Dng de-12012012

$10.00 | November/December 2012
PM40069240
12 What’s new in Solidworks 2013
22 T-Bots and H-Bots save space
and increase performance
36 Canadian engineer lends space
suit skills to historic freefall
Canadian
RoversCanadian space robotics
expertise produces rover
prototype ﬂeet for future
space exploration
Artemis, Jr., designed by the Neptec Rover
Team, is one of a half dozen robotic lunar
and Mars rover prototypes developed to
position Canada as a player in future space
exploration missions.
1-DES.indd 1 12-11-27 11:27 AM

Drive controllers
> Efficient
SoMachine
> Software
Logic-controller
> Flexibility
Motion controller
> Performance
HMI-controller
> Compact
Machines
Drive
Controller
HMI
Controller
Motion
Controller
Logic
Controller
Software
SoMachine
New flexible machine control offers
100% flexibility of your machines
Optimised control; shorter time to market
Gain the competitive advantage!
Start designing, maintaining, and commissioning
your machines in a single environment. Get your
FREE trial copy of SoMachine software!
Visit www.SEreply.com Key Code u425v
Flexible Machine Control
To reach 100% flexibility and optimisation, flexible
machine control incorporates pre-defined and
proven automation architectures and functions and
embeds intelligence in multiple hardware control
platforms. A single software suite helps you to
develop, program, and commission your machines.
Machines today need to be faster, more flexible, and must be able to solve
more complex automation functions than ever before. As a machine builder you
must constantly look at innovative ways to build more energy-efficient machines,
reduce development costs, and get your machines to market much faster.
Flexible Machine Control has made this history. Flexible machine control
incorporates SoMachine, a single software suite that runs on multiple hardware
control platforms to achieve 100 per cent machine flexibility: HMI, motion,
drive, and logic controllers. With SoMachine, you need only one software, one
cable, and one download to design, commission, and service your machines
from a single point. SoMachine minimises your work and capitalises on each
design.
Flexible machine control is part of our brand-new MachineStruxure solution,
designed to take complexity out of the business. The MachineStruxure solution
also includes:
Tested, Validated Architectures and Functions: Build a strong automation
platform through the use of our ready-to-use, proven, and fully transparent
automation architectures and application function libraries implemented with
FDT/DTM technology. Our architectures are predefined and dedicated to
your specific needs for optimum results.
Co-engineering Services: Design the optimal solutions for your customers
with innovative help from our experts! We implement the latest technological
evolutions and provide a unique hands-on industry application knowledge that
helps you stay ahead of the competition.
©2012 Schneider Electric. All Rights Reserved. Schneider Electric, MachineStruxure, and SoMachine are trademarks owned by Schneider Electric Industries SAS or its affiliated companies.
All other trademarks are property of their respective owners. www.schneider-electric.com • 998-2693_CA
One Software Environment
One software suite to develop, program, and commission
your machines, requiring only one tool, one download, one
connection, and one project file
Multiple Hardware Control Platforms
Embedded intelligence where it is needed
l
O
Speeds
Prices a
EPSON
EPSON-TSerie2-3-DES.indd 2 12-11-23 12:28 PM

The new epson
®
sureColor
®
T-series
• Extreme plotting accuracy at resolutions up to 2880 x 1440 dpi
• Capable of producing a precise, colour, D-sized plot in 25 seconds
• Advanced pigment ink technology for truly durable, full-colour plots
• High-capacity ink cartridges up to 700 mL for low printing cost
• Space-saving design with easy access front-loading paper and ink
EPSON SureColor T3000 - 24" | $3,075
lines as thin as
Our new plOtters print
EPSON SureColor T5000 - 36"
Speeds are based upon print engine speed only.Total throughput times depend upon factors such as computer, file size, printer resolution, ink coverage, and networking. For the SC-T3000, top speed for a D-sized plot is 28 seconds.
Prices are MSRP, before rebates. Please check with an EPSON Professional Imaging Authorized Reseller for actual price as dealer prices may vary.
EPSON and SureColor are registered trademarks and EPSON Exceed Your Vision is a registered logomark of Seiko Epson Corporation. Copyright 2012 Epson America, Inc.
mm018That’s less
than 1/55th of
the distance
between here and here.
than 1/55th of
EPSON-TSeriesAd-NovDec.indd 1 10/30/12 11:27 AM2-3-DES.indd 3 12-11-23 12:28 PM

SCHAEFFLER GROUP
INDUSTRIAL
The Straight Line
on Linear Solutions
Operational reliability begins with design.
INA linear products from Schaeffler are designed
with maximum load capacities across the range,
as well as high rigidity and misalignment
compensation within series designs. Patented
lubrication and sealing technology ensures
maintenance free operation, while continuous
product innovation embraces linear solutions with
increasingly longer and quieter service lives.
Behind design is versatility and service. INA offers
an extensive range of products backed by a
comprehensive service center to quickly create
and deliver highly customized linear assembly
solutions.
INA linear solutions from Schaeffler… the straight
line to operational reliability.
www.schaeffler-group.com
Straight Line 10/24/07 12:06 PM Page 1
4-5-DES.indd 4 12-11-23 3:21 PM

5IN THE NEWS
8 Mitutoyo appoints
new executives
8 ATS reports $8
million profit for Q3
8 General Dynamics
secures LAV III
upgrade contract
8 Toronto designer
wins concept
Popemobile contest
10 Kaspersky to
develop secure
Industrial OS
10 Canadian flying
saucer declassified
11 2012 Technology
Fast 50 winners
announced
11 P&WC Selects
Dassault’s
3DEXPERIENCE
Platform
Annual Subscription Rate
In Canada: $52.95 (1 year)
$71.95 (2 year)
Outside Canada: $99.95 (1 year)
Single Copy
In Canada: $10.00
Outside Canada: $22.00
Directory Rates
In Canada: $27.00
Outside Canada: $45.00
Reader Service
Contact Information
ecallaghan@bizinfogroup.ca
T: Toronto 416 442 5600 X 3538
Elsewhere -866-543-7888
Mail:
Business Information Group
Design Engineering Circulation Dept
80 Valleybrook Drive
North York, ON
M3B 2S9
Printed in Canada
READER SERVICES
Contents | Volume 58, No. 6
12 CAD Report
Solidworks 2013 abounds with time-saving
enhancements and handy features
16 Hardwire
MotoCzysz engineers speed design of
performance electric bikes with 3D mice
26 Shop Talk
DEX Appeal: Design Engineering tabletop
show draws enthusiastic engineering
crowd
28 Power Transmission
Designing the most efficient motor and
gearbox pairing takes time but can be
simplified by using the right selection
process
30 Idea Generator
The latest in industrial products including
sensors, fluid power and power
transmission components
Columns
18 Canadian Rovers
Canadian space robotics expertise
produces rover prototype fleet for future
space exploration.
22 Alpha-Bot Soup
T-Bot and H-Bot configurations can save
space and increase performance
36 Falling Free
Canadian engineer lends spacesuit skills
to historic freefall
Features
16
18
30
22
36
26
www.design-engineering.com November/December | 2012
4-5-DES.indd 5 12-11-23 3:41 PM

6 EditorialViewpoint
I enjoy hearing from you so please contact me at
MMcLeod@design-engineering.com and your letter
could be published in an upcoming issue.
@
www.design-engineering.com
Editor
Michael McLeod (416) 442-5600 ext. 3231
mmcleod@design-engineering.com
Publisher
Alan Macpherson (416) 510-6756
AMacPherson@design-engineering.com
Group Editorial Director
Lisa Wichmann (416) 510-5101
LWichmann@canadianmanufacturing.com
Accounts Manager
Laura Gergley (416) 510-5230
lgergley@design-engineering.com
Technical Field Editor
Pat Jones, P. Eng.
Art Director
Kathy Smith (416) 442-5600 ext. 3215
KSmith@plant.ca
Market Production Manager
Jessica Jubb (416) 510-5194
jjubb@bizinfogroup.ca
Circulation Manager
Cindi Holder (416) 442-5600 ext. 3544
CHolder@bizinfogroup.ca
BIG Magazines LP
Executive Publisher
Tim Dimopoulos
Vice-President of Canadian Publishing,
Alex Papanou
President of Business Information Group,
Bruce Creighton
Publications Mail Agreement #40069240
ISSN: 0011-9342 (Print), 1929-6452 (Online)
Privacy Notice: From time to time we make our
subscription list available to select companies and
organizations whose product or service may interest
you. If you do not wish your contact information to
be made available, please contact us via one of the
following methods:
Phone: 1-800-668-2374 Fax: 416-442-2191
E-mail: privacyofficer@businessinformationgroup.ca.
Mail to: Privacy Officer, 80 Valleybrook Drive,
North York, ON M3B 2S9
Subscriber Services: To subscribe, renew your
subscription or to change your address or information
contact us at 1-800-387-0273. Subscription Price:
Canada: $52.95 for 1 year; $71.95 for 2 years; $10 for
single copy. Outside Canada: $99.95 for 1 year; $22
for single copy. Directory/buyer’s guide: Canada $27;
Outside Canada $45.
Design Engineering, established in 1955, is published
6 times per year except for occasional combined,
expanded or premium issues, which count as two
subscription issues. Published by BIG Magazines LP, a
division of Glacier BIG Holdings Company Ltd.
Tel: 416-442-5600, Fax: 416-510-5140
80 Valleybrook Dr., Toronto, ON M3B 2S9.
Contents of this publication are protected by copyright
and must not be reprinted in whole or in part without
permission of the publisher. DE receives unsolicited
features and materials (including letters to the editor)
from time to time. DE, its affiliates and assignees may
use, reproduce, publish, re-publish, distribute, store and
archive such submissions in whole or in part in any form
or medium whatsoever, without compensation of any
sort. DE accepts no responsibility or liability for claims
made for any product or service reported or advertised
in this issue. DE is indexed in the Canadian Business
Index by Micromedia Ltd., Toronto, and is available
on-line in the Canadian Business & Current Affairs
Database. We acknowledge the financial support of the
Government of Canada through the Canada Periodical
Fund (CPF) for our publishing activities.
November/December | 2012 www.design-engineering.com
As the end of the year approaches, manufacturers in the U.S. and Canada
aren’t thinking about Christmas or the promise of a New Year. Instead,
their focus rests on whether the U.S. will collectively drive off the so-called
fiscal cliff, the slew of across-the-board cuts in U.S. government spending
coupled with tax increases set to kick in January 1, 2013 if President Obama
and U.S. law makers don’t reach a long sought after deal by the December 31
deadline.
It’s not hard to understand their pre-occupation. According to U.S. Con-
gressional Budget Office projections, failing to avert the $109 billion in
spending cuts and near ubiquitous tax increases would, it’s widely considered,
spark another international recession. In the U.S. alone, the Budget Office
says the unemployment rate would rise to 9.1 percent as the economy declined
by 0.5 percent in 2013.
Others don’t paint as rosy a picture. A study from the National Association
of Manufacturers (NAM) says failing to avert the fiscal cliff would result in
the loss of six million jobs, thereby bringing the U.S. unemployment rate to
11 percent. In addition, the NAM report predicts GDP would fall by 12.8
percent while household income would shrink by 10 percent.
As bad as that sounds, the real tragedy would be that the things seemed
to be turning around, especially north of the border. In November, for instance,
the Conference Board of Canada proclaimed that the Canadian motor
vehicle manufacturing industry could expect to post its third consecutive
profitable year in 2012. In its Industrial Outlook-Autumn 2012 outlook for
Canadian automakers report, the CBOC said that, with a projected $1.35
billion in pre-tax profits for 2012, the industry would enjoy its best bottom-
line result since 2002.
Across the border, auto sales have experienced double-digit growth for the
last three years in a row, culminating in a 15 percent increase in Canadian
exports this year, the report says. And, since U.S. sales are still well below
pre-recession levels, there’s every expectation that auto sales will continue
ramp up in the coming years.
Beyond car sales, Statistics Canada reported in November that Canadian
manufacturing sales grew 0.4 percent overall, from August to September, due
largely to a rise in the aerospace sector. While modest, the expectation is that
the economy will improve by year’s end and into 2013 due to a rebound in
U.S. manufacturing sector. This brighter prediction, however, is contingent
on measures being taken to avert the harsh measures imposed should the
U.S. fall off the fiscal cliff.
If U.S. lawmakers should fail to reach a deal, there’s serious doubt as to
whether they would allow the harsh sequestration measures to take effect,
opting instead to again “kick the can” to some point in the future. Still, there
will be inevitable consequences. What’s regrettable is that Canada’s, and the
rest of the world’s, economies may be forced, like lemmings, to go over the
cliff with them.
Mike McLeod
Cliff Diving
6-7-DES.indd 6 12-11-23 4:31 PM

