Machine Design 2012-03-08

March 8, 2012
A Penton Media Publication

Tune in to EngineeringTV.com
RECYCLING THERMOFORMED
PACKAGES, page 20
LOOKING GOOD WITH
STRUCTURAL THERMOSETS,
page 42
SETTING STANDARDS FOR
BEING GREEN, page 48
MORE FOR LESS WITH
OSCILLOSCOPES, page 58
Supplying
reliable
quality
components for
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The engineers choice
RS# 101
Industrial Pressure Gages
Very High Accuracy Digital

Pressure Gage
DPG409
Starts at
NEW RANGES!
$695
Sealed Gage
Optional Wireless
Compound Gage
Transmitter Available
Vacuum and
Barometric Ranges
5-Point NIST Traceable Calibration Included
High 0.08% Accuracy on Most Ranges
Selectable 4 to 20 mA, 0 to 5V or 0 to 10V Analog Output
Large Backlit Display with 25 mm (1") Digits
11 Selectable Pressure Units
Visit omega.com/dpg409
Damlanpalus / Dreamstime.com
General Purpose Digital Pressure

Gage
DPG8000 Series
$360
Industrial Digital Pressure Gages

DC-, Loop-, or Battery-Powered
Models
DPG9000 Series
Starts at
$425
DPG 2001B Series

Starts at
$349
Visit omega.com/dpg2001b
omega.com
Because of transmission frequency regulations, these wireless products may

only be used in the United States and Canada (915 mHz models) or Europe
(868 mHz models).
Digital Pressure Gages
No.
RS# 102
COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
VOLUME 84
ISSUE 3
MARCH 8, 2012
MATERIALS
The
advantages
of
STRUCTURAL
THERMOSETS
FEATURES
Structural thermosets are an attractive alternative

to metals and thermoplastics, thanks to excellent
physical properties and surface appearance.
From car-body panels and helicopter parts to electrical

enclosures and sporting goods, manufacturers increasingly rely on structural thermoset sheet-molding compound (SMC) and bulk-molding compound (BMC) to
address demands for strong, light, and durable materials.
Due to intrinsic limitations with metals and thermoplastics, many engineers are turning to structural thermoset compounds to bolster strength and corrosion resistance.
The strong molecular bonds inherent in thermosets impart
a tight web of inner connectivity that lets these materials
maintain excellent structural properties despite prolonged
exposure to chemical and temperature extremes. The materials also increase design flexibility for engineers and production efficiency for manufacturers. Heres a closer look.
Authored by:
Larry Landis
Director of Technology and Quality
IDI Composites International
Noblesville, Ind.
advantages of structural
42 The
thermosets
Structural thermosets are an attractive
alternative to metals and thermoplastics,
thanks to high strength, light weight,
corrosion resistance, and excellent surface
appearance.
Edited by Kenneth J. Korane

ken.korane@penton.com
Key points:
Structural thermoset compounds have

higher tensile and flexural strength per
unit weight than do most metals.
Cross-linked molecules keep structural
thermosets dimensionally stable at high
temperatures.
Unlike common metals, structural
thermosets wont rust or corrode
outdoors or in harsh environments.
Components often last for decades with
little maintenance.
Structural thermoset basics

Structural thermosets are distinguished from standard
thermosets by their use of more specialized resins and
higher levels of reinforcement glass, carbon, and aramid
fibers, for example. The added reinforcement increases
strength and stiffness, while resins protect the fibers and
improve the compounds overall physical properties.
Moreover, manufacturers can tailor these properties
by varying ingredients. For example, changing fiber type,
length, and mix proportion alters its flow, strength, and
Resources:
IDI Composites International, www.
idicomposites.com
42
MACHINE DESIGN.com
Structural
thermoset
SMC and BMC
materials offer
a number of
advantages
over metals and
thermoplastics,
including higher
strength per unit
weight, better
dimensional
stability and
corrosion
resistance and,
often, lower cost.
MARCH 8, 2012
rigidity; varying resin concentration and type affects overall strength, along with the compounds heat or corrosion
resistance.
Heating the material as it is molded forms three-dimensional covalent bonds between polymer molecules. This
process, known as cross-linking, is irreversible. Therefore,
cross-linked materials cannot be melted and reshaped.
The term thermoset accurately describes this chemistry.
Cross-linking creates a rigid 3D molecular structure that
lets thermosets maintain the desired physical and electrical properties during prolonged exposure to adverse conditions such as excessive heat. This distinguishes thermosets from thermoplastics, which are generally unsuitable
for high-temperature environments because they can be
remelted after solidification. Thermosets tolerate heat-distortion temperatures (HDT) and glass-transition temperatures (Tg) that would literally melt most thermoplastics.
Three of the most common thermoset resins are polyester, vinyl ester, and epoxy. Each has its own price and
performance characteristics, so base selection on an applications functional and cost requirements. For example,
engineers might choose vinyl-ester resin for corrosionresistant products, epoxy for high-strength applications,
and polyester when good overall performance and cost are
the driving factors.
As for reinforcement, many types of fibers can be used

depending on the molding process and strength requirements. Glass-reinforcement options include choppedstrand, mat with random-fiber orientation, light textile
fabrics, heavy woven materials, knitted materials, and
unidirectional fabrics. Carbon-fiber reinforcement is used
for applications that require exceptional strength coupled
with severe weight restrictions.
Structural thermoset SMC

Most structural thermosets are in the form of sheetmolding compound. SMC is a cost-effective, lower-weight
alternative to many metals. Standard SMC contains 10 to
30% reinforcement, while structural grades are typically in
the 40 to 65% range. Reinforcement is normally choppedstrand glass fibers 0.5 to 2.0-in. (12.7 to 50.8-mm) long.
Structural-thermoset SMC is manufactured in a continuous process that combines a viscous paste and glass
fiber on specialized equipment with a continuous web.
Paste containing the resin and additives is poured onto
a carrier film, then cut glass fibers are added, along with
a second layer of film. The paste and glass between top
and bottom carrier films creates a thin sandwich that
is run through a series of serpentine rollers. The serpentine action and resulting pressure causes the paste to coat
MARCH 8, 2012
42
880: Sustainability for

48 ULE
Manufacturing Organizations
Just because a company states they operate
in a sustainable fashion doesnt make it so.
New procedures from UL E help confirm their
claims.
49
MACHINE DESIGNs
LITERATURE EXPRESS
your fathers
58 Not
oscilloscope
Oscilloscope readings on a Web page? Even
low-end oscilloscopes can provide output in
a variety of formats that make measurements
more useful.
62 Synchronous technology can move between

Whats hot in CAD
history-based and direct modeling. The next

step in realistic CAD stereoscopic design?
...And more.
ELECTRICAL & ELECTRONIC
Not
your fathers
Even less-expensive oscilloscopes

provide data in a variety of formats
once available only from top-ofthe-line instruments.
OSCILLOSCOPE
Like most technologies,

oscilloscopes have evolved
over time. Digital-storage
oscilloscopes, or DSOs,
are now the preferred type
for most industrial applications. And features that
once were available only on
expensive, premium DSOs
are now becoming commonplace on even nonWindows scopes that
start in the $2,000 range.
Upgradable bandwidth,
deep memory, large displays, and fast update rates
are just a few examples. In
the past, only higher-end
oscilloscopes have offered
Oscilloscope display via iPad: Today VNC clients can be used to control
features such as Ethernet
Windows-based oscilloscopes via mobile platforms such as the iPad.
and USB connections.
Less-expensive offerings
have gone beyond floppyenable this connection, you connect a USB cable between
drive storage and GPIB programming.
a USB Host port on a PC and the USB Device port on the
New connectivity options have started to trickle down
oscilloscope.
to less-expensive oscilloscopes. In almost all cases, USB
A USB Device connection typically involves some sort
has replaced floppy drives as the de facto connection
of driver library. Scopes from Agilent Technologies Inc.,
on oscilloscopes. Now to save a screen or data file, usSanta Clara, Calif., for example, use an IO Library, which
ers simply insert a USB thumb drive into a connection
includes a connection expert program to assist with setting
typically referred to as a USB Host. Some oscilloscopes
up the link to the scope. With the connection established,
today can support USB thumb drives up to 128 Gbytes
remote commands can control the oscilloscope.
of storage. In addition to USB Host connections, many
oscilloscopes now have USB Device connections. Instead
Ethernet connectivity
of being used to connect thumb drives, these connections permit remote control of oscilloscopes via USB. To
While USB connectivity has been relatively common
58
MACHINE DESIGN.com
MARCH 8, 2012
58
Access our Reader Service
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in the pages of MACHINE DESIGN.
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MARCH 8, 2012
MACHINE DESIGN.com
43
Parts you use every day,

at everyday great prices
Weve got the pneumatic parts you need, and they
ship the same day* New are quick-disconnect hose
couplings, which allow easy changing of tools or
hose connections. Brass fittings work with water,
oil and many compressed gases. Aluminum
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And everyone needs a blow gun in their tool kit!
See everything at:
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Also Available
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Palm type with safety tip, pistol grips, pocket style, and
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Fittings and
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Go online or call to get complete information,
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Pneumatic
Solenoid Valves
and Manifolds
1-800-633-0405
Air Preparation
RS# 103
ON THE COVER
DEPARTMENTS
A geometry being created in a

PolyPlane.com video tutorial.
8 EDITORIAL
Old codgers always gripe about the kids
10 EDITORIAL STAFF
12 LETTERS
16 SCANNING FOR IDEAS
Rack-and-pinion lubricator ensures smooth operation and a long life
Enclosure protects electronics and controls from harsh environments
20
28
33
34
REPORTERS NOTEBOOK
LOOKING BACK
SENSOR SENSE
COMMENTARY
Problems with pre-engineering education?
36 BERKE ON SAFETY
GFCIs What they are and are not
38 VANTAGE POINT
Dont wait for government to address skills gaps Mark C. Tomlinson
40 INVENTORS CORNER
Spiral-chambered turbine engine packs a one-two punch
68 FE UPDATE
The role of parametric CFD analysis in design
71 PRODUCT SPOTLIGHT
Cylinders & valves
74
76
77
78
78
79
4
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BUSINESS INDEX
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BUSINESS STAFF
BACKTALK
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The Truth About Compressed Air!

If you think compressed air is too expensive and noisy - read this. The facts will surprise you!
Compare these Blowoffs
Facts about Blowers
There are a variety of ways to blow the water from the bottles shown in the photo below, but
which method is best? To decide, we ran a comparison test on the same application using
four dierent blowo methods: drilled pipe, at air nozzles, Super Air Knife (each using
compressed air as a power source), and a blower supplied air knife (using an electric motor
as a power source). Each system consisted of two twelve inch long air knives. The following
comparison proves that the EXAIR Super Air Knife is the best choice for your blowo,
cooling or drying application.
Energy conscious plants might think a

blower to be a better choice due to its slightly
lower electrical consumption compared
to a compressor. In reality, a blower is an
expensive capital expenditure that requires
frequent downtime and costly maintenance
of lters, belts and bearings. Here are some
important facts:
The goal for each of the blowo choices was to use the least amount of air possible to get the
job done (lowest energy and noise level). The compressed air pressure required was 60 PSIG
which provided adequate velocity to blow the water o. The blower used had a ten horsepower
motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page
summarizes the overall performance. Since your actual part may have an odd conguration,
holes or sharp edges, we took sound level measurements in free air (no impinging surface).
Drilled Pipe
Blower Air Knife
This common blowo is very inexpensive

and easy to make. For this test, we
used (2) drilled pipes, each with (25)
1/16" diameter holes on 1/2" centers.
As shown in the test results below, the
drilled pipe performed poorly. The initial
cost of the drilled pipe is overshadowed
by its high energy use. The holes are
easily blocked and the noise level is
excessive - both of which violate OSHA
requirements. Velocity across the entire
length was very inconsistent with spikes
of air and numerous dead spots.
The blower proved to be an expensive,

noisy option. As noted below, the
purchase price is high. Operating
cost was considerably lower than the
drilled pipe and at air nozzle, but
was comparable to EXAIRs Super
Air Knife. The large blower with its
two 3" (8cm) diameter hoses requires
signicant mounting space compared
to the others. Noise level was high
at 90 dBA. There was no option for
cycling it on and o to conserve energy
like the other blowos. Costly bearing
and lter maintenance along with
downtime were also negative factors.
Flat Air Nozzles
EXAIR Super Air Knife
As shown below, this inexpensive air

nozzle was the worst performer. It is
available in plastic, aluminum and
stainless steel from several manufacturers.
The at air nozzle provides some
entrainment, but suers from many
of the same problems as the drilled
pipe. Operating cost and noise level are
both high. Some manufacturers oer
at air nozzles where the holes can be
blocked - an OSHA violation. Velocity
was inconsistent with spikes of air.
The Super Air Knife did an exceptional

job of removing the moisture on one
pass due to the uniformity of the laminar
airow. The sound level was extremely
low. For this application, energy use was
slightly higher than the blower but can be
less than the blower if cycling on and o
is possible. Safe operation is not an issue
since the Super Air Knife can not be deadended. Maintenance costs are low since
there are no moving parts to wear out.
Filters must be replaced every one

to three months.
Belts must be replaced every three to
six months.
Typical bearing replacement is at least once
a year at a cost near $1000.
Blower bearings wear out quickly due
to the high speeds (17-20,000 RPM)
required to generate eective airows.
Poorly designed seals that allow dirt and
moisture inltration and environments
above 125F decrease the one year
bearing life.
Many bearings can not be replaced in the
eld, resulting in downtime to send the
assembly back to the manufacturer.
Blowers take up a lot of space and often
produce sound levels that exceed OSHA
noise level exposure requirements. Air
volume and velocity are often dicult to
control since mechanical adjustments are
required.
To discuss an application, contact:
EXAIR Corporation
11510 Goldcoast Drive
Cincinnati, Ohio 45249-1621
(800) 903-9247
Fax: (513) 671-3363
email: techelp@exair.com
www.exair.com/45/423a.htm
The Super Air Knife is the low cost way to blowoff, dry, clean and cool.
RS# 104
Blowo Comparison
Comp. Air
Type of blowo
SLPM
Horsepower
Required
Sound
Annual Approx. Annual
Purchase
Level
Electrical
Maintenance
Price
dBA
Cost*
Cost
First
Year
Cost
PSIG
BAR
SCFM
Drilled Pipes
60
4.1
174
4,924
35
91
$50
$4,508
$920
$5,478
Flat Air Nozzles
60
4.1
257
7,273
51
102
$208
$6,569
$1,450
$8,227
Blower Air Knife
0.2
N/A
N/A
10
90
$5,500
$1,288
$1,500
$8,288
Super Air Knife
60
4.1
55
1,557
11
69
$518
$1,417
$300
$2,235
*Based on national average electricity cost of 8.3 cents per kWh. Annual cost reects 40 hours per week, 52 weeks per year.
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EDITORS WEB PICKS
Structural thermoset
microsite
IDI Composites Internationals

new microsite focuses on
structural-thermoset compounds.
The materials resist corrosion
and are durable, strong, and
exceptionally light, making them
viable alternatives to metals and
thermoplastics. The site details
various resins, reinforcement
fibers, and specific SMC and BMC
products, and gives an overview
of markets and applications. See
www.idicomposites.com/products/
structural-thermoset-compounds.
Valve resource
Peter Paul Electronics has launched
a new Web site (http://peterpaul.com)
that details the companys valves and
valve operators for fluid power, medical, food, transportation, and other
markets. Resources include flow and
conversion calculators, downloadable
catalogs, and application assistance.
An online valve configurator will be
introduced later this year.
87,000 components
The new Stock Drive Products/
Sterling Instrument Inch Catalog
includes thousands of mechanicaldrive components, including timing
belts, pulleys, clamps, bearings, gears,
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couplings, and vibration mounts.

