.
ANSYS Mechanical is also used to validate the
structural integrity of the exhaust system by inputting
power spectral density data from the vehicle. Using these inputs
to drive a random vibration simulation determines frequency
response and stress distribution. The dynamic analysis also
determines modal frequencies of the exhaust system. If the
modal frequencies have the potential to be activated by the
engine, engineers make design changes.
The next step in simulation at Active Exhaust is to predict
the acoustic performance of exhaust systems prior to the pro-
totype phase. This is determined using ANSYS structural
mechanics features that utilize the output from modal analysis
CADBeat
Flow field
streamlines and
temperature distribution
inside a venturi-type aspirator.
24-27-DES.indd 26 14-10-07 1:27 PM
27. www.design-engineering.com October | 2014
data to calculate attenuation
and absorption of pressure
waves (sound) by the muffler.
Based on this data, the software
simulates the transmission loss across the
frequency spectrum and calculates noise
emission levels. Active Exhaust has
been able to utilize its library
of raw engine acoustics as a
source impedance to help
characterize insertion loss
values, a widely compared
value in the industry.
The most important advan-
tage in moving to a design process
based on simulation is that Active Exhaust now almost always
gets the design right the first time. Every new design is still
exhaustively tested, but up front simulation ensures that the
first prototype meets the customer’s requirements in nearly
every case. Simulation also provides much more diagnostic
information, making it possible for engineers to quickly identify
the root cause of problems and to make substantial improve-
ments in performance.
The company’s customers benefit from higher performance
and shorter lead times. Active Exhaust absorbs most design
costs with the intent of earning them back when the exhaust
system moves into production. Active Exhaust has won several
major contracts that can be directly attributed to the new design
methods. DE
www.activeexhaust.com
Matt Butson is the Engineering Services Manager and Ning
Cao is the Product Design Engineer at Active Exhaust Corp. in
Toronto.
27CADBeat
Flow field streamlines and temperature
distribution inside a muffler displaying
streamlines and temperature contours.
24-27-DES.indd 27 14-10-07 1:27 PM
28. October | 2014 www.design-engineering.com
28
Temporal Power’s flywheel design is putting
the Mississauga-based firm on the global
energy management map.
By Treena Hein
S
ometimes what seems like bad luck can turn out to be a
life-changing catalyst – the thing that sets us on a course
we never could have imagined.
That’s been the extraordinary experience of Jeff Veltri. A
non-work-related injury in young adulthood ended his five-year
stint as a pipe fitter and sent him back to school, into Ryerson
University’s mechanical engineering program. He was employed
for a while and then started his own firm, working over the next
ten years on industrial, biomedical and military projects. “I’ve
always been an inventor and a tinkerer, taking things apart to
see how they worked,” Veltri says. “But I’ve always had the goal
of being able to both create and manufacture a product.”
The realization of this goal started without Jeff realizing it
– in 2008, when the government of Ontario was introducing
time-of-use electricity rates. It prompted him to look at how
power could be purchased during non-peak billing times and
On the
FLY
CoverStory
A 500 kW flywheel being lowered
into the vault at Temporal Power’s
manufacturing facility to undergo
testing.
28-31-DES.indd 28 14-10-07 12:55 PM
29. www.design-engineering.com October | 2014
29
then used whenever it was needed in his home office-shop. In
his research, he was drawn to the flywheel.
“Any conventional energy storage device, like a battery,
degrades a little each time you charge it and discharge it, but a
device that is purely mechanical like a flywheel is immune to
that, if the design is proper,” Veltri explains. “A flywheel can
also deliver 100% of its capacity.”
As Veltri mused about flywheel use for his own business, he
realized it could be commercialized for grid use. “So, I designed
a small prototype and took it to the OPA (Ontario Power Author-
ity) to show it off.” The device had an analog power meter with
a disc that spun one way when the machine was charging and
the other way when it was discharging, which gave a good visual
demonstration.
To move forward, the next step was obtaining an $300,000
OPA Technology Development Fund grant, but applying would
involve business model expertise. “I hired Cam Carver, and he
was very enthusiastic,” Veltri explains. “He suggested partner-
ing and creating a new business, and we formed Temporal Power
in 2010 [Veltri is President and CTO, and Carver is CEO]. The
management of grids was changing and Cam realized the con-
cept would be of great value to the IESO (Independent Electric-
ity System Operator of Ontario) in terms of frequency regulation.”