www.automationdirect.com
1-800-633-0405
Go online or call to get complete information,
request your free catalog, or place an order.
... THE WAIT IS OVER!
The new Do-more H2 series CPUs leverage the existing
line of DL205 I/O modules and base units to create an
incredibly powerful PLC - at an incredible bargain.
Two CPU options are available:
H2-DM1E $399 (1) USB port for programming,
(1) full-duplex serial port,
(1) Ethernet port
H2-DM1 $299 (1) USB port for programming,
(1) full-duplex serial port
• Over 1M bytes total memory (includes
program, data and documentation)
• Program/monitor/debug over any embedded
communication port.
• Supports up to 256 I/O locally and thousands more
with optional Ethernet remote I/O.
• Supports inexpensive serial port expansion for connection
to bar code readers, printers, etc.
And each Do-more CPU comes with a coupon for a
30-day free trial of online video training.
Program Do-more with the completely
new - and FREE - Do-more Designer
software. (DirectSOFT and ladder programs
developed with DirectSOFT are not compatible
with these CPUs. ) Download the FREE
software!
Get started fast!
Choose a Do-more starter kit to get going fast. You get:
• Prewired, 3-slot base** with your choice of Do-more CPU
• 8-point input simulator module
• 8-point relay output module
• Do-more Designer software CD-ROM
• USB programming cable
• User manual
• Coupon for 30 days FREE
online video training
** AutomationDirect reserves the right to
substitute a larger base at its discretion
H2-DM1E-START $626 with H2-DM1E CPU
H2-DM1-START $536 with H2-DM1 CPU
H2-DM1
H2-DM1E
Built-in simulator
Starter Kit
So visit www.do-moreplcs.com for the details, watch overview
videos, and download the free software to take it for a spin.
Or go straight to:
www.automationdirect.com/do-more-plcs to buy!
If you’ve been using DirectLOGIC
205 PLCs, but you’ve been wanting ...
• More program memory
• More and flexible data type memory
• Faster program execution
• Easier-to-use instruction set
• Integrated Ethernet on the CPU
• Faster I/O for counting and motion applications
• More and easier-to-use communications
Free standard shipping is available for orders totaling over $49 U.S. (except for orders which require LTL shipping, see Web site for details). Also, save on brokerage fees
when shipping standard ground to Canada - you can choose to allow AutomationDirect to nominate a broker for your shipment for parts shipping via standard ground.
This can save you big on brokerage fees. See Web site for details and restrictions -
Our shipping policies make it easier than ever to order direct from the U.S.!
www.automationdirect.com/canada
6-7-DES.indd 7 12-11-23 3:59 PM

8
Mitutoyo Appointments
Mitutoyo Canada announced
the appointment of Jay Summers
as executive vice president of
Canadian operations effective
November 1, 2012. In addition,
Peter Detmers has been named
as vice president of sales, over-
seeing all aspects of Canadian sales and sales
support operations. Mitutoyo provides measure-
ment and inspection solutions including CMM,
vision, form and finish measuring machines, as
well as precision tools & instruments, and
metrology data management software.
www.mitutoyo.ca
ATS reports $8 million profit for Q3
ATS Automation Tooling Systems Inc.
announced that it earned $8 million in its lat-
est quarter. Excluding discontinued operations,
the company earned $9.7 million up from $9.3
million. Revenue totalled $141.4 million, down
from $145.9 million. ATS employs approxi-
mately 2,400 people at 20 factories in Canada,
the United States, Europe and Asia.
General Dynamics secures LAV III
upgrade contract
General Dynamics Land Systems-Canada was
awarded a contract modification valued at
$133.5 million to upgrade an additional 66
LAV III vehicles. This award modifies a contract
previously announced in October 2011 to
upgrade 550 LAV III
vehicles, valued
at $1 billion.
Survivability
upgrades will
include the intro-
duction of double-V-
hull technology, as well as
add-on armor protection and energy-attenu-
ating seats.
The upgrades represent armored vehicle
technologies developed by General Dynamics
Land Systems-Canada’s engineers and its
Canada-wide supplier base. Significant work
will be performed at General Dynamics’
facilities in London, Ontario, and Edmonton,
Alberta, as well as the company’s nationwide
network of over 500 Canadian suppliers.
www.gdcanada.com
UP FRONT Toronto designer wins
concept Popemobile contest
Italian auto parts OEM Berman S.p.A and the organizers of the
2012 Autostyle Design Competition recently named Toronto native
Eric Leong and classmate Han Yong-fei of Sweden’s Umea Institute
of Design, as the winners of the annual automotive design competi-
tion. The pair won for their concept design of a new Popemobile to
potentially replace the Pontiff’s more traditional Mercedes with a
more modern and eco-friendly set of wheels.
The new design, based on a modified hybrid Volkswagen Cross
Coupé, incorporates high tech touches beyond the standard bullet-
proof glass, including spider silk infused with titanium and spray-on
lithium-ion battery technology as well as bullet-proof Kevlar-belted
wheels and a solar panel on the roof.
Leong, an industrial design graduate of Humber College, and
Yong-fei were chosen from 70 international contenders invited to
Mantua, Italy in October by competition sponsor Berman. The com-
petition’s judges panel included design directors from Alfa Romeo,
Audi, Bentley, Fiat, Ford, Ferrari and Toyota.
www.berman.it
MDA selected for DARPA Phoenix program
MacDonald, Dettwiler and Associates Ltd. announced that it has been
selected to participate in the U.S. Defense Advanced Research Projects
Agency (DARPA) Phoenix Program. MDA will provide a variety of
servicing technologies and capabilities to the program, under multiple
contracts to DARPA and the Naval Research Laboratory (NRL).
The goal of the DARPA Phoenix Program is to salvage viable
components from nonworking satellites and create new space systems.
The mission will use a robotic on-orbit servicer and components
launched alongside commercial satellites.
A core element of the program is two primary robotic manipulator
arms,whichMDAwillprovide,inconjunctionwiththeNavalResearch
Laboratory via DARPA. The company says this sole-sourced element of
the program could add up to no more than $27.2 million for MDA.
Beyond the robotic arms themselves, MDA has also been awarded
two separate contracts from DARPA to develop advanced robotic
DesignNews
S
S
C
tr
st
a
w
m
ro
a
3
Sa
m
in
e
v
w
C
V
C
D
O
c
p
e
a
tw
C
c
V
m
fu
Jay Summers
previously announced in October 2011 to
upgrade 550 LAV III
vehicles, valued
upgrades will
include the intro-
duction of double-V-
hull technology, as well as
8-11-DES.indd 8 12-11-23 12:26 PM

Stainless Steel Cylinders
Same-Day Shipping
Considered the standard for indus-
try quality, Clippard’s stainless
steel, rolled-construction cylinders
are available in many bore sizes
with strokes to 40". Clear anodized
machined aluminum heads, and
rods ensure long life and perform-
ance. 15 bore sizes from 5/32” to
3”.
Same-Day Shipping on hundreds of
models, and thousands of products
including stainless steel cylinders,
electronic and directional control
valves, fittings, FRLs and more!
www.clippard.com/distributors
Clippard Proportional
Valve Driver
Clippard’s EVPD Proportional Valve
Driver is ideal for laboratories and
OEM product development, and
can be customized to fit many ap-
plications, including control param-
eters. This EVPD is designed for use
as a plug-and-play interface be-
tween Clippard’s EVP Proportional
Control Valves and PLC’s or other
controls.
Visit www.clippard.com/evpd for
more information or to request a
full-line catalog.
Same-Day
Shipping!
Complete Line of Flow
Control Valves
Clippard offers five models of ad-
justable flow controls with #10-32
through 1/8” NPT ports.
Request a catalog at clippard.com.
Pneumatic
Two-Hand,
No-Tie-Down
(THNTD)
Circuit
Clippard’s VA-023
module is a self-contained modular circuit board
with all interconnections required to provide a
THNTD pneumatic circuit. The main function is to
require a machine operator to use both hands at the
same time to actuate equipment, helping to insure
that the operator’s hands are not in a position to be
injured.
Call Clippard today at 513-521-4261 or visit
www.clippard.com/thntd for more information.
8-11-DES.indd 9 12-11-23 12:26 PM