The 1,520-page catalog includes an
87-page technical reference section.
Request or download a copy at www.
sdp-si.com/D810/D810cat.htm.
Ball-screw blog
Steinmeyer has added a new blog
to its Web site, www.steinmeyer.com.
Content includes product design,
engineering calculations, and
commercial issues. Industry experts
are available to offer advice on
machine-tool, factory-automation,
mechatronic, semiconductorequipment, and aerospace
applications, and users are free to
post comments. Visit the blog at
www.ballscrew-tech.com.
Motor-match tool
Groschopps new Web site (www.
groschopp.com) lets users precisely
size fractional-horsepower motors
and gearmotors. Motor Match
is based on the companys STP
Calculator, where users enter two
of three performance parameters
(speed, torque, and power) along
with motor type, gearbox type (if
desired), and voltage. The software
evaluates and matches desired
performance to the motor size
and specs from more than 4,200
products in the sites database.
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NEW VIDEO SERIES

ON PID FOR PLCs ON
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PID for process applications
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Our newest video series on
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Part 2 covers How Does a PID
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Part 3 shows an example of a PID
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Starting with Part 4, the videos
delve into the details of how to
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in the Productivity3000 ladder
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logic. There are a total of 11
videos in this series. Many
are accompanied by handy
downloadable training PDFs.
Visit http://learn.
automationdirect.com and
navigate to the PLCs section
for the PID Series (under
Productivity3000 PID Loop
Programming tab). Dozens
of additional videos are also
available on topics ranging from
data-acquisition software to
drives and motors.
Unscramble the letters in the

shaded boxes and enter the
secret code at
www.bestforcad.com/code
for a chance to win a
Dell Precision Workstation,
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You can also nd
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14
SOLVE
your
CAD puzzle
18
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48
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RS# 106
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EDITORIAL
Old codgers always
gripe about the kids
One of the many woes of todays society, we are told, is that our schools
are producing graduates totally unprepared to be a part of the workforce. Ammunition for that viewpoint comes from a recent study by the
Social Science Research Council of 2,300 undergraduates, which discovered that 36% of them demonstrated no significant gains in critical
thinking or written communication during their four years in college.
Another survey found business leaders moaning that their new hires
lacked, among other things, reading comprehension, a good work ethic,
and writing skills.
This hand-wringing has led to talk of a skills gap and what to do
about it. But what seems to be absent in these discussions is a recognition of the fact that complaints about kids entering the workforce have
been with us for as long as there have been older generations hiring
younger generations. On that score, it is interesting to go back in time
and see what managers thought of the young people they hired in the
1970s. Those youngsters, of course, are now the ones doing the hiring
and complaining about the quality of people filling out employment
forms.
Managers of the time did not paint a pretty picture of the criticalthinking skills demonstrated by kids entering the 1970s workforce.
Increasingly we hear from leaders in business, professions, and government that it is easy to find people who can do what they are told, but difficult to find people who know what to do without being told, lamented
York University professor David Bakan in 1969. Nor were the communication abilities of that generation anything special. Researchers from
Ohio University and Eastern Michigan University, writing in the Journal
of Business Communication in the mid-1970s, found that many new
graduates had grandiose views of their own abilities to write reports and
convey concepts verbally that werent shared by their supervisors.
I have concluded that some of the bellyaching about work skills is
just an older generation forgetting how many facets of performance
can come only from experience. If I am still around in 30 years, I fully
expect to read about managers, who today are supposedly ill-prepared
to hold down their first jobs, grumbling over the abject unreadiness of
the kids.
Finally, we should remember that academic excellence is only one
piece of the puzzle when it comes to career preparation. On that score,
consider the career of someone who might be the poster child for poor
high-school preparation, Don Mann. In his autobiography, he relates
how a teacher once inquired about the location of his textbooks. Mann
had to admit he had dumped them in his locker the first day of school
and had since forgotten where the locker was.
This inauspicious start didnt seem to slow Mann down, though. He
eventually entered the Navy, earned two BS degrees and an MS degree,
and retired as a SEAL/Chief Warrant Officer with a rsum that included time on the elite SEAL Team Six.
Not bad for somebody who graduated near the very bottom of his
high-school class.
Leland Teschler, Editor
RS# 107
MARCH 8, 2012
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Stephen J. Mraz,
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CAD/CAM
Leslie Gordon,
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RS# 109
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RS# 110
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LETTERS
Engineering school: A
hard-knock life
You are dead-on regarding the life,
and realities, of an engineering
student ( Tough Engineering
Courses Now Make Headlines,
Dec. 8). For me, graduating and
moving onto a real job was a
welcome relief. No longer did I
have to study for 16 hours a day,
and often past midnight. Persistence and patience earned me a
degree, not my limited 2.9GPA
or retak ing three classes be cause I initially got Ds in them.
After graduation, working 10 to
12hours a day and going home
with nothing to do was a wonderful break in life. And I could
eat normal food. (You forgot to
mention that engineering students are dirt poor because they
dont have time to work. As a result, the diet during college was
less than healthy.)
Jim Stoor
Great editorial. I couldnt help but
smirk when I read She switched
her major to psychology and
policy management from electrical and computer engineering
after a particularly tough assignment that kept her and her partner in the lab well past midnight
for several days. Several days?
Getting a bachelors degree in
mechanical engineering from
the University of Illinois kept me
in the lab or engineering library
well past midnight almost every single night. Sure, thoughts
of self-defenestration from the
third-floor library window came
to mind several times a semester
out of sheer frustration. But who
doesnt love failing 80% of their
exams after spending hundreds
of hours preparing for them?
At t h e e n d o f t h e d ay, Im
glad I stuck with it. I somehow
managed to graduate with a
2.999GPA, find a satisfying job,
and have been enjoying going
home at the end of the work day
12
MACHINE DESIGN.com
instead of the library for the past

seven years.
Steven D. Springer
I could not agree more with your
editorial. I found engineering
college difficult and completed
my degrees only through sheer
stubbornness. During my
first year I took two accounting courses during which the
head of the accounting department asked if I would consider
switching majors. I was doing
well and his impression was I
had a gift for it but I politely declined. I wanted to be an engineer. I couldnt imagine really
doing anything else.
I, too, put in many late nights,
and getting my BS degree was
arguably the hardest accomplishment in my life, but it has
made me happy, successful, and
I continue to learn. Its unfortunate that students would change
majors to improve their grades
rather than pursue their passion.
Perhaps they werent quite so
sure why they started in engineering in the first place.
MARCH 8, 2012
That passion began for me at

an early age. I think it stems from
the freedom given me by my parents to take things apart to see
how they worked (without overconcern for the consequences)
and my desire to invent, refine,
and make things through trial
and error. This included everything from my bicycle to kitchen
appliances to model rockets,
even my parents cars. My parents
were not technically minded, so
they gave me the support where
they could, mostly by giving me
the freedom to try.
My fourth-grade daughter is
currently a victim of the modern
school system in which so much
emphasis is put on the metrics of
mastering tests reading, writing, math. It leaves no time for
science. In contrast, I recall having a biology textbook in fourth
grade. So I dont see the support
from our school system needed
to grow that interest and passion
for science. Therefore, I do what
I can to interest my children in
science.
Adrian van der Kroef
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LETTERS
Advice to those listening
I couldnt agree more regarding
your advice for our job seekers
and occupy wall streeters (Advice for Occupy Wall Streeters,
Nov. 17.) Whoever thought they
would be well suited for employment with a liberal arts or history
degree, even 20 years ago, was
dreaming all the way through
college!
I have to admit I havent kept
up with the news on this, and
more specifically, on their complaints. But I have heard people
chastise them for wanting handouts and freebies. I can more than
sympathize with the movement
in strict regard to the prevalent,
in-situ greed on Wall Street and
rampant corruption in our government. I wish we could send
most of the guilty parties to jail,
but theres not enough room as
we have to make way for some of
the politicians and federal workers who egregiously helped create the quagmire we now find
ourselves in.
My son has just started high
school and you can bet Im going
to give him the same advice as
you advocate, not just for his own
future, but for the future health
and prosperity of the good old
USA as well. I appreciate the candor and succinct advice your editorial so eloquently provides.
Scott J. Sanders
I read your editorial this morning
and smiled. I graduated 10 years
ago from Western Michigan University with a Liberal Arts degree
in music and Spanish linguistics.
My first job out of school was
cutting steel and drilling holes
in a machine shop owned by my
friends dad.
Thanks to that experience,
I now work for an engineering

firm in Tennessee. I also own a
machine shop that supplies prototypes to our company. Its a
whirlwind, but its allowed me to
provide for a growing family and
let my wife stay home with our
children since the birth of our
first child. (She graduated with a
bio-chem degree from WMU.)
You are wise to suggest that
young graduates learn how to
weld or run a CNC machine. Id
hire them.
Jon Rogers
I had a couple of other letters from
liberal arts degree holders who
took what I said the wrong way.
Regardless of what your degree
happens to be in, Id say learning
a skill at a community college, if
necessary, is a good way to get a
foot in the door. Leland Teschler
RS# 113
14
MACHINE DESIGN.com
MARCH 8, 2012
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SCANNING FOR IDEAS

Edited by Stephen J. Mraz
Rack-and-pinion lubricator ensures

smooth operation and a long life
The lubrication subsystem from Wittenstein, Bartlett,
Ill. (www.wittenstein-us.com), keeps rack-and-pinion
drives lubricated, preventing gears from becoming
scratched and worn. The device works with the
companys drives as well as others on the market.
The subsystem consists of a canister that holds
Microlube GB, a mineral-oil-based NLGI grade 0
grease. The canister comes in 125 and 475-cm3 sizes.
Theres also a sensor
that alerts users
when the canister
is nearing empty.
Rack-andThe lubricating
pinion drive
fluid flows from
the canister to the
mounting shaft
through a plastic
hose. Holes in
the shaft let the
lubrication fluid
Pipe clamp for

mounting
150-mm-long cable lets

a machine operate the
lubricator.
Transparent
canister
Grease reservoir
Sensor
monitors how
much grease is
in reservoir
Aluminum hose
connection
Plastic hose
pass through
to a felt pinion.
This pinion
then distributes
lubricant onto the
rack.
Users program the
device using a series of
dip switches that open a
valve and dispense a given
r
formation via ou
number of grease-gun
Request free in Web site at
ice
rv
Se
er
ad
Re
strokes each day (a greasec
design.com/rs
gun stroke equals a cubic
ww w.machine
centimeter), a value that can
range from 0.3 to 4. That setting
can then be used for anywhere from 14 days to
18 months. A chemical reaction in the grease
builds up pressure, which moves the grease
through the various pipes and hoses. The unit
operates in temperatures from 10 to 50C.
RS# 401
16
MACHINE DESIGN.com
MARCH 8, 2012
For information on another

case-hardened rack, scan
this code or go to:
http://machinedesign.com/
content/case-hardenedrack-0928
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RS# 115
SCANNING FOR IDEAS
Enclosure protects electronics and

controls from harsh environments
The Hygienic Design (HD) enclosures from Rittal Corp., Urbana, Ohio (www.
rittal-corp.com), are built to be easily and quickly cleaned while keeping the
contents safe from water and chemicals. Engineers took care to ensure there
are no cracks or crevices that could hide debris. For example, smaller HD enclosures have stainless-steel screw covers while large versions use internal hinges
on the doors. The walls and door surfaces are angled to prevent anything from
sticking to them and to let water run off of the surfaces rather than pool.
The enclosures
can mount on walls
using rounded
Roof projection eases
Sloped roof for
stand-off brackets.
pressure on seals
debris-free cleanout
The brackets leave
room behind the
enclosure so water
can flow around the
entire unit during
wash downs. For
large enclosures,
optional leveling
feet keep the box
off the floor and
properly plumbed
despite an uneven
Internal hinges
floor. A wire shelf
eliminate
can also be added
crevices which
to help route
can trap debris
cables. All mounting
threads are covered
to keep them free of
debris.
Available to
A continuous siliNEMA-4X
cone gasket around
specifications
the door fits into a
precise channel that
creates a tight seal
without using adhesives. This makes
it easy to remove
or replace the gasket if needed. The
blue-colored gasket
ANSI stainless steel with
ensures any particu400-grain brushed surface
late splashed on it
stands out so it can
be removed.
All these features, including the 400-grain brushed-steel
surface finish, reduce cleaning times and the amount of
water and detergents used. They also significantly lower
the risk of contamination. The enclosures are also available
in configurations that meet NEMA-4X specifications.
RS# 402
18
MACHINE DESIGN.com
MARCH 8, 2012
Door chamfered
all around edge,
which simplifies
cleaning
Continuous
silicone seal
and gaskets
fit without
adhesives. They
can be replaced
without using
special tools
For more information on

enclosures, scan this code or go to:
http://machinedesign.com/article/
nanotechnology-keeps-enclosuresclean-0524
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RS# 116
REPORTERS NOTEBOOK
Thermoforms earn a C+ in recycling.
Theres plenty of room for improvement
Thermoformed packaging such
as blister packs and clamshells
typically end up in landfills, even
though many of are made of PC
PET, the usually recycled material
that is blow molded into soft drink
and water bottles. Thats a problem for manufacturers concerned
about sustainability and product
packaging. And the economics of
recycling will probably prevent
widespread recycling of thermoform-grade RPET for some time.
(The R of RPET means the polymer comprises virgin material plus
regrind, or recycled content.)
In a pilot study conducted by
thermoform-packaging maker
Dordan Manufacturing in Woodstock, Ill., the company shipped
50 of its RPET clamshells to a local
recycling facility to determine
how well the containers could be
sorted. The waste-management
facility uses optics to sort different
kinds of polymers.
The equipment could not dis-
tinguish the difference between

PET bottles and RPET thermoforms, says Dordan Manufacturings Sustainability Coordinator
Chandler Slavin. Theoretically, the
two could be recycled together,
but that depends on a lot of factors, many of which are a result of
the sorting equipment used. In
manual sorting, there are problems because clamshells and
blisters come in all shapes, sizes,
and materials, making it difficult
to train workers to sort packages
by material type via visual cues in
package design. Most clear, thinneck screw-top beverage bottles
are PET, for example, making it
easy to identify this recyclable
from those destined for landfills,
says Slavin.
Another issue: Industry experts
suggest there may be fluctuations
between the intrinsic viscosity
(IV) of PET and RPET that would
make them difficult to recycle
together. The IV of a material,
measured in deciliters per
Mail-in
your waste
The goal at TerraCycle Inc.,
Trenton, N. J., is to eliminate the
idea of waste. It does this by creating national recycling streams for
previously nonrecyclable or hardto-recycle waste. Anyone can sign
up for these programs and start
sending the company waste. The
company converts this into a wide
variety of products and materials.
According to the company, it has
20 million people collecting waste
in over 20 countries and has used
them to create over 1,500 different products available at major
retailers ranging from Walmart to
Whole Foods Market.
20
MACHINE DESIGN.com
gram, depends on the length of

its polymer chains. The longer the
chains, the higher the viscosity.
Also, RPETs can comprise different
ratios of PET, regrind, or recycled
polymers. This is one reason why
the National Association for PET
Container Resources concluded
it would be easiest to just recycle
PET thermoforms together and
keep them out of the PET-bottlerecovery system.
Recycling of thermoforms is an
evolving situation, says Slavin. Consequently, there are no standard
practices; all collection, sorting, and
reprocessing depend on the end
market of the material recycled,
which differ from region to region.
And information about recycling
specific materials often gets
handed down like folklore among
thermoform manufacturers and
other interested parties.
Waste management is a large,
complicated, and mature industry
that is slow to adopt technologies and processes due
to inconsistencies inherent in North American recycling behaviors and established
patterns of material recovery, she says. For
example, a package
or material type will
not be collected for
recycling if there is no
buyer, says Slavin. And
there will be no buyer if
there is not a consistent
quantity and quality
available for reprocessing. Moreover, lots of
postconsumer plastics collected for recycling get sold
Continued on page 22
The assortment shows examples
of blister packs that Dordan
manufactures.
MARCH 8, 2012
The machines are

converting PC PET film
via thermoforming into
clamshells or blister packs.
RESOURCES:
Dordan Manufacturing Co. Inc.,
www.dordan.com,
www.recyclablepackaging.org
TerraCycle Inc., www.terracycle.net
For more information, check out YouTube
videos on how recycling centers work
like http://www.youtube.com/watch?v=_
GP3JuiX5BY.
Visit this link for a list by material type
of what is recovered based on percent
generation with the focus on containers
and packaging: http://www.ftc.gov/bcp/edu/
microsites/energy/documents/Green-GuidesSummary-of-Proposal.pdf
The document describes what is
recycled and in what quantities thereby
demonstrating what is not: http://www.
epa.gov/osw/nonhaz/municipal/pubs/
msw2008data.pdf
Slavins research culminated in the release
of her Recycling Report: The Truth about
Clamshell/Blister Recycling in America with
Suggestions for the Industry:
http://www.dordan.com/pdf/dordan_
recycling_report.pdf
How recycling works