The company did secure the OPA grant, which allowed the
tech to be scaled up to bench size, a 1 kW model, and then to what
they now offer commercially: a 50kWh, 250kW or 500kW mod-
ule that can be arrayed to multi-MW scale. Along the way, Sustain-
able Development Technology Canada and Hydro One provided
assistance, and Lockheed Martin verified the design. Carver and
Veltri also secured an investment of $500,000 from MaRS Dis-
covery District, and $6 million from a Toronto-based venture
fund, allowing the company to move to a facility in Mississauga.
They are now at 30,000-sq.-ft. with 24 full-time employees, includ-
ing eight engineers.
“It’s been a period of great excitement mixed with some terror,”
Veltri chuckles. “It’s great to have all the support and confidence
of investors, and my very patient wife over the years, but the
pressure is there. My hair went from brown to mostly grey trying
to stay on budget, dealing with engineering challenges…but it’s
been the time of my life.”
A simple flywheel design
In simplest terms, a flywheel is a mechanical battery that stores
kinetic energy in a rotating mass. When charging, the motor
uses power from the grid to accelerate the rotor to high speeds.
Variable frequency drives feed the motor to convert electrical
energy to rotational kinetic energy. On discharge, the flywheel
slows and its inertial load drives the motor as a generator, add-
ing power back to the grid.
Through their ability to efficiently balance energy and control
energy frequency (at the standard 60 hz) by rapidly absorbing or
generating power, Temporal Power flywheels improve power
quality and lower costs. Veltri notes that problems with not being
able to regulate grid voltage and frequency quickly helped cause
the massive eastern North America power outage in 2003.
Temporal Power tech is also obviously very handy in integrat-
ing variable power generated from renewable sources like wind
into the grid. The size and patented design of these flywheels
allows them to hold massive amounts of energy many hundred
times greater than conventional (relatively tiny) flywheels. The
life cycle of the tech is 20 years with minimal maintenance and
full recyclability, Veltri says.
The rotating mass is steel, weighing in at 4,000 kg with a top
speed of 12,000 rpm. Veltri notes that while carbon fibre has
been used in smaller flywheels, it is not feasible in this case as
there are few companies who could make such a large rotor with
it; carbon fibre is brittle and detecting flaws in it is difficult.
“Steel has been around for hundreds of years, and it’s a mate-
rial that’s easily-obtained, relatively inexpensive and offers
excellent defect testing,” he explains. “We have the machining
done locally, and as much of everything else that we can within
Canada as well.”
The flywheel spins in a vacuum to eliminate wind resistance,
and the permanent magnet at the top forms a closed magnetic
circuit that lifts the entire mass off the mechanical bearings,
allowing them to do radial and axial positioning but under a very
light load. The friction losses are therefore very low, less than 1
KW, and the bearings are expected to last a long time.
One of the two main engineering challenges was rotor dynam-
ics. “At first glance, there is only one moving part, but with such
CoverStory
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30. October | 2014 www.design-engineering.com
30
a large mass spinning this fast, reso-
nance was a big issue,” Veltri explains.
“Any spinning object will resonate at
certain speeds and directions depend-
ing on the geometry, and we used rotor
analysis software to tell us theoretically
how things should be shaped, but you
still have to do prototypes. The models
are excellent, but the characteristics
change – things shake – because other
things within the entire system come
into play.”
Precision balancing of the rotor was
the other main challenge. “We’d out-
sourced this but had to bring it in-
house as no one had machinery that
could do the job, balancing a 4,000 kg
part within a few grams,” Veltri
explains. “We had to customize the
equipment to achieve the required tolerances, which are ISO
G0.4 to G1.0.”
Temporal Power flywheels are being used, so far, by a company
calledNRStorintheircontractwiththeIESOforfrequencystabil-
ity, and another proposal is in the works. They are also hard at
work at a wind energy facility in Tillsonburg for Hydro One.
“There is a lot of talk about energy storage, storing it now to
use later, but where energy storage has the most value in our
eyes is in high-speed precision voltage and frequency regulation,”
Veltri says. “This saves money, allows green energy to be inte-
grated into the grid and can save island nations enormously in
diesel fuel costs. We hope to have our technology used on islands
in the near future.” DE
www.temporalpower.com
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32. October | 2014 www.design-engineering.com
32
Assuring machine safeguarding compliance requires a team approach.