10
tools, cameras, tool caddies and advanced designs for a
hyper-dexterous robot.
An important element of the mission concept is the abil-
ity to launch components into space, frequently and cost
effectively, by piggybacking their launch onto a regular
commercial satellite launch. MDA is under contract from
DARPA to design and prototype the delivery system in which
the components are sent to orbit (called PODS).
Phase 1 of the program is under contract now and MDA’s
scope (not including the sole-sourced robotics arms) is
approximately $2.6 million, which is expected to grow when
Phase 2 gets underway next year.
www.mdacorporation.com
Kaspersky to develop secure Industrial OS
Kaspersky Lab Chairman and CEO, Eugene Kaspersky, has
confirmed that the company is currently developing a natively
secure industrial operating system to protect SCADA and
ICS systems from cyber attack.
The impetus behind the move, he says, is that industrial
systems are difficult to secure. Since they prioritize constant,
“always on” operation, Kaspersky says industrial systems
are rarely, if ever, updated, thereby leaving well-known
vulnerabilities in place for years. In addition, he says devel-
opers aren’t interested in source code analysis or patching
security holes until after exploits have been developed and
successfully infected target systems.
While short on details, Kaspersky says the company’s
secure OS will be inherently secure since it is being developed
to address one narrowly specific task and won’t allow any
third-party code or unauthorized applications to run.
www.kaspersky.ca
Canadian flying saucer declassified
It’s long been known by aerospace enthusiasts in Canada,
but recently declassified documents from the U.S. Air Force
confirm that it partnered with Canada’s Avro Aircraft to
build essentially a flying saucer in 1956. According to the
National Archives blog, the initiative—called Project 1794—
was intended to build a vertical take-off and landing (VTOL)
vehicle with a top speed between Mach 3 to Mach 4 and a
altitude ceiling above 100,000 ft.
According to the documents, the USAF contracted Avro
to build prototypes (which became the Avrocar) for approx-
imately $3 million. While the Avrocar did manage to fly,
the small craft quickly became unstable above a few feet
above the ground. Referred to as “hubcapping” by Avro’s
engineers, the craft experienced uncontrollable rolling dur-
ing flight tests above three feet and couldn’t go faster than
35 mph. Inevitably, the U.S. military officially abandoned
the project in 1961.
http://blogs.archives.gov
DesignNews
www.schunk.com
TENDO E compact, a toolholder from SCHUNK
The first hydraulic expansion
toolholder which transmits
torques of up to 2000 Nm
The first hydraulic expansion
Planet earth, home of all known life forms
The first planet rotating in
a 24-hour cycle
Superior Clamping
and Gripping
Where clamping technology and
gripping systems are concerned,
we are the superior provider.
SCHUNK is the No. 1 worldwide
supplier of high craftsmanship, all
from a family-owned company.
From the smallest parallel gripper,
to the largest chuck jaw program.
We would be glad to inform you.
8-11-DES.indd 10 12-11-23 12:26 PM

11
2012 Technology Fast
50 winners announced
Deloitte Canada announced the winners of its 15th annual
Technology Fast 50 program. Vancouver-based Avigilon
Corporation, a Vancouver-based company, which designs
and manufactures high-definition surveillance equipment,
topped the ranking with a revenue growth rate of 29,917
percent over the last five years.
Behind Avigilon Corporation, second and third spots
went to EcoSynthetix Inc. (25,327 percent), a Burlington-
based renewable chemicals company, and Real Matters (8,961
percent) a Markham-based property solutions manager.
Rounding out the top five are Hamilton-based VIZIYA Corp.
(3,816 percent) and Toronto-based NexJ Systems Inc. (3,153
percent).
www.deloitte.ca
P&WC Selects Dassault’s
3DEXPERIENCE Platform
Dassault Systèmes announced that Pratt & Whitney Canada
(P&WC), has selected started “Phase One” of implementing
Dassault’s 3DEXPERIENCE platform to run its enterprise
integrated product management process.
According to Dassault, P&WC benchmarked 3DEXPERI-
ENCE platform and its
associated ENOVIA
applicationsagainstvari-
ous other solutions and
competitors. The enter-
prise platform and its
opennesstoPratt&Whit-
neyCanada’sexistingSAP
andMicrosoftDynamics,
featured highly in the
final decision, as well as
Pratt&WhitneyCanada’s
working partnership with Dassault Systèmes.
In parallel with Phase One, P&WC has been working to
define a blueprint for the next phase of PLM in a true
enterprise-wide business transformation.
“We’re excited to be part of P&WC’s successful deploy-
ment of Phase One. But that’s just Phase One. We are com-
mitted to ensuring the success of ALL future phases in
P&WC’s strategic integrated product management process
evolution,” said Sylvain Laurent, Executive Vice President,
Business Transformation, Dassault Systèmes.
www.pwc.ca
www.3ds.com
DesignNews
8-11-DES.indd 11 12-11-23 12:26 PM

12
SolidWorks 2013 is officially out and there is some great new
functionality in this release. I still believe the CAD indus-
try has matured to a point that there isn’t much that can be
done on a development point of view. However, things are
picking up with the development of the SolidWorks product
with a more an enhancement-paradigm taking place.
Considering that we haven’t seen any real solid enhancements
or even development on the product since 2007, this is a welcome
change. The pushback from the “cloud” and the “V6” talk over
the last couple years seem to have re-focused the company on
its core product.
But, after five years of stagnating, it’s not hard to look good.
Still, Solidworks has finally picked up on some things the user
base has been asking for many, many years. Here is a list of my
favorite enhancements and some are huge time savers for all
of us here in the trenches:
Measure Tool
What might be most compelling about Solidworks 2013 aren’t
anyboldnewfeaturesbuthandyenhancementstothecommands
we use everyday. For example, the measure tool now includes
measure to midpoint of an edge or a line to another midpoint
or point. Virtual intersections can be measured to as well. You
could originally do this by creating a drawing or sketch and
creating points at virtual intersections but this obviously saves
multiple steps to get the
measurement.
Also, measuring arcs
and curves has histori-
cally been a bit of a pain
and SolidWorks in par-
ticular has been a bear
with “curvy” stuff. Now, arc measurement has been enhanced
to include new conditions such as edge-to-center and center-
to-center, as well as minimums and maximums.
Center of a face-to-face and edge-to-edge has been added
as well with the ability to choose arbitrary points on faces as
well in point-to-point mode. As I stated above, you could do
these things as workarounds but, in the end, these enhance-
ments are big time savers for the Q.A. types.
My favorite of the measure tool enhancements is the ability
to input settings such as having the default of circle-to-circle
measurements be maximum distance versus the old default of
center-to-center. Last, but not least, the tool now includes a
measurement history dialog with a list of the recent measure-
ments taken in the current session of SolidWorks.
Insert Multiple Components
In Solidworks 2013, you can now select multiple components
and insert them in succession without having to return to the
insert dialog command. This is one that should have been
implemented at day one of the software.
Tousethis,youCTRLselectcomponentsontheopendialog.
Then, there are two ways to insert components. The first inserts
all components at once, on the assembly’s origin which can then
be moved later. Note, the assembly origin has to be visible to do
thisandyouhavetodoubleclicktheorigintoactivatethisinsert
method. All parts are fixed at this point and you have to un-fix
via the right click menu to move them around.
I think this should be a user choice and, in my opinion,
all parts should be able to be set to float for those of us who
move things around. That said, it’s a great start to the enhance-
ment. The second option allows users to open multiple com-
ponents and click in the interface to drop all the selected
components one at a time.
Vary Patterns
ThenewVaryPatternenhancementcomesinhandywhenpatterns
are not really true patterns. We all have encountered this at one
CADReport
creating points at virtual intersections but this obviously saves
What’s New
in SolidWorks
2013
Latest version of the popular 3D modeller
abounds with time-saving enhancements
and handy features.
By Ben Eadie
o
Vis
to
F
Solidworks 2013 view orientation box provides a quick
way to change the view angle of a model.
The enhanced Measure tool
includes a history of recently
made measurements among
many other improvements.
12-15-DESv1.indd 12 12-11-23 2:19 PM

Others say they’re FAST...
Proto Labs’ entire operation is optimized to deliver quick-turn CNC
machined and injection molded parts in as fast as one business day.
We manufacture parts every day for thousands of customers, many of
whom come to us at the last minute with dozens of designs they need
to test ASAP. Since 1999, we’ve produced tens of thousands of molds,
and shipped tens of millions parts to our customers all over the world.
Sure, it’s our technology that allows us to make your parts faster
than anyone else. We back it up with large-scale global manufacturing
facilities with hundreds of CNC machines and injection molding presses
on three separate continents.
Whether your project calls for a few machined parts or thousands of
molded parts from 50 different designs—we have the scale to meet your
needs. Every time!
But do they have the
to deliver?SCALE
Check out
our virtual tour!
ISO 9001:2008 Certiﬁed • ITAR Registered
Proto Labs
2013 Calendar
Visit protolabs.com/parts
today and request your
FREE 2013 Proto Labs
Cool Parts calendar.
Enter code DE12F.
Call 877.479.3680
or visit www.protolabs.com
© 2012 Proto Labs, Inc
12-15-DESv1.indd 13 12-11-23 2:19 PM