When a clear PET bottle goes into a curbside bin, the bottle is often
picked up by the same truck carrying waste destined for a landfill. Usually the landfill and recovery facility are geographically close to one
another, so recyclables are dropped at the recycling facility and waste at
the landfill. (Transportation is one of the more-costly considerations in
waste management.)
Once at the reprocessing facility, recyclables are dumped on the
plant floor where a variety of conveyer belts spread the materials along
the line for easier identification. Paper is usually sorted first, falling
through slits in a tumbler due to weight and dimensions. Plastics are
sorted manually or automatically, depended on the facility. In manual
systems, workers on the line visually identify materials of a specific type,
i.e., HDPE milk jugs. They remove the jugs and place them in separate
containers that go to another sorting scheme in the facility or are baled
for transportation to an intermediate reprocessor. One popular automated sorting technology uses optics to separate PET from PVC and
other undesirables. Aluminum is sorted from other recyclables, and glass
is sorted through a weight-based scheme. Sometimes, the municipally
contracted hauler or reprocessor separates materials by feedstock type
(i.e., paper, plastic, and glass) and then sells the materials to an intermediate plastics or paper reprocessor. It is often privately owned and employs more-sophisticated sorting techniques based on the requirements
of the end market.
MARCH 8, 2012
MACHINE DESIGN.com
21
REPORTERS NOTEBOOK
The film has

been formed into
clamshells.
Continued from page 20

to China where the cost to manually sort it is less than the cost of
manually sorting it in the U. S. This
reduces the available recycling
stream in North America, making
the amounts necessary to sustain
recycling difficult to quantify.
In addition, a communitys
ability to recycle a package with
limited recyclability, like RPET
thermoformed containers, can
be dictated by whether facilities
are private or publicly owned,
says Slavin. Private facilities tend
to be better run and maintained
than municipally funded ones,
she says. They also tend to be
more economically sustainable.
And they use more-sophisticated
technologies for sorting and reprocessing. Other factors include
the geographical location of the
facility (East versus Midwest versus
West), which determines what
types of materials are collected
for recycling and technologies
used, based on the available end
markets.
And consider the collection
scheme, says Slavin. How materials are collected for recycling
curbside, drop off, single stream,
or commingled determines
how materials comes to recycling
facilities, she says. This also affects how and what materials are
collected for recycling and what
sorting schemes are used. Complicating matters further, buyers
22
MACHINE DESIGN.com
specs, or the specifications a buyer

outlines to suppliers of PC plastics
upon procurement, require the
material be of a specific material
type, such as PET, and packaging
type, such as thin-neck screwtop PET beverage containers. For
instance, most PET buyers say
they do not want bales with RPET
thermoforms included for fear of
contamination. This discourages
MRFs from investing in sorting
technologies that could pull out
RPET thermoforms from a batch of
look-alike contaminates like PVC.
The Sustainable Packaging
Coalition (SPC) developed the
Labeling for Recovery Project to
educate consumers on what types
of packaging are recycled via a
simple labeling scheme. Under
the scheme, the label lists components of the packaging and material it is made from. It is intended
to tell consumers what can and
cant be recycled rather than what
is assumed to be recyclable, says
Slavin. The hope was to have
consumers understand recycling
MARCH 8, 2012
based on the realities of the current system, thereby establishing

a demand for increased material
recycling. But in developing the
initiative, the project team ran
into obstacles regarding data applicability. Difficulties arose such
as how to determine the types of
packaging recycled and the quantity recycled in different geographical regions; whether a community
has access to a facility that can recycle the packaging; and whether
collection, end markets, and automated sorting are available.
Industry figures suggest that
30 to 59% of American communities can recycle PET thermoforms,
which falls within the limited
recyclability category as per the
FTC Green Guides definition. This
is changing, however, as industry
begins to take a more proactive
approach to recycling packaging,
says Slavin. I foresee the management of recyclables as shifting from
publicly to privately owned systems, due in part to the success of
such approaches overseas. MD
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RS# 117
REPORTERS NOTEBOOK
Laser-guided bullets hit targets a mile away

Researchers at Sandia National Laboratory have
developed a bullet for
small-caliber, smooth-bore
firearms that can guide
itself to a laserdesignated
target up to a
mile away. The
4-in.-long bullet carries an
optical sensor
that detects
the laser beam
reflecting off
a target. The
sensor sends
that data to
onboard electronics that
use an 8-bit
processor to
generate control signals
Resources:
about 30 times per secSandia National
ond for electromagnetic
Laboratory, http://tinyurl.
actuators. These actuators
com/6suglep
control the four fins on
the tail of the bullet.
The bullet is initially encased in plastic sabots that
create a gastight seal between the round and barrel
and protect the fins as the bullet travels through the
barrel. The sabots drop off when the round leaves the
barrel. The bullet must be used in smooth-bore weap-
The 4-in. bullet has fins that let it guide itself to the laserdesignated target. An LED attached to one such self-guided
bullet fired at night shows the path the bullet took to its target.
ons because rifling or spiral grooves in some barrels

makes the bullet spin. This guided bullet will not work if
it is spun out of the barrel.
So far, test have shown the bullet is accurate when
fired at 2,400 fps, about Mach 2.1. Researchers are confident it will remain accurate when fired at standard military speeds, which are about two to three times higher.
MD
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24
MACHINE DESIGN.com
MARCH 8, 2012
RS# 118
Airpot.com
Emergency lighting relies on

durable insulation
Resources:
By its very nature, emergency and exit lighting

Barron Lighting Group,
Formex material for lighting insulation
http://barronltg.com
must be durable and dependable, so these were
was die cut into a box shape, printed
RS# 406
key concerns for Barron Lighting Group, based
with warning information, and scored
Fabrico, www.fabrico.com
for easy folding during assembly.
in Phoenix, as part of its new design for LED exit
RS# 407
signs and emergency lights.
ITW Formex, www.
Company engineers needed to keep circuit
an excellent, lightweight insulatitwformex.com RS# 408
boards fully insulated, separating high and lowing material that meets safety
voltage areas. The idea was to enclose the circuit
and environmental standards. In
board within an insulated box, yet still have easy access
addition, Formex lends itself to fabrication and folding
to wire terminals and a 120/277-V dip switch. In addiinto three-dimensional shapes that retain their form. It
tion, the box needed an interlocking mechanism that
can also be embossed or printed with product or safety
would simplify installation and display operation and
information.
warnings.
To meet Barrons specifications, Fabrico die cut
We had a design in mind, said Barron Lighting
Formex into a box shape that included tabs for secure
Groups Mike Glaser, but admits it wasnt in their area
closure. Die cutting is held to tight tolerances with high
of expertise. We needed a company to help us with
repeatability, making it ideal for long production runs.
material selection, box fabrication, and developing the
Tolerances can range from 0.015 in. to 0.005 in., at
interlock, he says.
speeds up to 500 fpm. Electronic web-tension control
They turned to Fabrico, an experienced converter
ensures precise registration. Material thicknesses can
based in Kennesaw, Ga. It has an in-house lab that
range from 0.001 to 0.015 in., with widths up to 13 in.
can test a wide range of material parameters, such as
There is no limit to the length of sheeted materials, and
temperature resistance, shear and tensile strength, outindividual die-cut parts can be up to 22-in. long.
gassing, dielectric strength, and electrical and thermal
After die cutting, Fabrico printed the Formex
conductivity. After investigating a number of materials,
boxes with warning and voltage information. Then,
company engineers recommended Formex from ITW
they were scored for easy folding during assembly,
Formex, Addison, Ill.
and shipped flat.
This flexible polypropylene electrical-insulation
The box has been a success, according to Glaser.
material is often used to protect sensitive electronic
It keeps the circuit board completely insulated, yet
components and prevent unintended contact between
provides ready access to the electrical connections
circuit boards and housings, and between circuit
and voltage dip switch, he notes. And the design has
boards themselves. Formexs high-dielectric strength
proven to be easy for our production personnel to in(1,460 V/mil @ 17-mil thickness), low-moisture absorpstall. Keeping it simple has minimized production time
tion (<0.1%), and UL 94V-0 flame-class rating make it
and gives us a competitive advantage, says Glaser. MD
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RS# 119
MARCH 8, 2012
MACHINE DESIGN.com
25
When
it matters...
REPORTERS NOTEBOOK
Olympus: A green
supercomputer for the U. S.
The DoEs Pacific Northwest National Laboratory recently unveiled
Olympus, a new 162-teraflop supercomputer. Its the labs first large-scale
supercomputer and has the computational speed and power of about
20,000 PCs. The $4.4 million computer features a closed-loop, waterbased cooling
subsystem,
unlike other
large-scale
computers,
which rely on
air cooling. The
new cooling
subsystem
should save
the lab $61,000
annually in
electricity.
The new computer also has:
80 Gbytes/sec
of disk bandwidth, meaning
Resources:
it can read and
Pacific Northwest
write data to a disk about 800 times faster
National Laborator,
than a typical PC.
http://tinyurl.
com/7253gay
38.7 terabytes of memory.
604 Atipa computer nodes, including 1,200
dual AMD Interlagos 16-core processors.
About 3.75 miles of cabling, including a
684-port QLogic core switch. MD
GORE Electronic Materials
COMPANY NEWS
Enhance performance and
increase design exibility
in your electronic systems with
the latest EMI shielding and
RF grounding solutions from Gore.
gore.com/emi
RS# 120
EMI GASKETS AND

GROUNDING PADS
STUDY RESULTS
Agilent Technologies Inc., Santa Clara, Calif., has released the results
of a customer-focused study that ranked the companys electronic
test and measurement products highest in quality, compared with
competitors products.
Conducted worldwide in 2011, the independent, blind survey
showed that customers who purchased radio-frequency and microwave products from both Agilent and its key competitors, rated Agilent statistically higher in product quality.
SERVICES
TV SD America Inc., Peabody, Mass., has added Certified Professional for Requirements Engineering (CPRE) examinations to its Personal Certification Services in the U. S. through TV SD Examination
Institute. TV SD America Inc., a subsidiary of TV SD AG, Munich,
Germany, is a testing and certification organization.
MARCH 8, 2012
REPORTERS NOTEBOOK
Study shows green buildings

do save money
When failure
is not
an option...
Resources:
Pacific Northwest
Laboratory, www.pnl.go
The U. S.
courthouse in
Seattle, built to
green standards,
features radiant
floor heating,
high-efficiency
lighting, waterless
urinals, a natural
gas boiler, and a
high-tech energymanagement
system. It has
operating costs
35% less than the
industry baseline
despite slightly
higher janitorial
costs.
A recent report from the Pacific Northwest National Laboratory, a facility run by the Dept. of Energy, found that federal buildings built to green
standards emit 34% less carbon dioxide, use 11% less water, 25% less
energy, and cost 19% less to maintain than similarly sized conventional
buildings. The report also says those working in the buildings are 27%
more satisfied. The Lab evaluated 22 green federal buildings across the
country to compile the findings. MD
GORE Wire and Cable

PERSONNEL
Simrit, Elgin, Ill., has appointed Jos Caro as the head of global Simrit,
where he will be responsible for leading Freudenberg Sealing Technologies. Caro succeeds Dr. Jan Gupta, who has been appointed to
head of the oil seals division and will be responsible for directing the
largest division within Freudenberg Sealing Technologies.
When reliability, durability, and

performance can be compromised
by harsh environments,
GORE Wire and Cables
offer the best solution.
gore.com/electronics
Service Machine Co Inc., Loves Park, Ill., has selected Costimator
cost-estimating software from MTI Systems Inc., West Springfield,
Mass., to speed up cost estimating and enhance the accuracy of their
quotations. Service Machine Co, Inc. manufactures a variety of production parts ranging from small lot and high-volume parts to prototyping. MTI Systems is a software provider. MD
MARCH 8, 2012
RS# 121
WIRE AND CABLE
REPORTERS NOTEBOOK
10 YEARS AGO 2002
Up, up, and away!: The strap-on,
upright-flying aircraft known as
the SoloTrek Exo-Skeletor Flying
Vehicle has made its first controlled,
manned flight. During the test trip,
Michael Moshier, CEO and CTO of
the aircrafts developer Millennium
LOOKING BACK
Jet Inc.,
Sunnyvale,
Calif., hovered
for 20 sec
about 2 ft off
the ground.
Safety tethers kept the aircraft in
check while it hovered. The tethers
Request your 448 page copy at...
ondrives.us
www.
ww
ww.
provide enough slack so we can finetune the fly-by-wire control and stability system, but not so much that
we can get into trouble, explains
Moshier. Engineers plan to remove
the tethers for the next development
phase: free-hover testing.
30 YEARS AGO 1982
Coil readied for fusion tester: An

11-ton magnetic-field coil is the first
of 22 identical units being built by
Westinghouse Electric Corp. for the
Tokamak Fusion Test Reactor. Some
1,500 ft of copper conductor were
used to wind
the coil to a
10-ft ID and
14-ft OD. At
the Princeton
University
Plasma
Physics
Laboratory, the water-cooled electromagnets will be used in proof-ofprinciple experiments designed to
achieve fusion-energy breakeven for
the first time. The strong magnetic
field provided by the coils will hold
the fusion plasma, which is expected
to be at sun temperatures.
50 YEARS AGO 1962
Call us at 1
1-888-260-7466
888 260 7466 or fax us at 516-771-6444
516 771 6444
Request a catalog at catalog@ondrives.us
See us at www.ondrives.us
28
MACHINE DESIGN.com
.US Corp.
MARCH 8, 2012
Turbine casing completes Hoover

Dam: When delivered to the Hoover
Dam, this massive turbine spiral
casing completed the hydroelectric
project. Shown undergoing final
machining in the Eddystone, Pa.,
shops of Industrial Equipment Div.,
Baldwin-Lima-Hamilton Corp., the
casing will channel and distribute
Colorado River
water to runner blades of
a Francis-type
hydraulic turbine. Surfaces
are held to
dimensional and flatness tolerances
within a few thousandths of an inch,
assuring watertight mating with
matching covers. The turbine, rated
at 115,000 hp, 180 rpm under a net
effective head of 480 ft, is the sixth
and final large powerplant phased
into the Hoover-Dam project over
the past 25 years. MD
Accelerating the Speed of Design.
Your one solution for design creation.