By Tony Rigoni, Beckhoff Automation
Today, customers face greater challenges when figuring out
the proper way to safeguard their machines while meeting
the various safety requirements. Not only do they need to deter-
mine what safety standards to adhere to (e.g. ISO 13849-1, EN
954, ANSI B11.19, RIA 15.06, PMMI B155.1, Semi S2, NFP 79,
etc.) but also determine the proper way to conduct risk assess-
ments and safety risk mitigation.
At the end of the day, customers just want to make sure
their machines are running safely and that their employees
are protected. So, what is the best approach for a customer
to take, ensuring they not only meet the proper safety require-
ments, but also safeguard their machines in an appropriate
and productive way? Here are a few suggestions on how to
get there:
Develop an internal panel to discuss machine safety: Many
users already have an Environmental Health and Safety manager
but, in a lot of cases, EHS personnel aren’t well-versed in the
intricacies of machine controls. By developing in-house teams
of control engineers, maintenance workers and production to
work alongside EHS, companies can review the best approach
for them to ensure proper machine safety. This approach only
works if end-users have qualified personnel who can handle the
task and develop the necessary internal resources. Admittedly,
it can take a long time to develop and acquire the internal
knowledge needed here.
Turn to outside help: Many customers today have outside
consulting companies come in and take care of their risk assess-
ments and machine safeguarding. While this approach is by far
the easiest for a customer to take, it also usually is costly and
leaves you with little internal safety knowledge.
This approach might be best applicable if you are trying to
safeguard one machine quickly. However, another potential risk
is that many outside consultants are safety experts, but have
little knowledge of machine controls; this could result in an
overall solution that isn’t as productive as it should be.
Turn to the OEMs: End-users today are increasingly seeking
help from OEMs to implement and deliver safe machines. This
has been the standard practice in European markets and we are
MotionControl
Safe by
DESIGN
32-33-DES.indd 32 14-10-07 1:00 PM
33. www.design-engineering.com October | 2014
33
starting to see the same trend develop
in North America. Of course, nobody
knows a machine better than the OEM,
so they can decide what the best stan-
dards and practices to follow are. Many
OEMs are jumping onto this trend by
offeringturnkey,safeguardedmachines
compliant to the relevant standards.
So what is the best approach? Just
like there are several safety standards,
there are also several effective ways to
integrate safety into your machines.
By using products such as TwinSAFE
I/O terminals from Beckhoff Automa-
tion, for example, it allows the OEMs
to tie safety directly into their existing
controls network, reducing develop-
ment time and hardware costs.
Common safety functions—such
as e-stops, light curtains, safety doors,
floor mats, etc.—are easily connected
via distributed I/O terminals that act
as safety PLCs, as well as safety inputs
and outputs. This safety technology
ties seamlessly with standard I/O ter-
minals and standard controllers on the
same network (EtherCAT) and are
programmed using the same software
environment as the machine controls
(TwinCAT).
It’s critical to partner with a knowl-
edgeable safety expert who not only
understands safety, but also machine
controls. If there is one “best answer,”
it would be for companies to take
action and prepare their organization
to become complaint with the appli-
cable safety standards. This is not only
to protect employees, but to ensure
corporate responsibility for any
manufacturing company. DE
www.beckhoffautomation.com
Tony Rigoni is a Regional Sales
Manager and Safety Specialist with
Beckhoff Automation.
MotionControl
Safety products, like Beckhoff Automation’s
TwinSAFE I/O terminals, allows OEMs to tie
safety into their existing controls network.
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
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
32-33-DES.indd 33 14-10-07 1:00 PM
34. October | 2014 www.design-engineering.com
34
Quebec’s Soucy Track leverages Creaform 3D scanning technology to boost accuracy
of the company’s custom-built farming machinery rubber track systems.
Founded in 1967, Soucy International Inc. is a Quebec com-
pany that has developed state-of-the-art expertise in design-
ing and manufacturing parts and accessories for the agricultural,
industrial, military and recreational markets. Its “Soucy Track”
line of products is a world leader when it comes to rubber track
systems for farming machinery. These tracks are meant to replace
wheels on tractors and any other kind of vehicle, to improve
their traction and flotation, as well as make the ride more com-
fortable for the driver.
When coming up with Soucy Track, the company’s first
intention was to create a system that could easily be fitted on
the vehicles, without having to modify them, an idea that is still
the key driver of the design process. To maintain the integrity
of the vehicle, and to find a perfect fit, Soucy created a manu-
facturing process where the track system seamlessly adapts to
the axles of any vehicle.