Y
i
14
time or another—where holes may change shape or size in the
patternorspacingbetweeninstanceschanges.Youcannowvary
thespacingbetweeninstancesandhavethismeasurementincre-
mentaspecificvalueineachnewinstance.Forexample,youmay
have holes that space 1", then 2" then 3", etc.
You could do this before using a descriptive geometry sketch
and sketch pattern, but this saves a monstrous amount of time
in complex patterns. One last thing that really caught my eye
was the fact that you can change individual instances in the
pattern as well. If only one instance of a pattern is different
than the others, you can isolate that instance and change only
it, or in conjunction with incremental values.
Conics
The Conic tool now lets you sketch conic curves driven by
endpoints and Rho value. Depending on the Rho value, the
curve can be elliptical, parabolic or hyperbolic. This is great
since the only way to do this in the past was to use splines.
Even then, if you didn’t define the spline perfectly, you could
get inflection points. Inflection points are where there is a
wave or kink in the surface. This was a nightmare for anyone
doing any sleek curvy design.
Automatically Add Dimensions
You can automatically add dimensions to sketch entities if you
type a dimension value while sketching the entity in the graph-
icsarea.Inthepast,youcoulddothiswithauto-dimension,but
you had to always enter a dimension for each element. Now, if
you don’t choose to add a dimension value, it just skips adding
a dimension to that element and lets you carry on drawing.
Derived Components
When mirroring and deriving new components, you can finally
include properties such as sketches and model dims from a
seed component. This is a big time saver when you need to do
detail drawings of the mirrored components. Items that can
be brought into the derived component include: solid bodies;
surface bodies; axes; planes; cosmetic threads; absorbed
sketches; unabsorbed sketches; custom properties; coordinate
systems; model dimensions; hole wizard data.
View Selector
With Solidworks 2013’s new view orientation box, you can
re-orient the views of a model. I have tried macros that do this
over the years that work well but having the functionality baked
into the software with a clean visual interface is great. Everyone
could use a reverse orthogonal view of a part or assembly and
now you can get it very easily with a great UI
Release Interoperability
On first blush, being able to view and edit files from previous
releases and then use that model again in the previous release
without re-saving it in the new version format is a welcomed
addition. However, digging deeper shows it’s very limited; only
models from 2013 to 2012 R5 are possible currently.
It has been said that this functionality will only be imple-
mented between one major version of the software to the next.
So, in the end, it’s a good idea, but misses the point SolidWorks
customers have been asking for.
Center of Mass
You can now add a center of mass point in assemblies and
drawings. It remains associative during model changes in true
parametric form. Great to have but why has it taken so long for
SolidWorks to get to this? I see this as core functionality that
should have been there from the start.
SW on a Tablet?
Beyond the tweaks and new features in Solidworks 2013, the
companyrecentlyhinteditmayhaveplanstodevelopSWforthe
Windows tablet platform. But, as good as this sounds, how well
willSolidworksworkontablets?Willitbesluggishoraseriously
stripped down version that has limited functionality? We will
have to wait and see. DE
www.Solidworks.com
Ben Eadie is an Aeronautical Engineering Technologist, as
well as a prolific CAD blogger, developer, and trainer.
CADReport
Solidworks 2013 now allows for pattern size, shape and/or spacing to
be varied incrementally for each instance.
Solidworks 2013’s Conic tool helps overcome the challenge of sketching
precise curves by basing the geometry on endpoints and Rho value.
12-15-DESv1.indd 14 12-11-23 2:19 PM

Engineers Canada is the business name of the Canadian Council of Professional Engineers.
Great-West Life and key design are trademarks of The Great-West Life Assurance Company (Great-West), used under licence by its subsidiaries,
London Life Insurance Company (London Life) and The Canada Life Assurance Company (Canada Life). As described in this advertisement,
the group retirement and savings products are issued by London Life and the payout annuity products are issued by Canada Life.
Sponsored by:
You see the world differently–
including your retirement
See the difference lower investment
management fees could make to
your retirement savings. Join the
group plan sponsored by Engineers
Canada for professional engineers
and geoscientists.
Find out more – call
1-866-788-1293 ext. 5786 and
reference plan number 35408.
Scan this QR code to get the app
May not work on all mobile devices
My group advantage app
Let the numbers speak for themselves.
Visit www.engineerscanadafsp.grsaccess.com/app
12-15-DESv1.indd 15 12-11-23 2:19 PM

16 Hardwire
Across the
Finish Line
MotoCzysz engineers speed
design of performance
electric bikes with
3Dconnexion’s 3D mice.
16-17-DES.indd 16 12-11-23 2:22 PM

17
Amotorcyclist relies on focus, precision and determination
while racing to the finish line, just as an engineer does
while designing the elements of a high-performance sport bike.
Nick Schoeps, lead motorsports engineer of MotoCzysz,
and his team depend on 3Dconnexion 3D mice and SolidWorks
when designing the world’s fastest electric motorcycles.
This winning combination has helped the company
design the motorcycles that have won the Isle of
Man TT Zero race for three consecutive years
(2010 – 2012).
Schoeps was first introduced
to 3Dconnexion 3D mice at the
University of Michigan while
working with the solar car team.
This experience geared him up for
the start of his career at MotoCzysz,
where he was happy to find his colleagues using
SpaceNavigator 3D mice— essential tools for extensive
CAD work according to Schoeps, especially during the
busy seasons.
“It was great seeing 3D mice already implemented into
the design workflow here,” Schoeps says. “If they weren’t, I
would have bought one for myself to use—that’s how much
of a game changer they are.”
Faced with a steady influx of design projects and complex
design elements throughout the years, MotoCzysz needed an
intuitive solution that would help boost productivity. Often,
the company’s design engineers face tight deadlines, meaning
long hours and high expectations from management, which
can be both mentally and physically demanding.
Using the SpaceMouse Pro, Schoeps
says he saves about 20-30 percent
of design time— a critical advan-
tage in MotoCzysz’ fast-paced
working environment.
In addition to working more
efficiently within existing models,
the 3Dconnexion mice also help
Schoeps’ team shave time off the end-
to-end product development process.
For example, when MotoCzysz CEO
and founder, Michael Czysz, comes
up with a concept, he often draws it
by hand. The company’s designers
are then charged to move the concept
to realistic renders—which they can do more quickly than
before with the use of SpaceMouse Pros.
Though Schoeps admits that helping seasoned engineers
get comfortable using 3D mice can be a challenge, he says,
“Once you get into it, you’re hooked for good reasons.”
motoczysz.com
www.3dconnexion.com
Hardwire
NSD TupH. A breakthrough in
protection at the molecular level.
At last it’s here. A cost-effective alternative to stainless steel for the
harshest environments. NORD innovation busts the protection racket.
NSD TupH, NORD’s new sealed surface conversion,
is corrosion, chip and chemical resistant and highly
cleanable. Utilized on NORD’s robust aluminum
alloy housings, it establishes the required
protection of your most demanding applications
at a fraction of the cost you have been forced to
pay for stainless steel.
Welcome to NSD TupH, the better solution you have been asking for
is here. Now, you can start saving big money
on protection without compromise.
Contact us today and find out how you
can profit from NORD innovation.
I n n o v a t I o n b e y o n d t h e o r d I n a r y
1.800.668.4378 www.nord.com
NORDTupH.
Surface
protection
reinvented!
NORDTupH.
Surface
protection
reinvented!
harshest environments. NORD innovation busts the protection racket.
NSD TupH, NORD’s new sealed surface conversion,
is corrosion, chip and chemical resistant and highly
cleanable. Utilized on NORD’s robust aluminum
protection of your most demanding applications
at a fraction of the cost you have been forced to
Engineers at MotoCzysz
design the world’s fastest
electric bikes with the help of
3Dconnexion’s SpaceMouse Pro.
16-17-DES.indd 17 12-11-23 2:22 PM

18
Canadian space robotics expertise produces
rover fleet for future space exploration.
By Mike McLeod
In the international space exploration community, Canada is
known for doing one thing exceptionally well – space robot-
ics. While the Canadian space program, and the agency that
shapes it, has been historically small in comparison to the likes
of NASA or the European Space Agency (ESA), high profile
projects like Canadarm and Dextre helped cement Canada’s
commercial space companies as not only dependable partners
but masters in this niche but critical segment.
That’sagoodreputationtohave,saysJeanClaudePiedboeuf,
the Canadian Space Agency’s (CSA) director general of space
exploration, especially given NASA’s long-term goal of putting
an astronaut on Mars.
“From a scientific point of view, Mars is interesting for the
search for life and the next destination for human exploration,”
he says. “From a Canadian point of view, we are also targeting
the moon. When we established [the CSA] exploration plan in
2007, developing rovers was seen as the next step for Canada
to contribute.”
Toward that end, the federal government allocated $110
million over three years as part of the 2009 budget’s Economic
Action Plan. Of that, $60 million was dedicated to the Explora-
tion Mobility project, a CSA initiative to develop prototypes for
lunar exploration rovers and Mars science rovers.
Now, three years later, that investment has begun to pay off.
In October, the CSA rolled out a series prototype rovers devel-
oped by leading Canadian commercial space companies in line
with the requirements of anticipated U.S. or European led lunar
and Mars missions.
Before astronauts can set foot on Mars, engineers and scien-
tists will first have to return to the moon to learn how explorers
could live and work there for extended periods, says Brad Jones,
director of mobility and mission systems for Kanata-based
spaceflight engineering company Neptec.
Thereasonisthatlaunchingamannedmissiondirectlyfrom
Earth would be impractical given the travel distance. Factor in
thedifficultyofbreakingEarth’sgravitationalfieldwithenough
fuel,oxygenandprovisionsforaMarsexplorationcrewtomake
the round trip and the moon becomes a more advantageous
launchingpoint.Ofcourse,anextendedstayonthemoonwould
require exploiting resources locally. According to Jones, robotic
lunar rovers will play a key role.
“As part of the RESOLVE program, NASA has spent consid-
erable time developing technology that can manipulate and
process regolith—that loose layer of soil on the surface of the
moon—and pull from it whatever volatiles might be bound
into it, whether that be water ice or oxygen and hydrogen mol-
ecules bound to other minerals,” he says.
As one of the large prime contractors commissioned by the
CSAtodevelopterrestrialroverprototypes,NeptecanditsRover
Team—which includes Ontario Drive and Gear Ltd., COM
DEVCanada,McGillUniversity,NorthernCentreforAdvanced
Technology Inc. (NORCAT) and NGC Aerospace – have devel-
oped two lunar rovers: Juno and Artemis, Jr.
Neptec’s early prototype, Juno is the smaller of the pair but is
Canadian
Rovers
CoverStory
Top: Originally designed for the ExoMars mission, MacDonald
Dettwiler’s REX Mars rover features a unique drive system that allows
it to traverse steep slopes and uneven terrain. Above: Designed by
Neptec’s Rover Design Team, the Juno lunar rover prototype serves as
a test bed for its more sophisticated sibling, Artemis, Jr.
18-21-DES.indd 18 12-11-23 4:01 PM