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manufacturers (OEMs) a high level of technical expertise enabling the swift and accurate
design of leading-edge products.
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unmatched in the industry. With easy access to our industry experts, your projects move forward
with greater velocity, driven by in-depth technical expertise. That translates into faster time to
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RS# 123
REPORTERS NOTEBOOK
CERTIFICATIONS/
REGISTRATIONS
Two manufacturing facilities of Web
Industries, Atlanta, Ga., have received
industry certifications or registrations.
Its Atlanta facility has earned
AS9100C certification, and its Hartford,
Conn., location is now an FDA-registered
COMPANY NEWS
Medical Device Establishment. Web
Industries is a provider of custom
manufacturing and development
services for flexible materials.
Sterling Instrument, New Hyde
Park, N. Y., a manufacturer of precision
electromechanical components and
assemblies, has received certification of
its new ISO 7/Class 10000 Clean Room.
GREAT PLACE TO WORK

AutomationDirect, Cumming, Ga., has
been ranked #4 on the The Great Place
to Work Rankings: 2011 Best Small &
Medium Workplaces, presented by
Entrepreneur. This annual list recognizes companies that have exceptional
workplace cultures. In its eighth year,
the competition is divided into two categories, small (50-250 employees) and
medium (251-999 employees).
AutomationDirect provides high-quality automation products.
ACQUISITION
3D Systems Corp., Burlington, Mass.,
has acquired Z Corp. 3D will now be
capable of delivering an integrated
platform of mixed 3D printing
technologies, 3D content, and 3D
design services.
BOARD ELECTIONS
John Kowal, packaging market development manager for B&R Industrial
Automation, Roswell, Ga., was elected
to the Board of Directors of the Packaging Machinery Manufacturers
Institute (PMMI). Kowal is the first
Supplier Member to be elected to the
PMMI board. B&R provides automation-equipment products.
EXPANSION
Balluff Inc.s Automotive Industry
Management Team has expanded and
moved into a new facility in Troy, Mich.
The Automotive Industry Management
Team consists of 14 industry managers,
strategic account managers, project
managers, and technical support
managers.
Balluff, Florence, Ky., manufactures
inductive, photoelectric, vision,
capacitive, and magnetic sensors, as
well as linear position transducers, RFID
systems, and networking products. MD
30
MACHINE DESIGN.com
RS# 124
MARCH 8, 2012
Technology You Can Trust
Avago Technologies Optocouplers
Setting a Superior Standard

for High Voltage Protection!
Optocouplers are the only isolation devices that meet or

exceed the IEC 60747-5-5 International Safety Standard
for insulation and isolation. Stringent evaluation tests show Avagos
optocouplers deliver outstanding performance on essential safety and deliver
exceptional High Voltage protection for your equipment. Alternative isolation
technologies such as magnetic or capacitive isolators do not deliver anywhere
near the high voltage insulation protection or noise isolation capabilities that
optocouplers deliver.
For more details on this subject, read our white paper at:
IEC 60747-5-5 Certied
www.avagoresponsecenter.com/672
RS# 125
EVERY PLANT NEEDS A PARTNER TO

KEEP THINGS BUZZING
Well work hard to keep your plant buzzing using
the most advanced sensing technologyall from
a single-source partner. Weve stayed busy as a
bee for over half a century developing innovative
products that take the sting out of applying
sensors. Our sensors are crafted using state-ofthe-art components and the latest technologies
to ensure precision, reliability, and functionality.
In addition, we offer a wide selection of
accessories to meet all your application needs.
Go to www.sensing.net/buzz1 or give us a buzz
at 330.486.0001 and well devote a swarm of
technical experts to go to work for you.
Pepperl+Fuchs Inc.
Twinsburg, Ohio
330.486.0001
www.pepperl-fuchs.com
RS# 126
The abILITy To wIThsTaND

puNIshmeNT Is gooD...buT
avoIDINg IT Is eveN beTTer
SENSOR SENSE
Multipixel-array sensors
Multipixel-array (MPA) sensing for target detection within specific distances combines the benefits of background suppression, sharply defined sensing, and insensitivity to object color with the distance-based
detection of a distance-measurement sensor. This lets the user customize
sensor-target detection based on the distance to an object, whereas a
conventional photoelectric sensor simply detects an absence or presence
of an object.
MPA-type sensors
Multipixel-array operation
emit
light thats reDistance
flected by the target
object back to the
Distance
sensors light-senMultipixel
sitive receiver area.
array
Unlike conventional
Lens
photoelectric senEmitter
sors that use only a
single light-sensitive
sensor, the MPA
Sensor Target object
uses a pixel array
The light from the emitter reflects back to multiple
consisting of many
photoelectric sites within a multipixel-array sensor. The
photosensitive sites.
angle of reflected light, as measured by where it strikes the
array, is used to calculate the distance of the target object
Earlier technologies
from the sensor. Objects closer to the sensor produce a
used differential dihigher angle of reflection as shown by the dashed lines.
ode (two-segment)
receivers. A target
closer to or farther
away from the sensor changes the angle of the
Edited by Robert Repas
light beam, splitting the amount of light that falls
upon each light-sensitive diode. By measuring the
difference in light striking each diode, a rough estimate of the targets distance would determine if it was the valid target and not a false trigger.
In contrast, MPA sensors often use over 100 receiver elements per array
for higher resolution. Triangulation calculations of the reflected light between the source and where it hits the pixel array determines the distance
to the target object. In other words, MPA sensing is determined by the geometry of the reflected light. Closer objects reflect light at greater angles
than farther objects. Where the greatest concentration of light centers on
the array determines if the target is at the desired distance.
The high number of light-sensitive pixels in MPA sensors gives the
ability to create multiple switching thresholds or to establish sensing windows that force the target to fall within a specific distance from the sensor
before triggering the sensor output. This lets the sensor offer a higher
level of control than standard background-suppression (BGS) models that
have just one distance threshold.
And the fact that MPA sensors detect where the light is reflected rather
than how much light is reflected makes these sensors insensitive to variations of an objects reflectivity or color.
Sensing distances or spans are set using electronic rather than mechanical adjustment. The use of multiple sensing ranges lets a single sensor act as multiple single-point sensors.
Typical applications for MPA photoelectric sensing include presence
checking, trigger or leading-edge sensing, stack-height detection, tension
checking, stroke-height monitoring, fill-level monitoring, collision-avoidance monitoring, and web-break monitoring. MD
Pepperl+Fuchs (www.pepperl-fuchs.us) supplied information for this column.
MARCH 8, 2012
Durability vs Distance Its No

Longer a Decision
When selecting the best proximity
sensor for abusive environments,
the decision has always carried
a difcult tradeoff durability vs
sensing distance. The 100% stainless
steel X-series Pile Driver is the rst
sensor to deliver both.
How durable? Impact
withstandability is 20X beyond
traditional plastic-face products.
How far? Sensing ranges exceed
industry standards by up to 2.5X.
So what does this 1-2 combination
mean to you?
n Fewer sensor-target impacts
n Increased machine uptime
n Reduced maintenance and
troubleshooting
n Fewer rejects and increased quality
n Lower spare parts inventory
RS# 127
www.sensing.net/xpd
Pepperl+Fuchs, Inc. Twinsburg, Ohio 330.486.0001
COMMENTARY
Problems
with
PRE-ENGINEERING
EDUCATION?
You often hear about how excited kids get when they participate in technology
programs such as the FIRST Robotics Competition (FRC). This program tries to
cultivate interest in science and technology by having young people learn about
robots, build them, and then compete against other FIRST teams. But the reality
that emerges when you talk to some of the teachers actually in the trenches is that
it is often tough to get kids interested in technology.
For example, a friend of mine who teaches a high-school Tech Prep course at
a community college in a nearby state says too many students
today lack professionalism. That means being on time, having
your materials ready, and not sleeping during class, he says.
Many students dont take education seriously. Kids fall asleep
in class saying it is boring. Like real life though, not every job or
class can be exciting. Teachers can try to make things interesting, but sometimes kids must buckle down and do the tough
stuff like learn formulas.
A lot also depends on circumstances. A kids lack of interest
can be because of personal stuff. Maybe the parents are divorcing or there are problems at home. Or a kid might have depression issues and sleep in class because he is on medication.
A teacher may feel sorry for the kid, like the bright guy who could have straight As
but cuts class every other day. And consider the intelligent kid who looks at me like
I just came from the moon when I dock points because he was late for class, says the
teacher. Its like they try to play the system instead of just trying to succeed.
Although the No Child Left Behind program initiated under President George
W. Bush has been mostly phased out, similar restraints arguably restrict teachers.
For example, one solution put in place is the so-called Individualized Educational
Program (IEP). When a kid does poorly in math or reading in the lower grades, the
IEP kicks in, and the teacher must give a student one-on-one help. Case workers also
create a help list, like student needs extra time during tests, or, student should always use a calculator. By law, teachers not following through with IEPs can be fined.
Ostensibly, IEPs were designed to allow every student to succeed in school. But they
can slow down a class.
What about those students who should really not be in a technical field? They
need too much time, too many adjustments made for them, and they will never fully
succeed, says my friend. Some students might squeak by and then get a job. The
school cannot tell the employer that the kid was in an IEP. The employer just sees the
good grades. The kid gets hired and boom he or she cannot function. Needless
to say, the company will take no more students from that particular prep class.
Leslie Gordon, leslie.gordon@penton.com, Twitter @LeslieGordon
sometimes
kids must
buckle down
and do the
tough stuff
34
MACHINE DESIGN.com
MARCH 8, 2012
Fluid Power
FreudenbergNOK Sealing Technologies
Simrit: performance under pressure

Sealing designed for engine efciency and emissions performance
A chain is only as strong as its
weakest link. Thats why Simrit
takes a system-wide approach
to offering the ultimate sealing
solutions for hydraulic and
pneumatic sealing. Each of our
360,000 cataloged inch and
metric parts is designed for one
thing: unfaltering endurance.
Our proprietary materials include

NOK U641 urethane and NOK
UH05 urethane. We have developed
these unique sealing designs to
handle temperatures from 40 to
+248F, and to be compatible
with bio-fuels, as well as resistant
to hydrolysis and glycolysis.
1- 8 6 6 -2 74 - 674 8
w w w.si m ri t.co m
RS# 128
Simrit also offers a wide range of

standard products in other materials,
including urethanes, nylons, PTFE,
Hytrel, PEEK, and virtually
every elastomer.
To maintain the strength of your uid
power chain, always demand genuine
Disogrin materials from Simrit.
70,000
products
@
goodfellowusa.com
metals
ceramics
polymers
composites
Quantities from 1 piece
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Questions? Need
something unusual?
Email:
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call:
1-800-821-2870
(real live person)
small quantities fast
BERKE ON SAFETY
GFCIs
What they are
and are not
Fuses and circuit breakers are included in an electrical circuit to prevent an
electrical overload from damaging property, such as your house. But the electrical current needed to kill you is much lower than the amount that will cause
the fuse or circuit breaker to burn out or pop and interrupt the electrical current flow.
When you look at the normal 120-V outlet in your home, there are two vertical slots and a round hole centered below them. The left slot is slightly larger
than the right slot. The left slot is called neutral, and the right slot is called
hot. The round hole is a ground connection. If an appliance is working properly, all electricity the appliance uses will flow from hot to neutral. The ground
is not normally in the circuit that causes the appliance to function. The ground
is normally connected to the shell of the appliance so if the hot wire touches
the shell (a broken hot wire perhaps) the current from the hot wire will flow
to ground and cause the fuse or circuit breaker to overheat, pop, and stop the
current flow. The normal level of current necessary to actuate a breaker or fuse
is generally 20 A. In contrast, the amount of current necessary to put the heart
into fibrillation is less than 100 mA.
It is important to know what GFCIs do and dont do. They are designed to
prevent electrocution by detecting a difference in current flow between the hotwire current flowing into the appliance and the current flow out of the appliance
to the neutral. When this measured difference is as low as 6 mA, the GFCI will
shut down the circuit within one-thirtieth of a second. This means if the measured 6 mA or more at 120 V is going through you, you will get the full impact of
the shock, but the shock will not last long enough to put your heart into fibrillation, which could kill you.
As an example, consider a person using an electrical appliance outside in the
rain. Suppose that person is barefoot (another of Gods ways of thinning out the
gene pool). The appliance is wet, and there is a path from the hot wire through
the operator to ground. Electricity flowing from hot to ground through the operator could be fatal. The GFCI will sense that current may be flowing because
there is an imbalance between current flowing out of the hot wire and into the
neutral wire. As soon as the GFCI senses this imbalance, it will trip and cut off
the electricity.
The National Electrical Code requires GFCIs for receptacles in bathrooms,
some kitchen receptacles, some garage receptacles, and outside receptacles. Because of the many electrocutions that resulted from dropping a hair dryer into
the bathtub while bathing and the lawsuits that resulted from such incidents,
most manufacturers of hair dryers now build in GFCIs as an integral part of hair
dryers.
Remember, the GFCI will protect your heart from going into fibrillation but
will not protect you from getting severe shock. And you can still get hurt. I tell
my students when I am teaching Loss Control classes that, If you are using a
GFCI-protected electrical tool while standing on a 12-ft ladder and the tool
shorts to the case, the electrical shock will not kill you. But the fall from the ladder could. MD
Lanny Berke is a registered professional engineer and Certified Safety Professional involved
in forensic engineering since 1972. Got a question about safety? You can reach Lanny at
lannyb@comcast.net.
2012 Goodfellow corporation
36
RS# 129
MACHINE DESIGN.com
Edited by Leland Teschler

MARCH 8, 2012
www.heli-cal.com
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$6% ,62&HUWLHGDQG52+6&RPSOLDQW
RS# 130
VANTAGE POINT
Dont wait
for
government
to address
skills gap
In his State of the Union address, President Obama showcased the domestic manufacturing sector as the blueprint
for our nations future. He spoke of an economy built on
American manufacturing, American energy, skills for
American workers, and a renewal of American values.
No surprise there.
He referenced reshoring, skills training, and workforce
development as keys to continuing the momentum of
American manufacturing that we in the industry know to
already be driving the national economic recovery.
No surprise there, either.
The critical shortage of skilled workers is indeed the
greatest threat to American manufacturing. While the
President did note some solutions to this crisis do exist, many manufacturers should have been surprised by
the implication that more programs and more tools are
needed to truly solve the problem.
The Society of Manufacturing Engineers has, for
years, been developing and executing solutions to our nations shortage of skilled manufacturing workers, and I can
say without hesitation that the tools to solve this problem
are already available.
SME has done more than simply talk about these issues.
Our organization of manufacturing professionals has been
supporting, advocating, and actually addressing workforce
concerns with companies, educational institutions, other
associations, and government partners.
Surely, continued government support is necessary and
appreciated for example, tax incentives for businesses
creating American jobs. But what we really require now is
a stronger commitment from manufacturers and academia
to existing industry and government programs.
For instance, the recently expanded Skills for Americas
Future program links corporations with community colleges. It fosters the use of industry-created certifications
and mentorships focused on building the educated and
skilled workforce that U. S. manufacturers need to successfully compete in the global economy.
The Manufacturing Institutes Manufacturing Skills
Certification System which SME and other key organizations validated creates a framework by which both
companies and individuals can understand the needs of
the future workforce. This system aligns with the Dept. of
Labors Workforce Development Pyramid.
38
MACHINE DESIGN.com
MARCH 8, 2012
Mark C. Tomlinson
Executive Director and CEO
Society of Manufacturing
Engineers
Dearborn, Mich.
Ohio-based Tooling U, an SME program, offers more

than 400 technical courses in a flexible, on-demand, and
customizable online format. More than 1,200 companies
and 500 schools have already taken advantage of the program and helped more than 100,000 workers upgrade their
skills to meet the needs of todays advanced manufacturing
workplace.
These collaborative efforts pay off with qualified workers. The President spoke of the successful job transition of
single mother Jackie Bray, who lost her job as a mechanic
and earned new employment by redeveloping her skill
set through a partnership between North Carolina-based
Siemens and Central Piedmont Community College, both of which use online technology training from
Tooling U.
Millions of Americans are confronted with the same
dilemma needing new skills to secure employment, but
facing financial or other hurdles to achieving those skills.
Likewise, the skills gap Siemens recognized is far from an
isolated situation. There are currently more than 600,000
available manufacturing jobs that are unfilled due to lack
of skilled workers.
With time of the essence, how do we accomplish these
employment successes at a much higher rate?
With the necessary resources to surmount these barriers already available, industry and academic leaders
simply need to embrace them. In doing so, we will close the
skills gap, develop the workforce the manufacturing sector
needs, and improve the employment prospects of millions
of Americans. This will provide the human capital this nation needs to continue its recovery.
Manufacturing must be at the core of a viable economy.
But we cant wait months or years for the government to create new programs. The answer is to use existing programs
more effectively and to encourage widespread adoption.
That can be accomplished by generating greater awareness
of mutual benefits and by cutting through the maze, as the
President put it, of confusing training options. MD
The Society of Manufacturing Engineers, a leading source
for manufacturing knowledge, education, and networking,
collaborates with industry, academia, and government
partners to support a skilled workforce. For more information,
visit www.sme.org.
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RS# 131
INVENTORS CORNER
Edited by Leslie Gordon
Spiral-chambered turbine engine