In straightforward terms, this means Soucy doesn’t work
with digital files or 2D plans of the agricultural machinery.
Instead, Soucy scans the vehicle “as built” to make sure the
tracks comply with it. Most vehicles are measured in the factory,
but the company doesn’t hesitate to go to a dealership or even
to travel overseas to scan vehicles that are not distributed in
North America. Its measurement technologies therefore need
to be portable and, more specifically, easily transportable.
Arm Wrestle
Until 2010, Soucy used a FARO measuring arm. This probing
arm produced measurements that were accurate enough. How-
ever, the device was time consuming and required many
resources. As a result, the company would only measure the
parts of the tractor where the track system needed to be secured.
Furthermore, technicians needed to make so many manual
measurements, that they often forgot to keep track of important
data. In short, these limitations were causing problems when
the track system was mounted.
To solve this situation, Soucy Track’s Director of Engineering,
André Léger, started looking for a 3D technology that could
replace the probing measurements. The company was looking
for a solution that could also measure the axles as well as all the
nearby components of the machinery, without forgetting any
other part that could potentially interfere or be used to attach
the track system. In 2010, Mr. Léger discovered Creaform,
another Québécois company, and got interested in the potential
of its HandySCAN 3D contactless 3D scanning technology.
3D Scanning
C
M
Y
CM
MY
CY
CMY
K
SE
Tracking the
Path to SUCCESS
34-37-DES.indd 34 14-10-07 1:33 PM
38. October | 2014 www.design-engineering.com
38
Automation
Controller
WAGO introduced its PFC200, a real-time
Linux-based controller that features mul-
tiple fieldbus ports, a 600 MHz ARM
Cortex A8 processor and an integrated
web server that supports WAGO’s Web
Visu mobile application. In addition, the
PFC200 features 256 MB of on-board
storage plus 32 GB removable. Supporting
multiple protocols, the controller acts as a
fieldbus gateway to communicate between MODBUS TCP/UD/
RTU, CAN, PROFIBUS, Smart Grid and RS-232/RS-485, eliminating
the need for third-party converters. Configuration of fieldbus
networks is further simplified with the WAGO-I/O-PRO program-
ming and visualization software tool, the company says.
www.wago.us
HMI
CARLO GAVAZZI launched its
CGHMI Series of HMIs. Available
in four sizes (4.3, 7, 10 or 15
inches), the LED backlit HMIs
come in one of up to three dif-
ferent housing bezels: plastic, alu-
minum or wash down resistant
stainless steel (IP66K). The series features ARM
processors, 128MB ROM, 128/256MB RAM and WinCE 6.0 oper-
ating system. All models also offer an SD slot and Ethernet port
and connectivity via Profibus-DP, ProfiNet, DeviceNet, EtherNet/
IP, CANopen, EtherCAT and CC-Link. Models also come with CG
Design Studio software, with the option for CG Design Studio Plus
(featuring Symbol Factory and its 4,000+ HD symbols)
www.carlogavazzi.com
On-Machine Ethernet Switch
Rockwell Automation launched its Allen-
Bradley ArmorStratix 5700, an on-
machine Ethernet switch with IP67
protection. The Layer 2 managed
switch can be mounted directly onto
a machine or application. Using the
Cisco IOS network infrastructure
software, the switch manages the
transfer of production data to
enterprise-level databases and information systems. The ArmorStratix
5700 offers Quality of Service (QoS) and automated monitoring, as
well as 8, 16 and 24 fixed-port configurations. Each base model also
comes with M12 Ethernet connectors, SD flash card, dual-power
inputs and a panel-mounted design. An expanded ArmorStratix
5700 switch offering includes 10 and 18 fixed-port configurations,
with 2 gigabit ports, hardware-based IEEE 1588, hardware alarms
and up to eight Power over Ethernet (PoE) ports.
www.rockwellautomation.com
EtherCAT Box
Beckhoff released its EQxxxx
EtherCAT Box I/O series in
V2A stainless steel housings
that are rated at protection
class IP 69K and qualified for the
extended temperature range of -25 to
+60°C. Through an integrated EtherCAT
interface, the self-contained modules can
be connected directly to an EtherCAT network
without an additional coupler box. The performance of the Ether-
CAT industrial Ethernet system, with communication speeds in the
microsecond range, is maintained into each module. Each box is a
EtherCAT device and an EtherCAT slave, which can be connected
directly to any other EtherCAT device via a standard Ethernet cable
with 100BASE-TX.