18-21-DES.indd 19 12-11-23 3:51 PM

20
actuallycomposedofafamilyofsimilarroversthatshareacom-
mon U-shaped chassis with skid-steering, four-wheel drive and
awalkingbeamsuspension,similartothatonlargeutilitytrucks.
Roughly a meter square and weighing 300kg, Juno can carry
science payloads of 275kg at up to speeds of 13 km/h.
In addition, the rover can be operated remotely but has a
limited on-board processor and navigating capability, Jones
says, since Juno serves more as basic platform for testing sensors
and other components without the need to tie them into more
complicated robotic systems.
“In contrast, Artemis, Jr. has a sophisticated processor with
the software to go with it,” he says. “It’s remotely controllable,
but also has semi-autonomous capabilities. It can navigate from
waypoint to waypoint without human intervention by creating
terrain maps and avoiding obstacles as it goes.”
While lighter and considerably slower than Juno, Artemis
Jr. can operate for longer on its power supply and also integrates
a solar panel to power on-board science payloads. It’s two elec-
tric motors, one for each side, provide the rover’s four-wheel
drive and tank-like skid steering.
“We take the view that simpler is better,” Jones explains. “For
instance, it takes a bit more power to skid steer a vehicle than
articulated steering, but it also takes fewer motors and simpler
electronics. If you can meet all your mission objectives with a
less complex vehicle, we would argue that it will be around for
longer and better suited to a wider set of mission objectives.”
Like Neptec Design Group’s rovers, MacDonald Dettwiler
and Associates’ Lunar Exploration Light Rover (LELR) can act
autonomously or be tele-operated but is also designed to act as
an astronaut transport vehicle. As such, it’s the fastest (15km/h)
and heaviest (900kg) of the Exploration Mobility project rovers
andcancarryuptoa300kgpayload.AccordingtoRyanMcCou-
brey, a lead rover engineer at MDA, special consideration had
to be paid to make LELR human-centric.
“Toaccommodateahuman,weneededtohavealowfootwell
so astronauts could step into it easily,” he says. “Of course,
narrow beam sections are not good; you want
a deep box for strength. It was a big trade-off
betweenhowlowwecouldgetthatfloorboard
versus how strong the overall structure had
to be to handle the large payload masses and
all the terrain variations.”
LiketheCuriosityRoverpresentlyonMars,
additional rovers will be needed to investigate
the Red Planet, especially if Curiosity finds a
surpriseortwoduringitsmission.Towardthat
goal, MDA has developed two rovers, both
designed to perform geologic surveys.
OriginallyearmarkedfortheESAExoMars
mission, MDA’s Robot Explorer (REX) is
designed to simulate rock and soil sample
collection on Mars. To transport its scientific
payload, REX has a unique drive system that
allows it to clear obstacles up 15cm high.
Forexample,theleftandrightfrontwheels
are connected by a walking beam suspension, as are the rear
left and right wheels across the back of the vehicle, allowing all
of them to stay in contact with the ground under a variety of
conditions. In addition, REX incorporates 16 motors total; each
of its six wheels have individual drive and steering motors as
well as a “walking” motor.
“This allows the front left leg to walk forward followed by
the right front leg, then middle legs and finally the back legs
before the rover stands itself back up,” he explains. “This moves
the rover forward about 20cm but is done in a way that REX
doesn’t climb, but steps up a hill. That allows it go up much
steeper slopes and over much higher obstacles.”
Like REX, MDA’s Mars Exploration Science Rover (MESR)
has six wheels and similar suspension but doesn’t have REX’s
walking feature. Solar-powered, MESR is twice the weight of
REX but can carry 70kg of scientific equipment. Most impor-
tantly, though, MESR has been designed as a whole, with its
payload and locomotion sub-systems developed in tandem.
“This integration makes it easier on all fronts,” McCoubrey
says. “From a mechanical perspective, you can make sure your
roboticarmhasenoughreachbecauseyouknowwhereit’sgoing
to be mounted and from an electrical perspective you know
you’ll have enough power to deal with the payload.”
While NASA has field tested these Canadian built
vehicles, as yet, says the CSA’s Piedboeuf, the Exploration
Mobility project rovers are purely terrestrial prototypes,
rough sketch test platforms that may someday be chosen
for further refinement.
“If we want to go to the moon or Mars, we need to develop
the planning and operation capabilities, and then integrate all
that together and prove the systems work,” he says. “At the same
time, we need to identify potential missions and make sure our
technologies are ready. The important part, for now, is to learn
everything we can from these rovers.” DE
www.neptec.com
www.mdacorporation.com
CoverStory
|EK11-07USA|
A
Solar-powered, MDA’s Mars
Exploration Science Rover
features a stereo-imaging
system to help it navigate
extraterrestial terrain
autonomously.
18-21-DES.indd 20 12-11-23 3:18 PM

|EK11-07USA|
When is 12 mm a giant leap
for servo innovation?
It is when you shrink your machine's footprint using
12 mm EtherCAT Terminals for servo motors up to 4 A.
Motion
Automation
I/O
IPC
www.beckhoff.ca/EL7201
The EL7201 servo terminal for the Beckhoff EtherCAT Terminal system integrates
a complete servo drive for motors up to 200 W into a standard terminal housing:
Direct connection of servomotor, resolver and holding brake to a 12 mm wide EtherCAT Terminal
Ideal for applications with dozens of small servo axes
Considerable reduction in space requirements as well as wiring and commissioning costs
Integrated fast control technology designed for highly dynamic positioning tasks
The servo terminal supports synchronous motors with a rated current of up to 4 A.
When used in combination with the AM3100 servo motor, the EL7201 servo terminal represents
an inexpensive servo axis in the base performance range.
Cost effectively integrate servo technology instead of stepper motors and pneumatics
18-21-DES.indd 21 12-11-23 3:18 PM

22
Traditionally system designers looking to
create multi axis XY or XZ systems pur-
chase ball or lead screw actuators and bracketry
combining the two actuators into a single system. T-Bot and
H-Bot systems are available as ready-made, complete system
alternatives that can save space and increase productivity.
T-Bot and H-Bot structures are examples of application
specific designs that place more emphasis on model-based
design and system integration. Used extensively in pick-and-
place, sorting, gluing and inspection applications, these
structures (named for the shape of their construction) are
built around the belt drive components and employ two motors
mounted to two pulleys driving one belt.
This is in contrast to standard XY configurations,
which are constructed with two individual linear
actuators where one actuator carries the other. In
this standard configuration, the first actuator moves
all the mass of the second actuator. In T-Bot and
H-Bot configurations, the motors are stationery and,
therefore, less mass is moved. Also, the space require-
ments are reduced as one axis can be minimized.
The resulting increase in performance, along
with ease of manufacturing and the ability to fit
into a smaller space envelope, make these structures
attractive to machine builders; however, it’s impor-
tant to note that motion control programming can
be a challenge. When programming the machine,
both position and timing must be addressed if
accurate linear motion is required.
T-Bot and H-Bots work in a similar fashion to an Etch-A-
Sketch. When the motors rotate at the same rate in the same
direction, you have a linear motion along the X-axis. Moving
the motors in opposing directions produces movement along
the Y-axis. If one motor remains stationery and one motor is
moving the motion will run 45 degrees across the XY plain.
X-Y orthogonal actuator configurations utilize standard
Cartesian co-ordinates, which allows for each motor’s position
to be easily mapped to the linear distance along the actuator
or the axis of motion. T-Bot and H-Bots also move in the
same physical Cartesian plain; however, the motor position
coordinates are transformed as shown in the diagrams below.
The motion profile of the T-Bot (Figure 1) illustrates the
desired motion that we would like to achieve in real
space. This profile has been chosen to represent a
simple pick-and-place routine. The distance is rep-
resentative of a linear move by a single motor, seen
in pulses or steps.
When the two motors on a T-Bot move together,
independently or alternate, a different motion is
achieved. The equations that produce the required
motionoftheT-botareseenbelow—XandYrepresent-
ing the points on the desired T-Bot motion profile:
Motor 1 = -X +Y
Motor 2 = -X – Y
The moves that each individual motor must make to
achieve the desired motion can be seen in Figure 2.
Alpha-Bot Soup
T-Bot and H-Bot configurations can save
space and increase performance.
By Alexa Loiskandl, Myostat Motion Control
MotionControl
Figure 1: The motion profile of a T-Bot performing a simple pick-and-place
routine. The distance is representative of a linear move by a single motor.
Figure 2: To produce a linear motion, acceleration/deceleration rates and speeds of
the T-Bot motors must match to minimize deviation at the start or end of the move.
Alpha-Bot Soup
22-25-DES.indd 22 12-11-23 2:23 PM

22-25-DES.indd 23 12-11-23 2:23 PM

24
Here, the graph represents the distance each motor moves
individually to achieve the rectangular move. This is based
on equations that relate back to the way the single belt of the
T-Bot functions.
Accurate synchronization of the two motors is required to
produce a linear move, with acceleration/deceleration rates and
speedsmatchingtominimizeanydeviationfromthelinearmove
at the start and end of the move. Graph3 represents the motion
profile of the two motors working together.
The resulting motion profile is rotated 135 by degrees
and offset from the actual motion that the T-Bot accom-
plishes. Due to the way that the single belt of the actuator
functions, this movement of the motors produces the simple
pick-and-place routine commonly used in manufacturing
industries.
With the wide variety of motion controllers available on
the market, providing specific guidance on the implementa-
tion for these systems is difficult. However, with an under-
standing of the basic coordinate and speed transformations,
engineers should be able to implement one of these configu-
rations and take advantage of the unique mechanical advan-
tages offered by T-Bot and H-Bot systems. DE
www.myostat.ca
Alexa Loiskandl is a sales engineer with Myostat Motion
Control and a recent graduate of Carleton University with a
B.Eng Biomedical and Electrical Engineering.
MotionControl
Graph 3: The motion profile of a T-Bot’s motors working in tandem
to produce a common routine in manufacturing industries.
22-25-DES.indd 24 12-11-23 2:23 PM

www.rittal.ca
FDA approved blue gasket prevents ingress
Sloped surface to shed water
Designed for easy cleaning
Stainless Steel...
When Cleanliness and Sanitation are Paramount
Hygienic Design Enclosure
22-25-DES.indd 25 12-11-23 2:23 PM