packs a
ONE-TWO PUNCH
Alexander Van Holstyns Reflective Pulse Engine, a

spiral-chambered turbine, fires each chamber sequentially to maximize energy potential. Currently, the
engine is under development. The naturally aspirated
prototype will fire but does not yet run on its own, says
Van Holstyn. Its made out of mower-engine parts, automotive-ignition components, and a fabricated rotor.
The engine works like this: An outside compressedair supply enters the intake side through a bypass port
into the rotating chambers. Fuel is injected through
the port and ignited in the chamber. Combustion
follows the spiral path to the outer edge of the rotor
and forms a flame wall and shock wave. The engine,
therefore, produces two types of energy. The design
separates both types and uses them to boost rotation
in two separate ways.
The shock wave exits from the chamber and is reflected back to the rotor to generate additional rotation
energy at lower rpms. The remaining hot gases route
through the housing to recess vanes in the rotor and
apply more pressure on the rotor before being expelled
out the back side. All the work is done at the perimeter
of the rotor, which yields maximum leverage and instant conversion to rotation.
The design accommodates many engine configurations with multiple chambers in a rotor. Their size and
shape can also be varied. Thus, the engine is an entirely
new design platform for engines rather than an improvement on current designs. The engine only has the
compressor and electric alternator for load and almost
zero friction.
According to Van Holstyn, the design uses the best
features of the piston engine, a contained explosion,
and many features of turbines, except for constant
combustion. The mathematical model suggests that
the engine produces more horsepower and torque
than comparable piston engines when intake pressures
exceeds 2 atm. The engine can also run at lower rpm
ranges similar to a piston engine.
I have always had a passion for the question, What is
the best engine design between the gas turbine and the
piston engine?, says Van Holstyn. I first thought of the
basic concept of the Reflective Pulse Engine in the early
40
MACHINE DESIGN.com
MARCH 8, 2012
The engine
is an entirely
new design
platform for
engines.
1970s in a high-school physics class, but also assumed if it

was a good idea somebody would have done it already. I
put the idea aside as my career took me other directions.
I revisited the concept about 10 years ago and
I rolled it around in my head many times before I
started working on it. I researched the patent files
and found no comparable design. I found patents on
several types I had thought of before such as radialvane engines and orbital lobes that use an internalcompression cycle, but have seal issues.
The funny part is I could not make it through college mathematics, so I am not an engineer. I have
since patented the basic design and have started
working with a physicist to apply for grants.
The Web site is www.Reflective Pulse Engine.com and
the patent is #7,963,096. Reach Van Holstyn at Alex@
pulse-engine.com. MD
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RS# 132
www.twitter.com/avnetdesignwire
MATERIALS INDUSTRY FOCUS
The
advantages
of
STRUCTURAL
THERMOSETS
Structural thermosets are an attractive alternative
to metals and thermoplastics, thanks to excellent
physical properties and surface appearance.
Authored by:
Larry Landis
Director of Technology and Quality
IDI Composites International
Noblesville, Ind.
Key points:
Structural thermoset compounds have

higher tensile and flexural strength per
unit weight than do most metals.
Cross-linked molecules keep structural
thermosets dimensionally stable at
high temperatures.
Unlike common metals, structural
thermosets wont rust or corrode
outdoors or in harsh environments.
Components often last for decades with
little maintenance.
Resources:
IDI Composites International, www.
idicomposites.com
42
MACHINE DESIGN.com
From car-body panels and helicopter parts to electrical

enclosures and sporting goods, manufacturers increasingly rely on structural-thermoset sheet-molding compound (SMC) and bulk-molding compound (BMC) to
address demands for strong, light, and durable materials.
Due to intrinsic limitations with metals and thermoplastics, many engineers are turning to structural-thermoset
compounds to bolster strength and corrosion resistance.
The strong molecular bonds inherent in thermosets impart
a tight web of inner connectivity that lets these materials
maintain excellent structural properties despite prolonged
exposure to chemical and temperature extremes. The materials also increase design flexibility for engineers and production efficiency for manufacturers. Heres a closer look.
Structural-thermoset basics
Structural thermosets are distinguished from standard
thermosets by their use of more specialized resins and
higher levels of reinforcement glass, carbon, and aramid
fibers, for example. The added reinforcement increases
strength and stiffness, while resins protect the fibers and
improve the compounds overall physical properties.
Moreover, manufacturers can tailor these properties
by varying ingredients. For example, changing fiber type,
length, and mix proportion alters its flow, strength, and
MARCH 8, 2012
Structural
thermoset BMC
(on left) and
SMC materials
offer a number
of advantages
over metals and
thermoplastics,
including higher
strength per unit
weight, better
dimensional
stability and
corrosion
resistance and,
often, lower cost.
rigidity; varying resin concentration and type affects overall strength, along with the compounds heat or corrosion
resistance.
Heating the material as it is molded forms three-dimensional covalent bonds between polymer molecules. This
process, known as cross-linking, is irreversible. Therefore,
cross-linked materials cannot be melted and reshaped.
The term thermoset accurately describes this chemistry.
Cross-linking creates a rigid 3D molecular structure that
lets thermosets maintain the desired physical and electrical properties during prolonged exposure to adverse conditions such as excessive heat. This distinguishes thermosets from thermoplastics, which are generally unsuitable
for high-temperature environments because they can be
remelted after solidification. Thermosets tolerate heat-distortion temperatures (HDT) and glass-transition temperatures (Tg) that would literally melt most thermoplastics.
Three of the most common thermoset resins are polyester, vinyl ester, and epoxy. Each has its own price and
performance characteristics, so base selection on an applications functional and cost requirements. For example,
engineers might choose vinyl-ester resin for corrosionresistant products, epoxy for high-strength applications,
and polyester when good overall performance and cost are
the driving factors.
As for reinforcement, many types of fibers can be used

depending on the molding process and strength requirements. Glass-reinforcement options include choppedstrand, mat with random-fiber orientation, light textile
fabrics, heavy woven materials, knitted materials, and
unidirectional fabrics. Carbon-fiber reinforcement is used
for applications that require exceptional strength coupled
with severe weight restrictions.
Structural-thermoset SMC
Most structural thermosets are in the form of sheetmolding compound. SMC is a cost-effective, lower-weight
alternative to many metals. Standard SMC contains 10 to
30% reinforcement, while structural grades are typically in
the 40 to 65% range. Reinforcement is normally choppedstrand glass fibers 0.5 to 2.0-in. (12.7 to 50.8-mm) long.
Structural-thermoset SMC is manufactured in a continuous process that combines a viscous paste and glass fiber on specialized equipment with a continuous web. Paste
containing the resin and additives is poured onto a carrier
film, then cut glass fibers are added, along with a second
layer of film. The paste and glass between top and bottom
carrier films creates a thin sandwich that is run through
a series of serpentine rollers. The serpentine action and
resulting pressure causes the paste to coat and adhere
MARCH 8, 2012
MACHINE DESIGN.com
43
to the glass fibers. The SMC,

typically 12 to 60-in. wide, is
then packaged in continuous
lengths on rolls or soft-folded
into large, flat containers for
curing and handling. The
rolls and containers often
weigh in excess of 1,000 lb.
The packaged SMC is stored
for a specific period (usually
48 hr, depending on the formulation) at a controlled temperature and
humidity before it is shipped. This curing
or maturation step is critical because material
viscosity increases with time. Proper maturation lets the finished SMC product readily peel
from the carrier film, making it easier to handle.
Because of this, it is important to tightly control
the amount of water and chemical thickeners (such
as metal oxides, metal hydroxides, and isocyanates)
added to the paste during manufacturing.
Maturation is an ongoing chemical reaction, so there
is an optimum molding-viscosity window for the best end
results. Typically, SMC should be molded within 30 days
of manufacture unless it is stored below 75F. Many molders store structural-thermoset SMC below 32F to extend
its shelf life.
Though it can be used in transfer and injection-molding processes, structural-thermoset SMC is best suited
for compression molding. Structural SMC can be molded
into complex shapes with little scrap. Ease of handling and
sheet size often makes structural-thermoset SMC the only
Thermoplastic parts can

carbonize or melt if exposed
to electrical arcs, while the
thermosets in this electrical
control switch resist damage
under the same conditions.
reasonable choice for larger parts.
Structural-thermoset BMC
For structural-thermoset bulk-molding compound, manufacturers blend resin, fiber reinforcement, and several other ingredients to form a viscous, puttylike material. By weight, structural BMC
normally includes 25 to 40% reinforcement, usually
chopped-strand glass fibers measuring 0.03 to 0.5 in.
(0.75 to 12.7 mm) in length.
BMC is suitable for compression, transfer, and injection molding. It can be injection molded at cycles
as fast as 10 sec/mm of part thickness. Depending on
the application and formulation, structural BMC provides
tight dimensional control, flame and track resistance,
excellent mechanical properties and dielectric strength,
corrosion and stain resistance, minimal shrink, and color
stability. Available in numerous colors, BMC surfaces are
also receptive to powder coating, painting, and similar finishing processes.
Advantages
Structural-thermoset compounds hold a number of

important advantages over other commonly used materials. And just as important, identifying required attributes
Applications for structural thermosets

With excellent surface appearance and mechanical properties, structural-thermoset compounds are an attractive alternative to metals and thermoplastics in a variety of industries.
Important markets include:
Military and aerospace. Commercial and military aircraft
benet from structural thermosets ability to reduce weight,
cost, and production time, oer FST (re, smoke, and toxicity)
retardance, and prevent galvanic corrosion. Applications include military radomes, ammo-handling guides and containers,
helicopter components, rie hand guards, and other weapon
components.
Transportation. A large and growing number of exterior
automotive components are now made of structural thermosets instead of metals. Thermoset SMC is also gaining popularity among designers of interior parts. Reasons include:
Weight: Thermosets are 25 to 35% lighter than steel parts of
equal strength.
Dimensional stability: Thermoset SMC has a low CLTE and
holds up well to engine heat and summer temperatures, making it suitable for vehicle hoods, deck lids, and roof panels.
Memory: While metal panels permanently deform on im-
44
MACHINE DESIGN.com
MARCH 8, 2012
pact, structural thermoset SMC panels deform and spring back

to their original shape.
Cycle time: By reducing the number of parts in nished assemblies, structural thermosets shorten design and production
times.
Temperature resistance. Ability to maintain strength at high
temperatures makes it ideal for heat shields and skid plates.
Safety equipment. Heat resistance, re-retardant properties,
and high strength-to-weight ratios are critical considerations in
the safety market. Applications include remens helmets, reghting-equipment components, and composite toe caps.
Medical. Corrosion resistance, antimicrobial properties, dimensional control, thermal insulation, and dielectric strength
make structural thermosets well suited for the medical market. X-ray equipment components, instrumentation covers
and bases, biohazard receptacles, and prosthetics are just a
few applications.
Electrical. Structural thermosets hold up well during electrical arcing and tracking, with no signicant changes to shape
or performance. Parts molded from thermoplastic materials, on
the other hand, will often carbonize or melt. Structural thermo-
Structural-thermoset composites used in safety and

firefighter helmets are strong and light, resist flames, and
retain mechanical properties despite exposure to heat.
and material properties early in the design process lets

manufacturers create custom formulations tailored for
specific applications. Core advantages include:
Tensile and flexural strength. Structural-thermoset
compounds have higher tensile and flexural strength per
unit weight than do most metals. And compared to thermoplastic blends such as polycarbonate/ABS (acrylonitrile
butadiene styrene), nylon 6/PPO (polyphenylene oxide),
and polycarbonate/PBT (polybutylene terepththalate),
structural-thermoset SMC has significantly higher flexural and tensile strength and tensile and flex modulus.
Structural-thermoset compounds can also be custom
designed to meet the strength requirements of a particular
application. Unlike metals, which have equal strength in
all directions, structural thermosets are anisotropic and
sets oer comparative tracking index values exceeding 600 V

and dielectric strength above 15 kV/mm. In the electrical industry, structural-thermoset SMC and BMC are used for parts with
track resistance >600 min and arc resistance >180 sec.
Industrial. Excellent load-bearing capabilities, in addition
to corrosion resistance and dielectric strength, make structural thermosets a good choice for heavy industrial applications
such as load bearings and valve bodies, as well as downhole
plugs and other components for the oil and gas industry.
Alternative energy. Structural thermosets are widely used
to make fuel-cell end caps. They provide heat and corrosion resistance without the shrinkage or residual stresses that might
compromise a thin thermoplastic part. Structural-thermoset
SMC and BMC are also suitable for solar-power tiles and windturbine components such as electrical control panels. These applications require materials that wont warp or deteriorate during long-term exposure to the sun and other natural elements.
Marine. Structural thermosets material properties, including
corrosion resistance and high strength-to-weight ratio, suit the
marine market well. Applications include gimbal rings and cowlings, out-drive gimbal housings, and power-boat seat shells.
can be tailored for extra strength in a specific direction.

For example, if a thermoset part must resist bending in
one direction, most fibers can be oriented at 90 to the
bending force for structural stiffness in
that direction.
Thanks to their molecular structure, thermosets maintain strength
and other physical properties despite prolonged exposure to extreme temperatures. By contrast,
metals and thermoplastics exposed
to high temperatures may bend under applied loads. In addition, thermoplastics become brittle at low
temperatures. Some engineered thermoplastics offer physical properties
close to those of structural thermosets,
but these materials are expensive and
cannot always replace structural-thermoset SMC.
Dimensional stability. Besides
A prosthetic foot made of structuralthermoset composite is strong,
light, and flexible. It absorbs
impact when the heel strikes
the ground, and releases
the stored energy to help
propel the wearer
forward.
MARCH 8, 2012
MACHINE DESIGN.com
45
strength, the cross-linked molecules in

structural-thermoset compounds are
dimensionally stable at high temperatures. A thermoset part is far less susceptible to relaxation or creep failure
than a thermoplastic alternative.
The materials high fiber content
reduces structural variations
and makes thermosets ideal
for low-shrink applications.
The dimensional difference between structural
thermosets and thermoplastics can be
seen during tensile
and flexural tests
at elevated temperatures. Thermoplastics may stretch
several inches, while Automotive
structural thermo- engineers are turning to
sets stretch just thou- structural SMC
sandths of an inch. In to mold large
addition, tensile loads parts and cut
applied at high temper- weight by 25
atures cause molded to 35% versus
holes in thermoplastic steel. This
parts to elongate over heat shield
time, while holes in is built to
resist engine
thermoset parts retain temperatures.
their original shape.
Molded structural
thermosets typically shrink from 0.2 to 0% and, if needed,
some thermoset materials can expand after cooling. Minimal shrinkage helps ensure close tolerances in molded
parts, which often eliminates the need for secondary operations such as drilling and machining. For many applications, structural thermosets mimic the coefficient of
linear thermal expansion (CLTE) of metals. This lets engineers readily combine thermosets with other materials in
SMC property comparison

SMC R25, 25% SMC R50, 50%
glass reinforced glass reinforced
Property
Tensile
strength, MPa
Tensile
modulus, GPa
Flexural
strength, MPa
Flexural
modulus, GPa
Specific
gravity
Coefficient of
expansion,
m/mC 106
46
SAE 1006
steel
65 to 90
124 to 204
330
10 to 12.5
12.2 to 19.1
206.7
155 to 200
380
N/A
8.5 to 14
11.6 to 16.4
N/A
1.8 to 2.0
1.85 to 2.15
7.86
12 to 14
13 to 17
12.1
MACHINE DESIGN.com
MARCH 8, 2012
Roofing tiles made of structural

thermosets can last for
decades with little or no
maintenance.
a single design.
Corrosion resistance.
Unlike common metals,
structural-thermoset SMC
wont rust or corrode when
used outdoors or in harsh environments and holds up well
over the long term. For example,
thermoset ductwork in chemicalmanufacturing plants routinely
lasts more than 25 years, and thermoset compounds provide long service life in underground chemicalstorage tanks. The corrosion resistance
of structural SMC also make it suited for
applications subject to strict sanitary requirements. Frequent exposure to harsh
cleaning chemicals will
not damage the material.
In contrast, corrosive substances and environments can weaken
thermoplastics. And metals are notoriously susceptible to corrosion by water
and common chemicals. Metals used in corrosive environments must first be coated, or designers
must opt for expensive corrosion-resistant alloys.
Cost effective. Structural-thermoset compounds have
long lives. Many thermoset structures built in the 1950s
are still in use. In addition, structural thermosets require
little maintenance.
They can also reduce manufacturing costs. Complex
metal designs often require several parts. Individual pieces
are made in a series of progressive dies or costly stamping stations, then assembled into the final product. With
structural-thermoset SMC or BMC, on the other hand,
complex parts can be made as a single piece in a single
step. They generally require little final finishing, if any, and
benefit from molded-in color and an attractive, durable
surface. The simpler process translates into faster, moreefficient production with fewer secondary operations,
fewer errors, and lower costs.
Design flexibility. Finally, structural-thermoset compounds give designers more freedom than they have with
metals. Normal thermoset-molding processes permit
complex shapes and intricate details that are impractical
or even impossible with metals. And unlike metals, thermosets allow for a wide range of material combinations.
Various resins and reinforcements can be combined to
give a product unique properties. In some cases, structural
thermosets can be molded on the most basic systems for
R&D and quick prototyping. MD
SOLVE DIFFICULT SEALING PROBLEMS