www.beckhoff.com
Motors Drives
Mini Drive
WEG Electric introduced its CFW100 Mini Drive, a single-phase
variable speed drive designed to handle 150% overload for 60
seconds at 50°C ambient temperature rating. Approximately the
size of a typical panel contactor, the tiny VFD has power ranges of
1/4HP, 1/3HP, 3/4HP and 1HP at 230 VAC
with single-phase in and 1.5A, 2.6A and
4.2A three-phase output current. It also
features a built-in HMI, built-in PLC, DIN
rail mounting, detachable fan and plug-in
modules for communication and I/O
options. The CFW100 is also manufac-
tured with conformal coated circuit boards
classified as 3C2 per IEC specification
60721-3-3.
www.weg.net
Torque Motor
ETEL introduced its best selling torque
motor, its TMB motor series, to the
North American market. The
series comes in 50 standard
model sizes with different
windings to provide perfor-
mance based on torque, cur-
rent and speed requirements.
The company says TMB motors
can achieve a peak torque of up
to 31,200 Nm and speeds of up to
4,500 rpm. It can also be equipped with the company’s IMTHP
thermal module for temperature monitoring. Compatible with most
CNC controllers, the motor series has no backlash and requires
zero maintenance, the company says.
www.etelusa.com
IdeaGenerator
38-43-DES.indd 38 14-10-07 1:07 PM
39. www.design-engineering.com October | 2014
39
Stepper Motor and Driver
Oriental Motor introduced its CVK Series, standard-
ized 24V DC input driver combined with high
torque stepper motors. The series features two
motor types with three basic step angles:1.8°,
0.72° or 0.36°. The 1.8° motor type offers the
highest torque in the low speed range. The
0.72° motor type is designed for the mid- to upper-
speed range and the 0.36° provides positional accuracy com-
pared to 1.8° and 0.9° stepper motors. The CVK Series is available in five frame sizes: 20
mm (0.79 in.) to 60 mm (2.36 in.). For customers requiring a driver only, the CVD driver is
also available with a range of adjustable current settings.
www.orientalmotor.com
Power Transmission
Disc Coupling
Baldor announced that all its disc couplings now meet
ATEX certification, a European Union directive that
defines essential health and safety requirements for
equipment used in potentially explosive atmospheres.
The couplings meet all ATEX requirements for mining
applications and other applications with combustible dust
and gas atmospheres. Each Baldor-Dodge disc coupling has the following ATEX ratings: I
M2 c Sizes 94 to 310 with an ambient range of -30˚C to +65˚C; II 2 GD c 135˚C (T4) Sizes
94 to 310 with an ambient range of -30˚C to +65˚C; and II 2 GD c 100˚C (T5) Sizes 94 to
210 with an ambient range of -30˚C to +50˚C
www.baldor.com
Pipe Mount Clamps
Stafford Manufacturing released its Staff-Lok Hinged Shaft Collars
designed for pipe mounts and pipe hangers. The collars feature a
hinge with a conformal cam lever for clamping and a knurled nut
for adjusting the clamping preset. They also include a mounting
flat with a countersunk hole and attachment screw for securely
mounting pipe and tube requiring frequent or fast changes. The
collars come in eight pipe sizes from 1/4 to 2 inches and 12 shaft
sizes from 1/2- to 2-1/2-inch I.D.
www.staffordmfg.com
Black Oxide Bearings
SKF unveiled a line of black oxide bearings with a pro-
tective surface layer for wind turbines. The black
oxidation surface treatment — applied to a bear-
ing’s rings and/or rollers — involves up to 15
different immersion steps to create a thin, black
surface layer to upgrade performance for a range
of bearing types and sizes (up to 2.2m in diameter
and up to 1,000 kg per individual bearing compo-
nent). Suitable bearing types for the coating include
tapered roller bearings, cylindrical roller bearings, spherical
roller bearings and CARB toroidal roller bearings, among others.
www.skfusa.com
IdeaGenerator
38-43-DES.indd 39 14-10-07 1:07 PM
41. www.design-engineering.com October | 2014
41
Flow Control
Air Nozzle
EXAIR introduced its 1-inch High Power Stainless Steel
Flat Super Air Nozzle. The CE compliant component
produces a flat 1-inch (25mm) wide airstream with a
blowing force of 16 ounces (462g) when mounted 12”
(305mm) from the target. In addition, its Type 316 stain-
less steel construction makes it suitable for corrosive,
high temperature, food, pharmaceutical and chemical environments. Air consumption is
17.5 SCFM (495 SLPM) at 80 PSIG. Force and flow can be adjusted by installing different
shim thicknesses. The nozzle meets OSHA dead end pressure standard CFR 1910.242(b).