November/December|2012 www.design-engineering.com
26
Design Engineering
tabletop show draws
enthusiastic engineering crowd.
While scheduling a trade show to coincide
with the largest Atlantic hurricane on
record might seem like a recipe for disaster,
Hurricane Sandy did little to dampen the
spirits of Southern Ontario’s engineering
community. Engineers, product developers,
machine builders and systems integrators
turned out in force for the inaugural Design
Engineering Expo (DEX) on October 30th at
the Mississauga Convention Centre.
“When the hurricane hit only hours before
the doors opened I contemplated a run to Walmart to buy all
the life jackets I could get my hands on,” said Design Engineer-
ing Magazine Publisher and Show Manager, Alan Macpher-
son. “But I knew our audience would show
up and they did in large numbers despite the
gloom and doom predictions broadcast on
every news channel.”
During the one-day tabletop trade show,
DEX’s 70+ exhibitors showcased the latest
in design technologies, ranging from power-
ful 3D design software to the cutting edge
in additive manufacturing, reverse engineer-
ing, motion control and ﬂuid power products.
Ontario-based Siemens PLM vendor,
Designfusion, for example demonstrated the
latest version of Solid Edge ST5 with its
unique blend of push-pull direct modeling
and traditional parametrics. Similarly,
Autodesk Canada showcased its 2013 product line-up includ-
ing its recently released cloud-enabled analysis solution,
Simulation 360. The online, on-demand suite allows engineers
ShopTalk
Baumer Inc. · 4046 Mainway Drive · Burlington · Ontario · L7M 4B9
Phone 905-335-8444 · sales.ca@baumer.com · www.baumer.ca
Rugged, Accurate, Programmable
Unparalleled Flexibility
„ IP67 design withstands temperatures -40 to +100C
„ Industry leading precision and shock handling
„ Field programmable resolution and output voltage
HS35 Motor Feedback Encoder
Call. 800-526-9328
Click. www.motionindustries.com
Visit. Over 50 Locations
Motion Canada’s operations are
strategically located to serve you.
With 3 major distribution centers,
9 repair centers and over 50 local
branches, we are committed to
keeping your industry in motion.
Appeal
26-27-DES.indd 26 12-11-23 3:44 PM

www.design-engineering.com November/December|2012
27
to quickly run multiple FEA, CFD and plastic moulding
simulations remotely, thereby freeing local resources for more
pressing design work.
For fans of additive manufacturing, Oshawa-based Stra-
tasys vendor Cimetrix provided many their first opportunity
to check out the Mojo 3D printer. Stratasys’ recently released
desktop unit offers the company’s study FDM technology in
a sub-$10,000 package that bundles everything needed to
start producing prototypes out of the box.
In addition, Quebec-based Creaform demonstrated its
latest 3D scanner, the Go!SCAN 3D. The entry-level handheld
offers the same portability as its other scanners while its “white
light” LED technology simplifies setup and operation.
With compelling technologies like these and more, Show
Manager Macpherson said the Design Engineering Expo was
a resounding success. According to post-show surveys, more
than 80 percent of attendees and exhibitors said they would
return next year, to be held October 30 at the Mississauga
Convention Centre. Design Engineering would also like to
thank DEX 2012 sponsors: Autodesk, SEW-Eurodrive,
Designfusion and SKF Canada. DE
www.DEX2012.com
ShopTalk
7PLNT15928.indd 1 3/20/07 12:32:48 PM
DesignEngineering
PublisherandDEX
ShowManager,Alan
Macpherson,(left)
presentsSkytech
Industries’Sales
Engineer,KennethLaw
withtheDEXearlybird
registrationprize,a
show-branded
Xbox360.
26-27-DES.indd 27 12-11-23 3:44 PM

28
By Seth Hulst and Loren Kamstra
For design engineers in the process of selecting
components for an application, the motor or
gearmotor can be one of the more difficult compo-
nents to source. There are several key design param-
eters that should be considered when selecting a
motor or gearmotor for a motion control application.
As the motor or gearmotor selection process
begins, the designer must gather the relevant techni-
cal and commercial requirements. This first step is
often overlooked, but it is a critical component in
the design process. The gathered design inputs infor-
mation will then be used in the selection process
and will dictate the ideal motor for the application.
Failure to gather the proper inputs can lead the
designer down an unintended path. For this reason,
it is helpful to use the Application Checklist (Table
2) when developing the motor specification. These
parameters, along with some project specific
requirements, will be helpful when navigating the
selection process.
Next, the designer must consider what type
of motor technology best suits the intended
application. Using the design inputs, the
Motors Quick Reference Guide (Table 1) can
be used as a selection matrix in the first step
of the decision process. This reference guide
details four common motor types and provides
general information to consider when select-
ing each motor. Because each application has
its own unique characteristics, it is important
to determine which of the parameters (e.g.
horsepower, efficiency, life, starting torque or
noise ratings) are most important to the appli-
cation in consideration.
During the motor selection process, by
looking at the required speed and torque of
the application, it should become evident to
the designer if the motor chosen requires a
gearbox to meet the necessary requirements.
If a gearmotor is necessary for the application,
another level of complexity will be added and
several additional criteria need to be evaluated.
Conceptually, motors and gearboxes can be
mixed and matched as needed to best fit the
application, but in the end, the complete
Selecting a Gearmotor
Designing the most efficient motor and gearbox pairing takes time but can be simplified
by using the right selection process.
PowerTransmission
Table 1: Gearmotor Selection Process – complete the following steps to ensure a
gearmotor properly matches the application.
Table 2: Application Checklist – use this checklist to help formulate the specific
requirements to ensure the gearmotor vendor has the critical information
necessary to achieve the best match between the gearmotor and the
application.
28-29-DES.indd 28 12-11-23 2:25 PM

29
gearmotor is the driving factor. There are a number of
motors and gearbox types that can be combined; for
example, the right angle worm, planetary and parallel shaft
gearboxes can be combined with permanent magnet DC,
AC induction or brushless DC motors.
Though there are a vast number of different motors and
gearboxes combinations available, not just any one will work
for the application. There will be certain combinations that
will be more efficient and cost-effective than others. Knowing
the application and having accurate ratings for the motor and
gearbox is the foundation for successfully integrating the
gearmotor into the system.
As the designer looks at selecting a gearmotor, there are
two methods that can be used.
• Method 1: Select motor and gearbox separately
and assemble
• Method 2: Select a pre-engineered gearmotor
While both methods 1 and 2 are effective means of
finding the most compatible gearmotor, Method 2 reduces
design time and project risk for the designer. When select-
ing a pre-engineered solution, the manufacturer has done
much of the heavy lifting to ensure that the motor and
gearbox combination will work properly together. Since
performance calculations and testing have been per-
formed by the manufacturer, gearmotor failures caused
by miscalculations or improper component matching
will be minimized. Due to the complexity of Method 1
this article focuses on Method 2.
Once again, looking back to the gearmotor perfor-
mance data gathered from the Application Checklist
(Table2), the speed and torque required for the applica-
tion is critical in selecting the gearmotor combination.
Using the speed and torque measurements the designer
can then select the manufacturer’s performance curves
that match the application needs. The gearmotor curve
(Figure 1) combines the performance of the motor and
gearbox by displaying speed, torque and efficiency. If a
complete gearmotor assembly is purchased from a
manufacturer this curve is provided by the vendor.
Finally, after selecting a few performance curves
(Figure 1) that appear to meet the application needs,
it is important to review the design limitations. Look
for the following information in the manufacturer’s
performance calculations and use it to determine if
the chosen gearmotor will cause any issues within
the application: Thermal characteristics; full-load
gearbox torque; gearbox input speed; gearbox yield
strength; and intermittent duty considerations.
Once the gearmotor has been chosen and installed
in the application it is critical to perform several test
runs in sample environments that best reflect typical
operating scenarios. If extreme motor heat, unnatural
noises or obvious motor stress occurs, repeat the motor
selection process or contact the manufacturer. It’s
important to take the time and put in the effort to
properly select a motor because a hasty decision and lack of
testing can cause a host of problems with the gearmotor and
could possibly damage the application.
Though the gearmotor selection process can be arduous,
a properly selected gearmotor can last for years and will opti-
mize the application to its peak potential and efficiency. From
a company perspective, an optimal gearmotor will also reduce
operating costs and increase plant productivity. DE
Groschopp Engineering Manager, Seth Hulst and Design
Engineer, Loren Kamstra have more than 25 years of com-
bined experience in motor, gearmotor and motion system
design for OEM applications.
PowerTransmission
Table 3: Motors Quick Reference Guide - provides a comparison of common
parameters used during the motor selection process.
Figure 1: Gearmotor Performance Curves – the Speed/Torque and
Efficiency/Torque curves for a permanent magnet gearmotor.
28-29-DES.indd 29 12-11-23 2:25 PM

30
30
Electrical
Modular Connector
HARTING announced its
Han-Power T, a modular
power bus that supplies
power and control to mul-
tiple devices from a single
cable line. Instead of two
different connectors for
power and control, a single
Han-Power T connector has an internal contact arrangement
custom-tailored for both types of wiring. Power and control lines
traverse the “top” part of the T as feed-throughs, while drops
to individual drive motors exit the connector via the “down leg”
of the T. The system is rated for up to 600VAC power service,
and up to 250V signal service. Power and signal inserts are
available in different configurations for different wire sizes and
current-carrying capacity.
www.harting.ca
Modular Power Supply
SolaHD introduced its next generation of SHP Series heavy-duty
power supplies, that can be configured for up to 24 output
voltage combinations ranging from 2VDC to 60VDC. In addition,
the supplies feature a
maximum of 4,920W of
increased power capa-
bility per case and mod-
ules that can switch
between I2C or CAN-
BUS/RS485 communica-
tions. Other features
include single phase and three phase inputs; voltage adjustment
on all outputs and programmable voltage, current limit, inhibit/
enable through I2C. In addition, it also has overload protection
on all outputs; power factor correction (.99 typ.) and an end
mounted fan.
www.solahd.com
Motors
AutomationDirect has
expanded its line of SureStep
motion control products.
Stepping motors in standard
NEMA sizes (17, 23, 34)
now include dual-shaft, bi-
polar models with output
torques ranging from 61
oz-in. to 1288 oz-in. The
IdeaGenerator
30-35-DES.indd 30 12-11-23 2:26 PM

31
NEW IMPROVED PREMIUM
INSTANT ADHESIVES ARE
TURNING UP
THE HEAT!
With temperature resistance up
to 250°F, you can keep the strength
and fixture time you need in higher
heat applications.
All marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates
in the U.S. and elsewhere. © Henkel Corporation, 2012. All rights reserved. 9223 (7/12)
www.instantsolutions.loctite.com
1.800.lOcTITE (562.8483)
31
motors feature front and rear shafts to allow installation of an encoder, hand crank
or a second load onto a motor; a pigtail cable with locking connector allows for
easy hook-up. The motors travel 1.8 degrees per step, providing 200 steps per
revolution. Backed with a one-year warranty, the stepping motors are CE and RoHS.
The SureStep motors can be controlled by SureStep microstepping drives, pro-
grammed with SureStep Pro software.
Servo Controller
Maxon’s introduced its ESCON 36/3 EC, a 4-quad-
rant PWM servo controller designed for control
of BLDC motors (brushless DC motors, so-called
EC motors) with Hall sensors up to approximately
100 Watts. The controller has a speed range of 0
to 150,000 rpm and can be run in various operat-
ing modes (speed controller, closed loop), speed
controller (open loop, current controller). The unit
is controlled by means of an analog set value that can be specified by means of
analog voltage, an external or internal potentiometer, a defined value or by means
of a PWM signal with variable duty cycle. In addition, the controller requires no
additional external filters or motor chokes for operation.
www.electromate.com
Automation
Distributed Modular I/O
Balluff introduced its next generation of Distrib-
uted Modular I/O, which features IP67 protection
and industry standard connectors. Utilizing the
vendor neutral standard IO-Link, the master block
can communicate with up to 4 slave devices and
then send their combined data back to the control-
ler over the CC-Link network. In lieu of a back-
plane, each slave device is connected to the
CC-Link IO-Link master by an M12 port, creating an IP67 connection. With the
ability to be installed within a 20-meter radius from the master device, slave devices
can be easily distributed across the machine without the use of the controls cabinets
typically used in CC-Link network architectures.
www.balluff.com
Micro Stages
Steinmeyer, Inc. announced its MT 196LM
series, a line of high precision micro stages,
available in two travel options: 100 mm or 200
mm. The MT196LM has a footprint of 110 mm
x 196 mm, height of 45 mm and, depending
on which stage chosen, weighs 4.1 or 4.7 kgs.
Manufactured from high strength anodized
aluminum, the table series offers a positional
accuracy of 2 µm; straightness/flatness runout of +/- 5 µm for 100 mm of travel;
and +/- 10 µm for 200 mm of travel with repeatability of +/- 0.2 µm. Features include
preloaded cross roller bearings, fixed stops, incremental linear encoder with 0.1 µm
resolution and a linear piezo motor drive.
www.steinmeyer.com
IdeaGenerator
30-35-DES.indd 31 12-11-23 2:26 PM