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DEFLATED
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INFLATED
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SEAL OPERATION
When inflated it expands to the striking surface creating a positive

seal. When deflated it returns to its original configuration allowing
free movement of one or both surfaces.
Fabric-reinforced for strength and

structural integrity for optimum
inflation/deflating operations, they
are not subject to the compression
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Strong, versatile and flexible,
Seal Master seals have been solving
troublesome problems
for industry since 1974.
Design assistance offered
SEAL MASTER CORPORATION

Inflatable seals and other custom rubber products
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800.477.8436 330.673.8410 FAX 330.673.8242
E-mail: info@sealmaster.com www.sealmaster.com
RS# 134
RS# 133
2010 Seal Master Corporation
Hydraulics & Pneumatics
CONTINUES THE
FLUID POWER EDUCATION
MAY 1-2, 2012 LAS VEGAS

Waste collection, reduction, processing, and
recycling have been a hot industr y for years, and theres no
end in sight. So weve par tnered with Waste Expo, the largest event in the waste
management industr y, to take advantage of the many oppor tunities in this growing sector of fluid power.
UNIVERSITY OF MINNESOTA JUNE 26-27, 2012

The Twin Cities area was already one of the countr ys most active locations for fluid power, and with it
becoming the headquar ters of the Center for Compact and Efficient Fluid Power, its now a real hotbed
of fluid power technolog y, industr y, and academia. Seminar attendees, exhibitors, and sponsors will all be
able to take advantage of this rich concentration of technolog y.
R E G I S T E R O N L I N E AT :
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OEM SERVICES
Sustainability for Organizations

ULE 880 standardizes exactly
what makes a company green.
Travelers in the green sphere, those who desire products made using green or sustainable processes, have no
end of choices in standards and organizational bodies
to determine if particular products meet their definition of green. But what about the company that made
that product? Does the company operate in a sustainable fashion, or does its operations totally negate any
advantages of their green product? How do you rate the
greenosity of a manufacturer?
The folks at Underwriters Laboratories were asking
the same questions. So in late 2009, Underwriters Laboratory Environment (UL E) partnered with the GreenBiz Group to develop a way to identify and rate the sustainability of manufacturers. The result is a certification
process called ULE 880: Sustainability for Manufacturing Customers
Organizations.
Today, more than two years want to do
later, ULE 880 is entering its
first pilot programs after several business
rounds of development talks
and conferences with stake- with green
holders: individuals, companies
and organizations that possess companies.
an interest in the development
of the standard. First round
talks generated over 1,500 comments from 740 stakeholders,
the greatest number ever received for a UL standard.
ULE 880 was patterned after the Leadership in Energy
and Environmental Design (LEED) model used to establish the green rating of buildings. Developed by the U. S.
Green Building Council, LEED identifies and implements practical and measurable green building design,
construction, operations, and maintenance through a
point-based system. In similar fashion, manufacturers
seeking ULE 880 certification receive point awards based
on established auditable criteria as measured by outside
third parties. The point value is submitted to UL Environ48
MACHINE DESIGN.com
MARCH 8, 2012
ment, who issues a certificate at a level complying with the

manufacturers measured sustainability quotient.
Primarily, ULE 880 develops a uniform set of standards. This creates opportunities for manufacturers to
heighten their green credentials by being seen as operating
sustainably across a spectrum of issues.
The response to ULE 880 confirms the need for established procedures for independently auditing sustainability practices, particularly in light of increasing calls for
transparency and combined financial and sustainability
reporting. It also throws a spotlight on the growing need
for companies to face the problems of difficult social conditions and environmental degradation and directly manage these external problems.
ULE 880 distills the best thinking on organizational
sustainability into a single standard that helps companies
and their customers understand what it takes to become a
more sustainable corporate citizen.
ULE 880 architecture

ULE 880 defines five core areas of interest or domains
for manufacturers: sustainability governance; environment; workforce; customers and supplies; and community
engagement and human rights.
Sustainability governance includes strategic planning
for sustainability, board oversight, internal stakeholder engagement, ethics, and creating infrastructure and fostering
behaviors to create a culture of sustainability.
Environment covers aspects of product stewardship,
sustainable resources use, environmental management,
energy efficiency and carbon management, materials optimization, facilities and land use, habitat restoration, and
waste prevention.
Workforce includes professional development, workplace integrity, employee satisfaction and retention, workplace safety, and employee health and well being.
Customers and suppliers cover fair marketing practices, product safety, customer support and complaint
MARCH 2012
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s
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p
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t
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ADVANCED ANTIVIBRATION
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AIR PRESS COMBINES MUSCLE WITH PRECISION

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tool-saving, low-impact forces from 2,900
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High Strength UV
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UV18
Outstanding water/chemical resistance

Electrically insulative
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Fabco-Air, Inc.
For more information, contact
FABCO-AIR at (352) 373-3578 or
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FOR A FREE COPY, CIRCLE NUMBER
HELICAL COUPLINGS, U-JOINTS AND MACHINED SPRINGS

Helicals 28-page catalog features miniature flexible couplings, u-joints, power transmission couplings and machined springs. Couplings are available in high strength
17-4PH stainless steel or 7075-T-6 aluminum.
Quick-reference, product summary chart highlights features and technical data. Easy-touse part number builders make ordering easy.
METRIC GEAR COMPONENTS

New 528-page catalog Q420 has technical specs for 3,800+ standardized
stock metric gear components, including spur, helical and internal gears,
straight and helical racks, straight and spiral
bevel gears, worm and worm gears, ratchets,
splines and gear couplings in modules 0.5 to
10. Materials include carbon & chrome-moly
steel, brass, bronze, nylon and cast iron.
QTC Quality Transmission
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Web: www.qtcgears.com
CROSS-REFERENCED TO METAL CAM FOLLOWERS FOR EASY REPLACEMENT
DEUBLIN ROTATING UNION CATALOG AVAILABLE
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well in subzero temperatures (-40F). For load ratings and sizes go to www.intechpower.com/icam.
Deublin, the leading manufacturer of rotating unions,has a new, updated 56-page catalog that
includes complete information for selecting unions for a variety of applications, from water and
steam, to air and hydraulic, oil and coolant. Both operating data and dimensional specifications are provided in one comprehensive catalog, along
with installation and service information. This reference catalog provides detailed information on over 50
application categories and over 500 models. The catalog is available free via reader response, phone or email.
Deublin Company
Intech Corp.
2050 Norman Drive West

Waukegan, IL 60085
Phone: (847) 689-8600
E-mail: info@deublin.com
Web: www.deublin.com
250 Herbert Ave., Closter, NJ 07624

(201) 767-8066
Fax: (201) 767-7797
Web: www.intechpower.com
MINITURE THREADED CHECK VALVES

An economy line of check valves and checked orifices which can be installed
JOGFNBMFUISFBETJOTJ[FT tBOEt$PNQBSBCMF
metric sizes are M3.5, M5, M6 and M8. Valves
are available in all metal construction, brass or
stainless steel or also with resilient seating Buna
N or Viton.
6/32 10/32 1/420

5/1618
CATALOG TCV-1
OKeefe Controls Co.

(800) 533-3285
Email: sa@okcc.com
Web: www.okccbo.com
ACE STAINLESS INDUSTRIAL SHOCK

ABSORBERS FOR LONG LIFE APPLICATIONS
Made of V4A high quality stainless steel for long life and extreme environment applications. The ACE PMC Series includes a Teflon bellows
cap that protects against damaging environmental
agents. Ideal for packaging, food processing, medical, marine and more. Energy capacities from 175 to
30,000 in. lbs/cycle (20 to 3,400 Nm/cycle).
ACE Controls Inc.
Floyd Bell Inc
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Email: shocks@acecontrols.com
Web: www.acecontrols.com
AUDIOLARM II PIEZOELECTRIC ALARMS

The industrys largest selection of piezoelectric whoops, warbles, sirens, beeps and more. Available in variety of voltages and output up to
103dB! Rugged panel mount products are
IP68 and NEMA 4X when used with optional gasket. ISO 9001:2000 registered
company all products made in the USA.
(614) 294-4000
Fax: (614) 291-0823
Email: sales@oydbell.com
Web: www.oydbell.com
13
SEAL CATALOG
TURBO MINIATURE PIEZOELECTRIC ALARMS
The 2012 Seal Catalog contains over 600 pages of inch and metric cylinder repair seals in the most popular
styles. The easy to use format quickly enables you to locate u-seals, piston seals, wear rings, wipers, o-rings,
piston rings, buffer rings and much more. Each listing includes seal material, temperature, pressure specifications and a cross-sectional drawing. A color index has been added
with enlarged profiles for ease of identification. A Custom Seal
section is available in the front of the Seal Catalog, with a choice
of piston, rod or rotary seals, along with wiper, guide or gasket/
backUp rings. Custom orders placed before 3pm (Eastern Time)
ship the same day. Technical and drawing assistance is available
free of charge through the Hercules Engineering Department.
Tiny (approx.1x1) piezoelectric alarms provide LOUD output with a supersleek design. Available in variety of voltages and output up to 103dB! Rugged, tamper-proof, lo-profile panel mount
design is IP68 and NEMA 4X. Optional
manual volume control offers increased attenuation. ISO 9001:2000 registered company all products made in the USA.
Hercules Sealing Products

Clearwater, Fl
(888) 525-0094
Fax: (800) 759-6391
Online Ordering Available Now:
www.HerculesUS.com
Floyd Bell Inc

(614) 294-4000
Fax: (614) 291-0823
10
14
ULTRA LOUD PIEZOELECTRIC ALARMS

FOR A GREEN FUTURE
All Metric Small Parts, a division of Designatronics, Inc., has announced the availability
of a NEW 512 page catalog titled M100. The
catalog features over 5,600 RoHS compliant, Metric components. The products detailed include: Handles, Handwheels, Cranks,
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Floyd Bell Inc
Request your FREE copy today.
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Fax: (614) 291-0823
ALL METRIC SMALL PARTS

New Hyde Park, NY
516-302-0152, FAX: 516-302-0153
Web: www.allmetricsmallparts.com
Ultra Loud selection of piezoelectric whoops, warbles, sirens, beeps and

more offers 100Hz lower frequency than industry counterparts. Available
in variety of voltages and output up to
108dB! Rugged panel mount products are
IP68 and NEMA 4X when used with optional gasket ISO 9001:2000 registered
company all products made in the USA.
11
15
ADVANCED CERAMIC SOLUTIONS
TURBO LIGHT WATERPROOF LED PANEL INDICATORS
Astro Mets unique advanced ceramics provide cost effective solutions to material
performance problems in a wide range of demanding applications. Amalox 68 a
99.8% alumina ceramic and Amzirox 86 an yttria
stabilized zirconia provide superior wear resistance,
corrosion resistance, high temperature stability,
low thermal expansion, high stiffness to weight ratio, biocompatibility and high dielectric strength.
Tiny (approx.1x1) LED Panel Indicators provide BRIGHT output with supersleek design. Available in variety of voltages and output up to 14,500 cd/m2! Rugged, tamper-proof, lo-profile panel mount design is IP68 and NEMA 4X. Available in 5 colors
and 3 brightness levels. ISO 9001:2000 registered company all products made in the USA.
Astro Met, Inc.
Floyd Bell Inc
Cincinnati, OH
(513) 772-1242
Fax: (513) 772-9080
Email: fgorman@astromet.com
Web: www.astromet.com
(614) 294-4000
Fax: (614) 291-0823
12
MACHINE Design.com
16
51
ENERGY EFFICIENCY
TECHNOLOGY
Conference & Expo
SHOW PREVIEW Pg. 31

A Penton Publication
MARCH / APRIL
10
THE TECHNOLOGISTS TOOL FOR ENERGY-EFFICIENT PRODUCT DESIGN
WELL ALMOST
Super low-power circuitry

makes it possible to run remote,
hard-to-reach applications
INSIDE THIS ISSUE
Computer
simulation
gets a bigger
role in wind
power design
Pg. 14
Do energy
efcient induction
motors
always pay for
themselves?
Pg. 20
ARE YOU THE WORLDS SMARTEST DESIGN ENGINEER?
PLAY NOW TO FIND OUT AND WIN GREAT PRIZES

www.smartestdesignengineer.com
Tricky!
The difculties
of driving
high-brightness
LEDs
Pg. 36
School
is back in
Session
Designing out
electronic
failures
Page 22
A PENTON PUBLICATION
MARCH 2010
Designing in
lithium-ion
batteries
Page 25
Canopen
can do
Page 29
THE SOURCE FOR THE DESIGN AND MANUFACTURING OF MEDICAL DEVICES
Focus on
Medical
Silicones
Page 34
www.medicaldesign.com
A Penton Publication
July 2010
Page 20
Inside
Rotary actuators
take their turn
Page 24
Comparing servo to
proportional valves
Page 30
Where to place
that hydraulic lter
Page 36
w w w. h y d r a u l i c s p n e u m a t i c s . c o m
Let the Learning begin!
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machinedesign.com/dg-subs
WE WANT TO LEVEL WITH YOU
NEW SMALLEY ENGINEERING & PARTS CATALOG
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Smalley Steel Ring Company

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LEAKPROOF VALVES & FITTINGS TO 10,000 PSI
ELECTRIC CYLINDERS
CPVs product line brochure can be a valuable first step in identifying

the exact valves and fittings a particular application may require. Once
reader has identified type of product(s)
needed, the appropriate CPV catalog
with full specifications and ordering instructions can be requested at no cost.
RACO Electric Linear Cylinders with ballscrews or acme screws are an environmentally safe
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lbs., speeds to 30/second, and strokes to 20 ft. Modular system allows custom built units using the special high torque RACO actuator motor or servo and
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Request your free copy today SDP/SI 2012 Inch Master Catalog, D810, is available online
and in print, now features over 87,000 components including an entirely new section of industrial quality leveling foot mounts. Many new items
and sizes included. For fifty years, SDP/SI has been
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Sterling Instrument
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Phone: (800) 819-8900
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Fabco-Air, Inc.
For complete information, contact
http://www.fabco-air.com
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23
ARC POWER CATALOG B217

BRECOflex CO., L.L.C. offers state of-the-art polyurethane timing belts with the patented
ARC tooth design. ARC POWER timing belts are available in open ended, welded and
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ARC POWER is ideal for linear drives, conveying
and power transmission applications. Download or
order free catalogs online at www.brecoflex.com
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MACHINE Design.com
24
53
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INDEX TO ADVERTISERS
ADVERTISER. . . . . . . . .PAGE#
FLOYD BELL INCORPORATED. . 51
OKEEFE CONTROLS, INC. . . . . 50
ACE CONTROLS . . . . . . . . . . . . . 51
HELICAL PRODUCTS
COMPANY, INC. . . . . . . . 50
QUALITY TRANSMISSION
COMPONENTS. . . . . . . . 50
RACO INTERNATIONAL, L.P.. . . . 53
ALL METRIC SMALL PARTS . . . . 51
HERCULES SEALING
PRODUCTS. . . . . . . . . . . 51
ALTECH . . . . . . . . . . . . . . . . . . . . 56
IGUS, INC. . . . . . . . . . . . . . . . . . . 50
SMALLEY STEEL RING

COMPANY. . . . . . . . . . . . 53
ASTRO MET ASSOCIATES INC. . 51
INTECH TRADING CORP . . . . . . 50
STOCK DRIVE PRODUCTS. . . . . 53
BRECOFLEX CO LLC . . . . . . . . . 53
MASTER BOND, INC. . . . . . . . . . 50
TRIM-LOK INC. . . . . . . . . . . . . . . 53
ADVANCED ANTIVIBRATION
COMPONENTS. . . . . . . . 53
CPV MFG. INC. . . . . . . . . . . . . . . 53

DEUBLIN COMPANY. . . . . . . . . . 50
FABCO AIR, INC. . . . . . . . . . . . . . 50
FABCO AIR, INC. . . . . . . . . . . . . . 53
To receive the catalogs or brochures described in this

issue of Machine Designs Literature Express, simply
circle the inquiry number on the Reader Service Card and
mail or go to http://www.machinedesign.com/rsc
While every effort has been made to ensure the accuracy of this index,
the publisher cannot be held responsible for any errors or omissions.