Sound level measures 82 dBA which meets OSHA noise exposure standard 29 CFR 1910.95(a).
www.exair.com
Check Valves
SFC KOENIG announced that it has added check
valves to its line of sealing and flow control products.
The valves feature a ball-style, one-piece, self-con-
tained design and can be used to maintain system pressure
and prevent backflow. The components are available in both forward-flow and reverse-flow
models in a range of standard size diameters, cracking pressures and flow rates. According
to the company, the components don’t require thread machining, don’t generate debris and
prevent contamination during installation. Their metal-to-metal seal design requires no
additional sealants or threads. SFC KOENIG parts offer field failure rates less than 0.5 PPM
(parts per million), the company says.
www.sfckoenig.com
Sensors
Linear Encoders
HEIDENHAIN Corporation released its absolute LC 185 and
LC 485 sealed linear encoders as a complete family,
including options for common encoder interfaces
such as EnDat 2.2, Fanuc, DRIVE-CLiQ and Mitsubishi.
The LC 185 also features dual sealing lips. The resolu-
tion of the LC 185 and the LC 485 is 5nm with an
accuracy grade of 3µm. The LC 485 features an improved design that allows the upgrade
of slim-line linear encoders from incremental to absolute without drilling or tapping new
mounting holes.
www.heidenhain.us
Industrial Amplifier
HBM, Inc. released its PX460 industrial measurement
amplifier that measures raw and filtered torque,
frequency, pulse, speed and angle of rotation. It can
acquire up to four channels of data from torque trans-
ducers simultaneously with an analog bandwidth of up to 6 kHz.
In addition to powering the torque transducer directly, the PX460 can also
acquire encoder signals of up to 2 MHz. The amplifier interfaces with most reac-
tion arm-based dynamometers. Using an on-board, position-based CASMA filter, the PX460
smoothes torque measurements so that they can be fed directly into a dynamometer or
machine control system using real-time fieldbuses or by using an analog output.
www.hbm.com
IdeaGenerator
www.diequa.com
630-980-1133
See our complete
product line!
DieQua offers
more gearboxes
plus application experience to help
select the best one for your needs
• 1-75 HP Capacity
• Motorized or Adapters
• Right Angle or Inline
• Shaft Mount Designs
• Multi-Stage Ratios
• Modular Design
Helical Gearmotors
• 7 sizes, 28-110mm CD
• Fret-free Connection
• NEMA or IEC Adapters
• Coupling Input
• Aluminum Housings
• 2-Side Worm Support
Worm Reducers
• Precision or Economy
• Inline or Right Angle
• 40-155mm Frames
• Low Backlash
• 1 and 2 Stage Ratios
• Lubricated for Life
Planetary Gearheads
• 3 Backlash Levels
• Shafts or Hollow Bores
• Single or Dual Outputs
• 11 sizes, 25-200mm CD
• Capacity: 10-7000 Nm
• 20,000 Hour Ratings
Servo Worm Gearheads
• 9 Sizes
• 1-250 HP Capacity
• Low Backlash Option
• Ratios from 1:1 to 6:1
• Output Shaft Options
• Machined Housings
Spiral Bevel Gearboxes
• Add-On Options
• ModifiedDimensions
• High Speed Applications
• Special Environments
• Special Duty Needs
• Custom Designs
Special Designs
38-43-DES.indd 41 14-10-07 1:07 PM
42. To advertise your solution in this section call Taebah Khan at 416.510.5230
October | 2014 www.design-engineering.com
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.
Clippard
www.clippard.com/scientific-a
Tel: 1.877.245.6247 • Email: sales@clippard.com
NEWEST WEAPON FOR THERMAL MANAGEMENT
Master Bond EP30AO is a thermally conductive,
electrically insulative epoxy used for potting,
bonding, sealing and coating. Featuring low
viscosity, superior dimensional stability and high
physical strength, EP30AO cures at room
temperature. This high performance compound
is widely used where electrical insulation and
environmental protection are required and heat
transfer must be maintained.