32
32
AS-I Master Module
WAGO Corporation introduced
its 750-655 AS-Interface Master
Module, which links AS-Interface
(AS-I) devices to higher-level sys-
tems. The 12mm wide, DIN-rail
mount module utilizes AS-I Spec
3.0 (Rev 2) software and common
fieldbus protocols to connect AS-I
sub-network devices. Part of the WAGO-I/O-SYSTEM, the
750-655 connects with up to 62 AS-I V3.0 slaves for monitor-
ing and controlling up to 248 input and 186 output data
channels. The Master Module supports Profibus, Ethernet,
CANopen, Lon and DeviceNet protocols. It also enables field-
bus migration to suit changing application requirements. The
750-655 module supports both programmable and non-
programmable buscouplers.
www.wago.us
Vision System
Teledyne DALSA announced its GEVA-
300, a compact, low-cost vision system
for multi-camera applications. The fan-
less system offers six Gigabit Ethernet
(GigE) ports and houses a 1.8 GHz Intel
dual-core ATOM processor with 2 GB
RAM and a 40 GM SSD drive. Internally,
the system runs Windows 7 Embedded
64-bit O/S with a write filter to protect
the drive image when power is lost. The
vision system can also be expanded with
an optional PL-USB companion module
that offers I/O expansion and integration
of up to four Teledyne DALSA Genie
cameras. In addition to GigE ports, it
includes dedicated display and USB ports
for setup and run-time control, and a
serial port for factory communication.
Camera triggering, strobe outputs and
opto-isolated I/O are interfaced using
the companion PL-USB module.
www.teledynedalsa.com
Sensors
Programmable Linear
Position Sensors
Novotechnik U.S. introduced its LS1 Series,
a line non-contact linear position sensors
based on the company’s non-contacting
IdeaGenerator
30-35-DES.indd 32 12-11-23 2:26 PM

33
33
inductive technology. The sensors are insensitive to magnetic fields and have no
mechanical sensor track. Programming the its end points is achieved using a signal
processor integrated into the sensor and two LED programming status indicators. The
LS1 Series includes a 25 to 100 mm measurement range for the return spring version
and 25 to 200 mm for the rod-only version. Resolution is to 0.05 percent and repeat-
ability to less than 0.05 percent. Four output options are available: 0.1 to 10 V, 4 to
20 mA, 10 to 0.1 V and 20 to 4 mA. Sensor life is 100 million movements.
www.novotechnik.com/ls1
Non-Contact Temperature Sensor
Omega has released its OS212 series of compact
non-contact temperature sensors. The series
features a fast response with high stability,
2-wire 4 to 20 mA output proportional to target
temperature, optional manual emissivity adjuster
with display and stainless steel housing, sealed
to IP65. This product is intended for research,
industrial applications, HVAC, oil, automotive
and beverage industry. Applications include
non-contact temperature monitoring associated with liquids, motors, plumbing,
food, refrigerated rooms, manufacturing, chemical plans and oil refineries.
www.omega.ca
Encoders
AutomationDirect has added Koyo inch-size
light and medium-duty encoders to its line of
positioning and motion control products. The
TRDA-2E series light-duty and TRDA-20 series
medium-duty encoders have a 0.25-inch diam-
eter 0.375-inch diameter stainless steel solid
shaft, respectively, and offer resolutions from
100 to 2,500 pulses per revolution and provides
up to 200 kHz response frequency. The TRDA-
25 series medium-duty encoders have a 0.375-inch diameter stainless steel solid
shaft and offer resolutions from 100 to 2,500 pulses per revolution. Fitted with a
military-style connector, these encoders also have a removable 2.5-inch round
flange. All TRDA encoders feature a reinforced aluminum die cast casing; have an
operating temperature range of -10 to +70 degrees C; and have no mounting
restrictions.
Color Sensor
Balluff introduced its BFS 33M true color
sensor, which uses fiber optic cable based
optics allowing the placement of the detec-
tion optics in very tight spaces. The sensor
also provides seven channels and three
digital outputs for set-point detection and
can use the serial interface to configure the
unit and output color data to perform color
evaluations. The BFS has a sensing range up
to 400mm; a switching frequency of 1.5 kHz and can distinguish between differ-
ent color shades. As a True Color sensor, it precisely detects every color in the
technical color space.
www.balluff.com
IdeaGenerator
HAVE A NEED
FOR SPEED?
NEW IMPROVED PREMIUM
INSTANT ADHESIVES REPlAcE
SlOW fIxTURINg ADHESIVES
Get the heat resistance without
the wait by switching to Loctite®
Premium instant Adhesives.
Reach 250ºF resistance 15-second
fixture time on many substrates.
1.800.lOcTITE (562.8483)
30-35-DES.indd 33 12-11-23 2:26 PM

34
To advertise your solution in this section call Alan Macpherson at 416.510.6756
34
Pressure Transducers
Automation Products Group
announced that its PT-400 Heavy Duty
Pressure Transducers have received
ATEX and IECEx certification, rated EX
II 1G Ex ia IIB T4 Ga, for use in hazard-
ous locations. PT-400 pressure trans-
mitters provide a minimum of 10
million operating cycles with high
accuracy up to ±0.1% F.S. (B.F.S.L.),
in operating temperatures from -40
to 180°F. They cover pressures ranging
from 0 up to 20,000 psi, along with
high burst pressure to 3x full scale
(limited by the process connection)
and overpressure to 2x full scale for
in-process reliability. The PT-400 is designed for demanding
applications in oil drilling, water and wastewater industries as
well as for general use in other industries. The ATEX and IECEx
certification applies only to 4-20ma units.
www.apgsensors.com
Fluid Power
Proportional Valve
Sauer-Danfoss announced
its PVG 16 proportional
valve, designed for the
low-flow segment. The
valve facilitates the inte-
gration of load-sensing
system design and elec-
tro-hydraulic actuator
technology. The PVG 16
is rated for a flow of up
to 65 l/min (17.2 gpm) and work port pressure of up to 400 bar
(5,800 psi). A new actuator – the PVE Series 6 – provides the
valve with its electrohydraulic platform. Incorporating a micro-
controller for closed loop control, the actuator delivers spool
control and built-in fault monitoring. The Sauer-Danfoss PVG
valve family also includes the PVG 32, PVG 100 and PVG 120 –
providing flow up to 240 l/min [63.4 gal/min].
www.sauer-danfoss.com
IdeaGenerator
DesignSolutions
OMEGA Introduces State Data Logger OM-CP-STATE101A
Omega’s new state data logger is an advanced, low cost, battery powered data logger that records
input transitions or contact closures from external sources such as transducers or state initiators. This
CE compliant product offers a 10 year battery life, 4 Hz reading rate, a multiple start/stop function,
ultra-high speed download capability, 406,323 reading storage capacity, optional memory wrap,
battery life indicator, optional protection and more. Ideal for HVAC, chemical and environmental.
Contact: info@omega.ca
Visit us at: www.omega.ca
Ideas To Improve Production Efficiency! Look to Seal Master Inflatable Seals.
Sealing is just one of many tasks for custom-built, fabric-reinforced elastomeric inflatable seals. Simple,
versatile and with close tolerance capability, they’re ideal for use as actuators, brakes, valves, clutches,
wipers and for other innovative applications. Backed by in-depth technical/customer service, they’ll replace
cumbersome, hard-to-maintain proccessing and handling components to lessen downtime. Ask about
our RSVP Design Assistance program
Contact: info@sealmaster.com
Visit us at: www.sealmaster.com
Clippard Offers Miniature Pneumatic Products Catalog for
Scientific/Medical Applications
A leader in miniature pneumatics, Clippard provides the scientific/medical industry a variety of
products and solutions. The product range is illustrated in a color brochure featuring the most
complete line of miniature fluid power products for the medical, pharmaceutical analytical and
dental fields. To get your copy today please visit our website at the address printed below.
Contact: sales@clippard.com
Visit us at: www.clippard.com/scientific-a
30-35-DES.indd 34 12-11-23 2:26 PM