56
MACHINE Design.com
MARCH 8, 2012
25
Authored by:
resolution, and sustainable supply-chain manAssociate Editor

agement, monitoring, and
robert.repas@penton.com
improvement.
Key points:
Finally, community en ULE 880 sets compliance
gagement and humanstandards in sustainability for
rights involves a community
manufacturers.
impact assessment, commu The standard breaks down into
nity investment, and human
five domains with a total of 100
rights issues for members of
indicators and 1,000 points.
the community.
Companies well on their way to
E ach domain bre a ks
green certification may only score
down into a series of prereq200 of the 1,000 total points.
uisites, core indicators, and
Resources:
leadership indicators. OverGreenBiz Group, www.
all, the standard includes
greenbizgroup.com
seven prerequisites, 19 core
indicators that can award up
UL Environment, www.
ulenvironment.com
to 159 points, and 74 leadership indicators with 841
U. S. Green Building Council,
points available. The core
www.usgbc.org
and leadership indicators are
weighted with a point value
based on whats currently happening in the manufacturing
sector, what are considered best practices, and how much
effort it takes to accomplish this indicator. All items are
factored in and a point value is assigned to each indicator
for a total of 1,000 possible points across the entire standard. In addition, there are 25 innovation indicators that
recognize performance beyond these requirements that
can add to the overall score.
An applicant for ULE 880 certification must first meet
all seven prerequisites. Then the company must score a
specified minimum number of points in all 19 core indicators across every domain before they are considered for
certification. Earlier work with other standards showed
companies could score big in one area while not scoring at
all in other areas and still obtain certification. By demanding a minimum score in all core indicators, companies are
forced to acknowledge that area in their operations.
Though a business must possess points in each core
area, it need not and likely wont receive all of the available
points in any individual core item. Points are designed to
be attainable but aspirational, meaning a company must
possess exceptional practices to reach those higher point
values. In addition, the leadership core states that the company must earn points beyond the core competencies
for certification, especially if it wishes for recognition at
higher levels. A company well on its way to green certification may score only 200 points or so of the 1,000 points
available.
Businesses may gain an additional 25 points by submitting achievements for consideration in areas such as
inventories and baselines, policy and procedures, performance, and reporting. For example, analysis of a companys inventories and production baselines measures system
performance using collected data. The company must outline the method by which the data is collected, and what
Robert Repas
Employees and
job seekers
want to work
for companies
that are part
of the solution
not part of the
problem.
steps are taken to assure

its continued collection
and maintenance over
time. Operational processes and norms must be
specified.
Once certified, a company may not rest on its
laurels. It must set specific
goals for the coming years
with measured progress
against each goal. Recertification demands an audit each year of company
performance to meet
these future goals. Meeting these performance indicators
shows demonstrated improvement against the previously
established goals, establishes new goals for the future, and
verifies future performance against the new goals.
Why seek ULE 880 certification?

Aside from the bragging rights of certification, ULE
880 validates manufacturers sustainability achievements.
There are customers and businesses that want to do business with green companies. In fact, many marketing
and shopping groups are putting pressure on suppliers to
improve their products by taking proactive sustainability measures. Some employees and job seekers also want
to work for companies they see as part of the solution
rather than part of the problem. And some investors
want audited data to assess risks and opportunities associated with sustainability.
With the start of the pilot program, a training program
for auditors is under development called the Sustainability
Quotient (SQ) Program. UL Environment will be the only
certifying agency, but auditing companies for certification
will be handled by third parties. Audit results will be submitted to UL for examination.
Companies that reach ULE 880 certification can display a trademark identifying them as meeting ULE 880
goals with the tier level theyve attained. However, they can
not display that trademark on any of their products, as this
is not a product-based standard. Proper use involves overall organization materials such as Web sites, shareholder
reports, and other company-wide marketing materials.
There is one caveat for companies seeking certification.
There is a legacy requirement built in that covers how the
company acted and reacted to past environmental transgressions. For example, a large petroleum company would
have trouble qualifying for green certification if they had
a major oil spill from an offshore drilling accident in their
history. However, it is possible to overcome prior legacy
events based on actions taken during the spill, follow-up
responses, and continuing high levels of green activities.
ULE 880 is only the first green standard for organizations. Getting ready to take center stage is ULE 881, a sustainability standard that targets companies in the service
sector. MD
MARCH 8, 2012
MACHINE DESIGN.com
57
Not
your fathers
Even less-expensive oscilloscopes

provide data in a variety of formats
once available only from top-ofthe-line instruments.
OSCILLOSCOPE
Like most technologies,

oscilloscopes have evolved
over time. Digital-storage
oscilloscopes, or DSOs,
are now the preferred type
for most industrial applications. And features that
once were available only on
expensive, premium DSOs
are now becoming commonplace on even nonWindows scopes that
start in the $2,000 range.
Upgradable bandwidth,
deep memory, large displays, and fast update rates
are just a few examples. In
the past, only higher-end
oscilloscopes have offered
Oscilloscope display via iPad: Today VNC clients can be used to control
features such as Ethernet
Windows-based oscilloscopes via mobile platforms such as the iPad.
and USB connections.
Less-expensive offerings
have gone beyond floppydrive storage and GPIB programming.
enable this connection, you connect a USB cable between
New connectivity options have started to trickle down
a USB Host port on a PC and the USB Device port on the
to less-expensive oscilloscopes. In almost all cases, USB
oscilloscope.
has replaced floppy drives as the de facto connection
A USB Device connection typically involves some sort
on oscilloscopes. Now to save a screen or data file, usof driver library. Scopes from Agilent Technologies Inc.,
ers simply insert a USB thumb drive into a connection
Santa Clara, Calif., for example, use an IO Library, which
typically referred to as a USB Host. Some oscilloscopes
includes a connection expert program to assist with setting
today can support USB thumb drives up to 128 Gbytes
up the link to the scope. With the connection established,
of storage. In addition to USB Host connections, many
remote commands can control the oscilloscope.
oscilloscopes now have USB Device connections. Instead
of being used to connect thumb drives, these connecEthernet connectivity
tions permit remote control of oscilloscopes via USB. To
While USB connectivity has been relatively common
58
MACHINE DESIGN.com
MARCH 8, 2012
A scope save/recall
screen. Via a remoteuser interface, users
can save and recall
setups directly from
a PC. Also savable to
a PC are images, data
sets, and even masks.
in scopes for some time, Ethernet

connectivity, particularly on lessexpensive, non-Windows scopes,
is fairly new. Users can remotely
control a scope over Ethernet and
even hook the instrument to network-based printers. And a new
type of Ethernet connectivity,
called LAN eXtensions for Instruments (LXI), provides an entirely
new way to interact with such test
equipment.
There are many differences
between LXI and the earlier GPIB
standard which permitted the
remote programming of instruments. LXI uses standard computer IO as the communication
method. The LXI standard also
defines a standard framework for
Web-based interfacing and programmic control. In addition, the
LXI interface supports peer-to-peer
and master/slave communication and
distributed systems other the LAN.
And because LXI is based on Ethernet,
designers can get better communication throughput as Ethernet speeds
rise from 10 to 100 Mbytes/sec and
1 Gbyte/sec.
The first Agilent scope to have LXI
compatibility was the 80000-Series, introduced in 2006. A few months later,
LXI came to the 6000-Series of scopes
as well. LXI makes it easy to configure
Ordinary Web browsers

can now access
oscilloscopes that have
built-in Web servers.
Authored by:
Richard Markley
Agilent Technologies Inc.
Santa Clara, Calif.
Edited by Leland Teschler
leland.teschler@penton.com
Key points:
Some scopes now include a Web server that is

hosted from the instrument. Instrument store/
recall state capabilities can be used to speed
setup of front-panel settings.
Some instruments allow their states to be
saved as files, which can then be stored
to a USB drive and loaded onto another
instrument.
Resources:
Agilent Technologies Inc., www.agilent.com
LXI consortium Web site, www.lxistandard.org
For more information
on est instruments, scan
this code or go to: http://
machinedesign.com/
article/test-instruments-intexas-1122
MARCH 8, 2012
MACHINE DESIGN.com
59
a test system and integrate other instruments into it using a variety of connectivity options (including legacy
standards like GPIB). It also has special capabilities for
interacting with the oscilloscope.
For example, LXI instruments from Agilent host
a Web server in the instrument itself. This integrated
Web page gives users several conveniences. For example, it identifies oscilloscope information, like the
model number, serial number, host name, IP address,
and VISA (address) connection string. It also implements a front panel through which a user can control
the scope remotely. In addition, the instrument can
store and recall its settings. Some instruments allow
the state to be saved as a file, which can then be put on
a USB drive and loaded into another instrument. There
is also an ability to send SCPI (Standard Commands for
Programmable Instrumentation) via an applet window.
60
MACHINE DESIGN.com
MARCH 8, 2012
LXI lets a PC interact with the instrument in tasks

such as saving/recalling setups and waveform data (in
multiple formats). Its also possible to capture screen images on the PC for easy addition to documents. Another
convenience is the ability to have a message flashed on
the instrument to identify it helpful when you want
to identify the scope as it sits in a large rack of scopes.
Finally, LXI provides an opportunity to remotely install
firmware upgrades.
Similarly, LXI-based instruments can be controlled
via a remote front panel displayed on a PC. Today, remote front panels are strictly for PCs. The feature wont
work natively on an iPad or iPhone, although some virtual-network computing (VNC) clients can be used to
see and control the remote front-panel interface of Windows-based oscilloscopes. The remote front panel recreates all the oscilloscope functions. Some oscilloscopes,
A virtual oscilloscope front panel. Through this remote-control interface, the

oscilloscope front panel is reproduced exactly, allowing someone familiar with
the panel to begin using it immediately. Virtual front panels are also useful for
training and collaboration across multiple sites.
A basic remote front panel.

The more compact the
display, the more suited it
is for use on low-resolution
displays and/or where a
mouse is the preferred
method of control.
like the Agilent InfiniiVision X-Series, allow use of either

a simplified, basic remote front panel or a remote front
panel that exactly recreates the physical oscilloscope
front panel.
The basic remote front panel is useful for remote control on a PC that has limited screen resolution in that it
takes up a smaller area. It is also more suited to being
driven by a mouse than a finger.
A full-blown remote front panel is useful for someone
who frequently operates the scope both directly and remotely theres no difference between the two operating
modes. In addition, the remote front panel can work via a
touchscreen PC rather than depending on mouse clicks.
A remote oscilloscope front panel is particularly helpful for training and education. For example, when bringing up a new production line or getting a group of engineers up to speed on instrument functions, all users
within the same firewall can log in to the scope and see
the actual front panel they will encounter when they receive their new scopes. They can practice on the remote
panel, learn how to interact with the scope, and immediately feel comfortable when their new lab is up and
running.
Similarly, remote operation is helpful for teaching institutions where access to a scope is limited. Of course,
multiple operators cant operate the scope at the same
time, but a remote control is extremely useful for minimally equipped labs where sharing is the norm.
A remote front panel also comes in handy when debugging involves multiple teams spread out geographically. A team of engineers in another lab can see the scope
display and settings as engineers on site demonstrate the
problem. MD
MARCH 8, 2012
MACHINE DESIGN.com
61
CAD TECHNOLOGY GUIDE

Edited by Leslie Gordon
Whats hot in
CAD
Synchronous technology can move

between history-based and direct
modeling. The next step in realistic CAD
stereoscopic design? ... And more.
Synchronous technology
sheds light on surgical laser design
Energist Group in Nyack, N. Y., recently moved from
several different CAD packages to standardize on one.
The intent was to improve the design and manufacture
of its surgical lasers and light-based devices for hairremoval and skin treatments. The company found that
using multiple packages tended to bottleneck designs,
which raised costs, lowered quality, and increased time
to market. Theses issues were critical because Energist
was increasingly competing against firms that did not
comply with ISO, FDA, or Health Canada standards. The
firms inexpensive, unapproved products were hurting
Energists bottom line.
The company turned to Solid Edge 3D CAD from
Siemens PLM Software, Plano, Tex., which came as a suite
that included part, assembly, and sheet-metal modeling, as
well as drafting, simulation, and piping design.
Energist devices contain anywhere from 76 to 3,500 parts,
and some components and assemblies are provided by outside suppliers. Energist Chief Technical Officer Andrew
Thomas estimates that the companys designers use Solid
Edges synchronous technology for about 95% of the design
process. (The remaining 5% is piping and wire-harness design). Synchronous technology lets users easily move between constraint-driven and history-free modeling.
Not only is it easier to design parts and assemblies
from scratch using synchronous technology, another important advantage is how quickly we can process engineer62
MACHINE DESIGN.com
MARCH 8, 2012
ing change orders (ECOs). And it doesnt matter whether

the design was done using Solid Edge or a third-party CAD
package, says Thomas. For example, when we needed to
reduce the size of a cooler, it took only 2 hours to relocate
the internal parts and assemblies using Solid Edge. Drawings and STEP files were distributed to manufacturing the
same day. Making a change like that would have taken a
few days previously.
In another example, the company needed to quickly
create a prototype of a component that had originally been
modeled in another CAD package. The original file had
two design errors a missing surface and an overlapping edge, says Thomas. Without synchronous technology, we would have had to understand the history of how
that piece was created. Even then, the changes would have
been difficult to make. In fact, some individuals thought
we would have to remodel the part. But it only took a few
minutes to import the file and fix the errors.
Energist also uses Solid Edge simulation capabilities
to quickly evaluate real-world performance issues such as
how a temperature drop from ambient to 37.4F will affect
the material in a hand piece. According to Thomas, answering such questions using software eliminated the need
for at least one physical prototype for this design.
The combination of faster ECOs and fewer physical
prototypes lets us get new products to market in only three
months. Previously, it took 19 months, says Thomas. MD
Solid Edge with

synchronous
technology made
it simple and
quick to import
a file from a
different CAD
package and
fix two surface
design errors
on this medicaldevice housing.
Resources:
Energist Group, www.
energistgroup.com
RS# 621
Siemens PLM
Software, www.
siemens.com/solidedge
RS# 622
r
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ww w.machine
Stereoscopic designs
look like real objects
zSpace uses a proprietary stereoscopic display, trackable
eyewear, a new type of direct-interaction stylus, and software that lets designers see solid models as if they were in
open space. The full color and high-resolution models can
be directly manipulated. The technology gives users a natural way to navigate, grab, slice, carve, zoom, and explore
models. The immersive zSpace lets users interact with 3D
applications just as naturally and intuitively
as they would with real physical objects.
zSpace can enhance and improve user
workflows by letting designers and
engineers represent their ideas more
effectively and realistically than
possible with todays 2D displays.
Resources:
Infinite Z Inc., 375 Ravendale
Dr., Mountain View, CA
94043, (877) 977-2231,
www.zspace.com
RS# 623
63
The best way to learn 3D modeling?