Master Bond
www.masterbond.com/tds/ep79fl
Tel: 1.201.343.8983 • Email: info@masterbond.com
DUST COLLECTORS NEW - FULL LINE LITERATURE GUIDE
This impressive NEW guide outlines dozens of
N.R. Murphy dust collectors, installations,
capacities, styles and models. A must for any
reference library. N.R. Murphy Limited has been
in business over 70 years and has thousands of
satisfied customers. “Dust Collectors are all we
do; so get it done right the first time. Just Ask the
Experts.”
N.R. Murphy Limited
www.nrmurphy.com
Tel: 1.519.621.6210 • Email: 4nodust@nrmurphyltd.com
ARC POWER CATALOG “B217”
BRECOflex CO., L.L.C., offers state-of-the art
polyurethane timing belts with patented “ARC” tooth
design. This revolutionary continuous engagement
tooth form produces the smoothest running and
quietest timing belt available. Typical applications
include medical imaging, camera motion control and
precision extrusion pulling or where the most
advanced belting technology is required.
BrecoFlex
www.brecoflex.com
Tel: 888-463-1400 • Email: info@brecoflex.com
DRYLIN® W - FOR ALMOST UNLIMITED DESIGN FREEDOM
DryLin® W was developed to promote both design
flexibility and quick assembly in both single and
double rail configurations. DryLin® W is also
available in several mounted assemblies
eliminating the need for both shaft alignment and
bearing assembly. All DryLin® W systems have
lubrication-free liners, reducing friction and
optimizing bearing life. Request a free DryLin®
W sample linear guide kit from igus®.
igus
www.igus.ca
Tel: 1.905.760.8448 • Email: webmaster@igus.com
MORE FOR LESS – 1.8°, 0.9° OR SPUR GEARED STEPPER
MOTORS
With up to 1.7 times more torque at new lower
prices, the PKP Series 1.8° or 0.9° offers over
400 new high-torque bipolar stepper motors.
Designer advantages of utilizing more torque are;
less heat is generated, lower vibration and
downsizing of the motor. Available in bipolar
windings, encoders or Spur gearhead, all with
quick shipping.
Oriental Motor
www.orientalmotor.com/PKP/
Tel: 1.800.468.3982 • Email: sales@orientalmotor.com
38-43-DES.indd 42 14-10-07 1:07 PM
43. www.design-engineering.com October | 2014
43
Current Transducer
NK Technologies announced
that its ATH Series cur-
rent transducers now
accommodate 120VAC
power supplies. ATH cur-
rent transducers are
also available in solid-
core or split-core 24V
models. ATH current transducers are compatible with most automa-
tion systems and are designed for monitoring burst-fired, time-
proportional control of heating systems. The systems provide an
output signal directly proportional to the RMS amperage and are
accurate even though there are periods of time when the heating
circuit is intentionally off, using no power. Their design enables the
sensor to remain installed over the conductor while the heating
circuit is powered or when it is being serviced, regardless of what
may be connected to the output terminals and even when there
is nothing connected.
www.nktechnologies.com
Safety Relay
Pilz Automation released its safety
relay PNOZ s50 that can control two
powerful brakes simultaneously
without the use of contacts. The
relay is designed to control holding
brakes or safety brakes in the 24/48
Volt DC range on vertical axes up to
PL e of EN ISO 13849-1 or SIL CL 3
of EN/IEC 62061. The relay has an
output current of 3.5 amps, with peak currents
of 6.5 ampere. The PNOZ s50 also offers fast shutdown of the
power circuits or a slow shutdown for low-noise switching of the
brakes. Four safety-related and two standard inputs are available
to activate the functions.
www.pilz.com/en-CA
Torque Sensor
SensorData Technolo-
gies introduced its
Model T261 Series, a
family of rotary transformer
coupled torque sensors. Units
are available in standard rated
capacities of 5K, 10K and 20K
rpm. Rated speed of the series is
10K RPM, with nonlinearity and hysteresis specifications of ±0.05%
of rated output. Non-repeatability is ±0.02% of rated output.
Series sensors are constructed of SAE 4340 alloy steel with satin
nickel finish. The series also features an onboard shunt circuit for
ease of remote calibration. As a rotary transformer torque sensor,
the SensorData T261 Series requires the use of stand-alone AC
strain gage signal conditioning electronics.
www.sensordata.com
IdeaGenerator
38-43-DES.indd 43 14-10-07 1:07 PM