35
35
Pneumatic Rod Locks
Advanced Machine Engineering Co., (AME)
announced its Amlok RLI, the company’s fourth-
generation power-off rod lock. The rod lock’s
standard features include anodized aluminum
construction, a heavy-duty clamp system and
power-off clamping. The standard seal material
is carboxylated nitrile. The unit uses dry-filtered
air and has a release pressure ranging from a
minimum of 4 bar/60 psi to a maximum of 8
bar/120 psi. The operating temperature ranges
from 10°F to 180°F. Maximum rod tolerance is +0.000 in./-0.002 in. The Amlok
RLI is available in various sizes for rod diameters of 16mm, 20mm, 25mm, 32mm
and 40mm and cylinder and bore diameters from 40mm to 160mm. Holding forces
range from 200 lbs/890N to 2,450 lbs/11kN.
www.ame.com
Power Transmission
Linear Rail System
Haydon Kerk Motion Solutions introduced
its BGS08, the latest addition to the com-
pany’s BGS linear rail product line. Maxi-
mum roll, pitch and yaw moments are 22.5
lb-ft (30.5 Nm), 19.4 lb-ft (26.3 Nm), and
22.3 lb-ft (30.2 Nm) respectively. Maximum
horizontal load is 225 lbf (1,000N). Lead
screw resolution available for the BGS08
ranges from 0.098-in (2.50mm) to 1.00-in (25.40mm) per revolution. When
combined with a 200 step/rev stepper motor, linear positioning resolution ranges
from 0.00049-in (0.0125mm) to 0.005-in (0.127mm) per input pulse. Stroke length
is 1-in (25mm) to 30-in (760mm). At the heart of the BGS08 is a Haydon size 23
(56.4mm) linear actuator driving a Kerk 303 stainless steel precision lead screw.
Depending on the load requirements, the BGS08 linear rail is available with the
size 23 single stack or double stack stepper motor.
www.HaydonKerk.com
Clamp Style Coupling
Zero-Max announced an improved clamp
style hub design for its series of ServoClass
couplings. According to the company, the
new clamp style hubs provide superior
shaft engagement and increased clamping
strength. Available in 12 sizes in single
and double disc models, ServoClass cou-
plings handle torque ratings ranging from
0.5 to 250 Nm. Manufactured of RoHS
compliant materials, ServoClass couplings
with improved clamp style hubs are designed with 304 stainless steel disc members.
To ensure precise alignment of the assembled components, ISO 4762 CL 12.9
corrosion resistant socket head cap screws are utilized with a carefully controlled
assembly process.
www.zero-max.com
IdeaGenerator
INSTANT ADHESIVES ARE
NEW AND
IMPROVED!
PREMIUM INSTANT ADHESIVES
ExcEED OUTPERfORM
INDUSTRy STANDARDS
improved temperature resistance to 250ºF
without sacrificing speed or strength!
FIXTURE SPEED
SECONDS MINUTES HOURS
100%
Upgraded LOCTITE®
Premium Adhesives
Fixture Time:
15 SECONDS
SIMILAR TEMPERATURE
PRODUCTS
Acrylic:
1-minute ﬁxture
Epoxy:
5-minute ﬁxture
NOTE: Represents typical results in Laboratory testing across a variety
of substrates. For complete testing data, review the Technical Data Sheet
available on instantsolutions.loctite.com
Strength(%)
Time
FULL CURE
24 HOURS
HEAT AGING AT 250ºF
0 200 400 600 800 1000
110
100
90
80
70
60
50
40
30
20
10
0
Upgraded
LOCTITE®
Premium
Adhesives
Industry
Standard
Formulation
NOTE: Represents typical results in Laboratory testing across a variety
of substrates. For complete testing data, review the Technical Data Sheet
available on instantsolutions.loctite.com
Strength(%)
Aging Time (hrs.)
Innovat
1.800.lOcTITE (562.8483)
InnovatIon
30-35-DES.indd 35 12-11-23 2:26 PM

36
By Treena Hein
On Sunday October 14th, 2012 millions of eyes around
the world were glued to screens, watching to see whether
or not Felix Baumgartner would successfully complete the
highest freefall ever attempted—from 39,000 m back to Earth.
Keep in mind that fighter aircraft fly up to a maximum of
20,000 m and airline jets to 12,000 m.
But no one’s eyes were more intensely watching the feat
than the team at Massachusetts-based David Clark Com-
pany—the people who had designed Baumgartner’s suit—
including Canadian engineer Shane Jacobs.
Jacobs and his colleagues have made Baumgartner the first
human to reach supersonic speed outside of a jet or space
vehicle. He fell at a speed of Mach 1.24, pushing the freefall
record from a previous height of 31,333 m set in 1960 by Air
Force test pilot Joe Kittinger (who was, by the way,
also sporting a David Clark Company suit).
“We were all ecstatic that the mission
went so well,” says Jacobs. “Before
and during the event, I was
thinking about all of the
testing, training and
engineering that had
gone into this
moment.” Two success-
ful freefalls earlier this
year (21,640 m in March
and 29,566 m in July) gave
Jacobs a solid amount of con-
fidence.
“I was comforted by the fact that
inathermal-vacuumchambertest,Felix,
the suit and the capsule had been through
the entire thermal and pressure profile of this
jump – and of course, a ton of other tests,” he
says. “The only unknown was what would
happenashepassedthroughMach1,butour
analysis showed that the air would be very
thinwhenhebrokethesoundbarrierand
thathewouldthenslowdowngradually
as the atmosphere thickened.”
Those at David Clark also drew
confidence from the famous Bill Weaver incident in 1996.
“He survived the breakup of an SR-71 jet at Mach 3 while
wearing a state-of-the-art David Clark pressure suit of the
time,” Jacobs explains, “and we’ve made significant improve-
ments since then.”
Jacobs’ journey to the David Clark Company followed his
youth in Calgary, a mechanical engineering degree at McGill
in Montreal and a stint back on his stomping grounds devel-
oping running shoe technology at the University of Calgary’s
Human Performance Lab.
While at McGill, Jacobs was bitten by the space tech design
bug (several of his professors did aerospace-related research)
and he soon was enrolled at the University of Maryland to
get a PhD in aerospace engineering, focused on space suit
design. Upon graduation, he was snapped up by David Clark.
“My career dream is to see astronauts walking on the moon
or Mars wearing the suit that I helped design,” he
says. “Funding is an issue for this right now,
but we continue to work with NASA
on related projects, and hope-
fully we’ll get the chance
to fully work on a lunar
or Martian suit
again.”
When one con-
siders all the differ-
ent conditions
Baumgartner trav-
elled through—extreme
temperatures, near-vac-
uum—and all the potential
contingencies that could have
occurred—the critical importance of
integrated design and teamwork become
crystal clear.
“Spacesuit development is such a
systems-level discipline,” Jacobs says.
There was some fogging of Felix’s hel-
met on ascent, involving an issue with
a power supply for the visor’s integrated
heating circuit, which showed how
integrating all of the systems is one of
the most difficult challenges. How-
ever, Jacobs says the issue also dem-
onstrated the team’s ability to
overcome obstacles and work
together; switching over from cap-
sule power to chest-pack power
Falling Free
Canadian engineer lends spacesuit expertise to historic freefall.
CanadianInnovator
RSM2800
Canadian design engineer, Shane
Jacobs, in a prototype “demonstrator
suit” and precursor to Felix
Baumgartner’s Mach 1 freefall suit.
36-40-DES.indd 36 12-11-23 4:30 PM

Novotechnik U.S., Inc. • 155 Northboro Road • Southborough, MA 01772 • Tel: 508-485-2244 Fax: 508-485-2430
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 patented
non-contact multi-turn for absolute
5,760° (16 turns) measurement.
This new wear-free technology
combines advanced capabilities
with mechanical simplicity in a
very compact and sturdy housing to
provide for longer life and lower cost
than optical encoders.
Contact us for samples or for complete specs,
visit www.novotechnik.com/rsm
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
Housing OD=30 mm
IP rating options:
IP54 or IP67
No gears, no optics,
no batteries
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I

RSM2800 Ad-DE 12/2/11 10:07 AM Page 1
36-40-DES.indd 37 12-11-23 2:33 PM

38
solved the problem.
Integration and working together is also critical within
Jacobs’ specific area. As softgoods design manager, he leads
development of suit parts that employ advanced textiles—
working on increasing the pressurized mobility at joints while
maximizing comfort and minimizing mass, with other engi-
neers, designers, technicians, modelers and many others. For
this suit, they leveraged a proven design from David Clark
suits used in the U-2 rocket program.
“It automatically maintains pressure, ensuring that the
absolute pressure inside the suit never goes below 3.5 psi” says
Jacobs. “It was a unique challenge to design a pressure suit
for skydiving, in that the suit had to enable Felix to maintain
the delta position while falling and also provide him the
pressurized mobility to perform a lot of tasks not typically
performed in a pressure suit.”
JacobsissatisfiedwiththeoutcomeofBaumgartner’sfreefall
on several fronts. “We’ve expanded the performance envelope
foraerospacecrewprotectiveequipmentandproventhetechnol-
ogy for high-altitude free falls of this height and velocity,” he
says. “We’ve also gathered valuable data both for future NASA
missionsaswellasthenascentcommercialspaceflightindustry.
We’ll continue to build on this accomplishment.” DE
www.davidclark.com
CanadianInnovator
DMR_E
Advertiser Website Page
Automation Direct www.automationdirect.com 7
Baldor Electric Company www.baldor.com 40
Baumer Electric Inc. www.baumer.ca 26
Beckhoff Automation www.beckhoff.ca 21
Bosch Rexroth Canada www.boschrexroth.ca 19
Clippard Instrument www.clippard.com 9
Daemar Inc. www.daemar.com 39
Drive Products Inc. www.driveproducts.com 24
Encoder Products Co. www.encoder.com 38
Epson Canada Ltc. www.epson.ca/printers 3
Great West Life www.engineerscanada.ca 15
Henkel Canada Corp. www.henkelna.com 31, 33, 35
Motion Canada www.motionindustries.com 26
Myostat Motion Control Inc. www.myostat.ca 11
Nord Gear Ltd. www.nord.com 16, 17
Novotechnik US Inc. www.novotechnik.com 37
Proto Labs Inc. www.protolabs.com 13
Rittal Systems Ltd. www.rittal.ca 25
Rosta Inc. www.rostainc.com 27
RotoPrecision Inc. www.rotoprecision.ca 30
Schaefﬂer Canada Inc. www.ina.com 4
Schneider Electric Canada www.schneider-electric.com 2
SCHUNK Intec Corp. www.ca.schunk.com 10
Swagelok Company www.swagelok.com 23
Tsubaki of Canada Ltd. www.tsubaki.ca 32
Advertisers Index
Designed by Jacobs and his collegues at
David Clark Company, the freefall suit
maintains pressure but increases mobility.
36-40-DES.indd 38 12-11-23 2:34 PM

DMR_EssentialComponents_September-2011-outline_01.indd 1 8/15/2011 12:43:40 PM36-40-DES.indd 39 12-11-23 2:34 PM

• Superior Reliability
• Unmatched Quality
• Local Sales and Support
• Quickest Delivery Available
When it comes to industrial electric motors, power
transmission products and drives, no other manufacturer
offers more than Baldor...that is why Baldor is The Industrial
Choice! Whether your application requires a fractional
or 15,000 Hp motor, a variable frequency drive, mounted
bearings or gearing, a pulley or sheave or even a standby
generator, Baldor is the choice most preferred by industry.
When your next project demands the most reliable and
energy efficient products available, look to Baldor as your
one source for more industrial solutions.
baldor.com 479-646-4711
©2011 Baldor Electric Company
The Industrial Choice
36-40-DES.indd 40 12-11-23 2:34 PM

Dng de-12012012

Recommended

Recommended

More Related Content

Viewers also liked

Viewers also liked (16)

Similar to Dng de-12012012

Similar to Dng de-12012012 (20)

Recently uploaded

Recently uploaded (20)

Dng de-12012012