Dont focus on the software
At least, at first. Thats
part of the philosophy at a
new instructional site that
emphasizes the broader
concepts of 3D graphics
before delving into the
dashboard of a particular
CAD application.
People just starting
out in 3D modeling are
forced to wrap their brains
around a lot of unfamiliar concepts, says the author of the PolyPlane instructional video series
Gabriel Mathews. At the
outset, stepping back and
understanding the process of modeling in general actually makes learning an application a lot less
frustrating.
The first series of free videos at PolyPlane.com
called Preflight gives the overall lay of the land (or
grid, in this case) for students before they even get into the
cockpit of a modeling application. Each 3 to 4-min lesson
focuses on a basic concept in the problem of generating 3D
geometry.
We try to build an overall framework of modeling
for the newcomer. We dont want to just define a term
but show why its important and how it works in the big
picture, says Mathews. Once users have the big picture,
it makes it much easier to take command of the software
when they finally approach it, because they know what to
look for. A short time on PolyPlane lets users pick up any
kind of modeling application.
Applications can include engineering packages such as
SolidWorks or Pro/Engineer, curvilinear Nurbs-based applications like Rhinoceros or Alias, or tools for animators
and artists like 3DStudio Max, Blender, or Maya. Knowing
more about the basic tenets of 3D can also help students
make smart choices about which software is most in line
with their interests, Mathews says.
Mathews says there are dozens of other sites with modeling tips as well as tutorials put out by software developers, but he finds that too often they expect the viewer to
already have a background familiarity that amateurs usually lack.
Usually tutorials are about 45 min long and loaded
with acronyms and technical jargon, says Mathews. An
amateur is not going to know what a UVW map is. Its discouraging to slog through a long tutorial and only grasp
64
MACHINE DESIGN.com
MARCH 8, 2012
50% of it, And if the instruction is too centered on the

software of a particular brand, it also tends to assume the
viewer has a working knowledge of modeling already.
In contrast, each short PolyPlane video explains in
simple terms and clear illustrations another piece of the
puzzle. Visitors to the Preflight Series are said to be able to
accumulate a solid background of the principals in a few
spare moments during the week, without opening up a
modeler app.
A lot of modeling is problem solving, more of a mental maneuver, like how to break up the object you want
to make into more basic geometry, for instance. says
Mathews. The modeler is not going to do this for users.
Its something they learn to visualize.
Each video imparts more know-how such as why Nurbs
are important or why it matters how you set up an origin
point a particular way. As users get into modeling the rules
of thumb eventually become second nature. In starting
out, these rules often become the roadblocks to understanding the software.
Learning by doing eventually is part of the ride, too.
PolyPlane has longer 2-hr Series, called Sketch-to-Model,
which put the basics to work in a practical, step-by-step
modeling project. Here it helps to follow along in a modeling application, Mathews says, but it doesnt much matter
which application.
PolyPlane plans new free videos every week throughout 2012 including more advanced projects and other
design resources for the beginner. Check out other video
lessons at www.polyplane.com. MD
SolidWorks is a registered trademark of Dassault Systmes. 2012 Dassault Systmes. All rights reserved.
THE HOT ROD

BABY BUGGY
IS ROAD READY
PRO J E CT O F LE TS GO DE SIG N
In this interactive web series, SolidWorks brings together CAD fanatics from
around the world to collaborate on innovative design projects. With their help, our
host Jeremy Luchini successfully designed the rst hardcore baby buggy for dads.
Watch its development from design to build - and how SolidWorks was used to
bring ideas, comments and your votes to life at LetsGoDesign.tv
RS# 135
Simulation software helps build

amphibious vehicle for Arctic-oil facilities
Arktos Developments Ltd. (ADL),
Surrey, B. C., Canada, the designer
and manufacturer of an amphibious
vehicle known as the Arktos Craft,
uses simulation software to prepare its vehicles to operate in some
of the worlds most environmentally
demanding locations. Originally
designed as an amphibious evacuation
craft for Arctic offshore oil facilities,
the Arktos Craft can move from frigid
50C (122F) temperatures through
burning flames, and back again, as
in the case of evacuating a burning
oil rig. Additionally, the Arktos Craft
can easily navigate ice-rubble fields,
ice ridges and open water and
can even climb up or down vertical
steps making the Arktos a highly
capable exploration craft. Autodesk
Simulation from Autodesk Inc., San
Rafael, Calif., provided the mechanical simulation software.
Valmont West Coast
Resources:
Engineering (Valmont),
Arktos Developments Ltd.,
D elt a, B. C., C anada,
which provides finite-ele- www.arktoscraft.com
Autodesk Inc., http://usa.
ment-analysis (FEA) serautodesk.com
vices to ADL, was responby temperature extremes would
RS# 624
sible for predicting vehicle
combine with mechanical stress
Valmont West Coast
performance in severe enin the articulated arm. AddiEngineering, www.wceng.com
vironments. We used Autionally, the arm would see retodesk Simulation to prepeated compressive and tensile
dict critical stresses for the
loading so Valmont also anaArktos at extreme temperatures and loading
lyzed fatigue life using the Autodesk Simulaconditions, says engineer Ioan Giosan at
tion multiphysics tools.
Valmont. After finding an optimal design
We continue to modify the original
using FEA methods, we relied on physical
Arktos design for each of our new customers
testing and field use to validate the accuracy
special needs, says ADL President Bruce Seof our results.
ligman. Autodesk software makes it easy for
The key to the Arktos Crafts mobility is
us to design new attachments for the craft,
an articulated arm between the vessels two
and then simulate how those modifications
main compartments. As the craft climbs up
will affect performance. Sharing early cononto an ice shelf from the water, the hydraucepts and results with stakeholders digitally
lics in the arm help push the front unit of
is a critical part of our development workthe craft out of the water so the special track
flow today and it is all powered by Autodesk
spikes can grab the ice.
software.
Using the multiphysics capabilities of
Arktos Craft units are currently operatAutodesk Simulation, Valmont could show
ing in Alaska, China, and the Caspian Sea in
ADL engineers how thermal stress caused
Kazakhstan. MD
66
MACHINE DESIGN.com
MARCH 8, 2012
The design of
the Arktos Craft
amphibious vehicle
was analyzed in
Autodesk Simulation
software.
Modeler for
organic shapes
Freeform Version 12 adds over 50 new features
and enhancements. It lets users efficiently and cost
effectively create complex models, with organic and
manually sculpted looks that cant be modeled in
Nurbs.
Highlights include faster and more-flexible deformation and roughing-out tools and a bigger toolset
for developing engineered production-ready organic
models across representational types. For example,
uses can break up polygon models for articulation,
interactively optimize mold pull direction, fix moldability problems, and develop complex parting surfaces. In addition, Version 12 lets users interoperate
between polygon models, Nurbs, and voxels.
Resources:
Sensable, 181 Ballardvale St.,

Wilmington, MA 01887,
(781) 937-8315,
www.sensable.com
RS# 625
MARCH 8, 2012
MACHINE DESIGN.com
67
FE UPDATE
The role of parametric CFD analysis in design

Fluid dynamics is one of the primary engineering sciences used to
design a wide variety of vehicles,
machines, and other devices. In
the past, fluid-dynamic analysis
was fairly simple, using empirical
formulas from engineering handbooks or other simplified analysis
techniques. However, as computer
power becomes less expensive,
fluid-dynamic analysis is shifting
toward more-complex, powerful
computational-fluid-dynamics
(CFD) techniques.
A low-cost, rapid way to analyze performance and optimize
designs comes from what is called
parametric CFD analysis. It includes five steps: problem definition, dimensional reduction, experimental design, management
of CFD simulations, and metadata
analysis. The metadata analysis
stage may also include surrogate
modeling, visualization, optimization, and sensitivity analysis.
Consider an aerodynamic design that entails placing vortex
generators (VG) on the wing of a
commercial airliner. VGs are typically added to correct undesirable
flight attributes such as low-speed
instability or too-little control. Even
minor changes to an aerodynamic
configuration such as this can

significantly harm the aircrafts handling and, thus, necessitate complex analysis. Engineers mastering
the five stages of parametric CFD
analysis better understand how
the device behaves and, therefore,
produce better designs. Here is an
example of using the five steps of
parametric CFD analysis.
Problem definition. For all
designs, engineers must define
requirements for the system, component, or process. For machines,
requirements include the operating envelope of the equipment,
which defines the range of conditions over which the device must
operate safely.
In the case of commercial airliners, the operating envelope is the
range of all parameters at which
the aircraft may safely fly. Among
the requirements for an airliner are
that it be efficient and safe. Aircraft
designers extensively test designs
to meet these requirements using CFD simulations, wind-tunnel
tests, and flight tests.
Undesirable flight attributes
often arise because of a boundarylayer separation on the wing
surfaces. This occurs when the
boundary layer, a thin layer of
slow-moving air caused by friction

near the surface, separates from
the surface of the wing. Due to
the wing sweep, boundary-layer
separation on the outer portion
of the wing is a common problem
on commercial jets. VGs circulate
high-energy flow into the boundary layer, suppressing boundarylayer separation and mitigating
the problems.
While common, vortex generators are actually an aerodynamic
compromise. They delay the onset
of boundary-layer separation, but
Authored by:
Scott Imlay
Chief Technology Officer
Tecplot Inc.
Bellevue, Wash.
Resources:
Tecplot Inc., www.tecplot.com
Edited by Leslie Gordon, leslie.gordon@
penton.com, Twitter @LeslieGordon
Scan this code for another feature on
computational fluid
dynamics (CFD), or go to:
http://machinedesign.
com/article/cfd-revealsless-work-1122
VGs are placed along part of the

wing of a commercial aircraft.
Photo by Fred Hall Photos
68
MACHINE DESIGN.com
MARCH 8, 2012
also increase parasitic

wing drag. Increasing drag
reduces fuel efficiency, so
aerodynamicists are careful about when and where
they use VGs.
So where to place
them? Obviously, aerodynamicists must test a
wide variety of locations.
Tests will likely focus on
the landing configurations
and high angle-of-attack
regions where boundarylayer separation happens.
However, other flight
conditions and configurations cant be ignored.
For example, certain VG
distributions may work to
eliminate boundary-layer
separation at landing
configurations, but cause
more drag at cruise configuration.
Because the location of VGs alters
flight attributes and aircraft performance, engineers must evaluate
it throughout the flight envelope.
The problem is a constrained-optimization problem, which in this
case is best solved with a parametric analysis.
The placement of each VG is
defined by three parameters:
spanwise (wing root to wing tip)
location, chordwise (leading edge
to trailing edge) location, and
angle relative to the aircraft plane
of symmetry. In the example, the
wing has 21 VGs; therefore, because each VG has three degreesof-freedom (DOF), including all
the DOF would add 63 parameters
to the parametric analysis. When
added to the five flight parameters
and six (minimum) configuration
parameters, the design space has
74 dimensions quite large.
Dimensional reduction. Like
most engineering-design problems, the full problem definition
results in too many dimensions for
a reasonable parametric analysis.
Fortunately, its possible to reduce
the number of dimensions by taking advantage of previous studies
on similar devices. For example,
VGs have been used since the
The Tecplot
screenshot
shows CFD data
management
and metadata
analysis for
a high-lift
configuration.
1940s and guidelines for their use

are available in literature. These include suggested size, spacing, and
angle of the vortex generators. The
chordwise position is more problem-dependent and thus allowed
to vary in the parametric study.
This brings the number of dimensions down to 21 VGs, and 32 overall, still a large design space.
To further reduce the number
of DOF, use analytical distributions
for the chordwise position of the
VGs. The outer five VGs are in a
straight line at a constant chordwise position one DOF instead
of five. The chordwise positions of
the inner 16 VGs could be approximated by a quadratic equation resulting in three DOF instead of 16.
The upshot is a total of four DOF,
which, when added to the 11 flight
and configuration parameters, results in a total of 15 dimensions.
Experimental design. In this
context, experimental design
refers to the set of cases that the
CFD code will run. The cases are
selected to efficiently span the design space, with the goal of minimizing drag at cruise while retaining stability and control throughout the operating envelope.
High-resolution CFD solutions of
full aircraft configurations espeMARCH 8, 2012
cially landing configurations are

expensive, so the number of cases
is limited. A space-filling design
such as Latin hypercube (a statistical method), or one of its optimal
variants, would probably be used
to ensure coverage of the full
range of each parameter.
For 15 dimensions, even a small
parametric study would likely include hundreds of runs. Each run
generates a large amount of 3D
field data in addition to metadata
results. Ideally, the 3D data is kept
to verify solution quality and investigate the underlying cause of
anomalies in the metadata
Management of CFD simulations. A key requirement for
high-quality CFD solutions is that
the grid-spacing be fine enough
to resolve the dominant flow
features. Ideally, a sufficiently fine
grid would be used to resolve all
of these flow features to a high degree, but there are seldom enough
computing resources to do this.
Also, certain subgrid quantities,
such as turbulence, are modeled,
so no model is ideal for all flows.
For this reason, CFD experts must
evaluate the results to ensure assumptions arent violated.
The analysis of VG placements
strain the current capabilities of
MACHINE DESIGN.com
69
FE UPDATE
CFD simulations.
When the simulaHow vortex generators aect boundary-layer separation
tion calculates the
vertical flows, a fine
Before VGs
grid is needed in
the spanwise direction. Normally, the
boundary layer is
resolved using a fine
Boundary layer
Wing
Smooth
wall-normal grid and
begins
to
separate
stalls
airow
the grid spacing in
After
VGs
the spanwise direction. The streamwise
directions are left
coarse, reducing
the number of grid
Boundary
Vortex
points. Near the VG,
Boundary layer
layer remains
airow
the grid must also be
energized by vortices
attached
refined in all three
directions. When the
velocity field in 21
streamwise vortices
must be resolved, the number of
point in parametric space and rethe parametric space, or create an
grid points gets large, making the
turns a set of dependent variables.
iso-surface plot of any variable in
CFD simulations time consuming.
The surrogate model is an apany 3D subspace of the parametric
A CFD expert must verify that
proximation of the values that are
space. Using these visualizations,
the fine grid is properly placed
obtained by running the CFD code
users can recognize relationships
to compute the vortices. Finally,
at that point in parametric space
between variables and identify
there have been efforts to reduce
and runs much faster.
local minima and maxima in the
the number of grid points by modSurrogate models take a wide
subspaces.
eling the vortex-generator geomevariety of forms. This aircraft wing
A common concern in engitry as a step-function in secondary
example is a polynomial in 15
neering design is how sensitive
velocities a subgrid effect. This
dimensions. If it were a quadratic
the device is to changes in the
allows a comparatively coarse grid
response surface, a second-order
independent parameters. More
in the streamwise direction and
polynomial with cross terms, it
specifically, it would be helpful to
reduces the computer resources
would have 136 terms. To use this
know the leverage of each inderequired for the CFD simulations.
model, the experimental design
pendent variable on the changes
Ideally, the tools used to manmust contain at least 136 cases.
in each dependent variable. Using
age the parametric data make it
Higher-order response-surface
a surrogate model, it is relatively
easy to verify the quality of the
models, like fourth-order modstraightforward to estimate the
CFD solutions. The metadata and
els, are also common but have
sensitivity or perform an analysis
links to 3D field data files get
far more terms and require more
of variance (ANOVA).
stored in a database. A graphical
cases.
Mastering CFD for engineerfront-end to the database simpliSurrogate models allow the
ing design. Parametric CFD analyfies the access to the data, perhaps
visualization of metadata even
sis has been shown to play a cruthrough clicking on scatter symwhen the experimental design has
cial role in the engineering design
bols representing individual cases
cases widely dispersed throughof fluid-dynamic devices. Without
or data in tables. This practice
out the highly dimensional space.
it, engineering methods can be
allows rapid evaluation of a flow
The surrogate model effectively
costly and time consuming. By the
field and grid to look for potential
fills the empty space between
time a project is complete, there
quality issues.
cases with an approximation of
could already by a more-efficient
Metadata analysis. The efthe true data. The surrogate model
way to utilize the device. An unfectiveness of the VGs is evalulets users create XY plots of the
derstanding of the five stages of
relationship between metadata
parametric CFD analysis gives usated through metadata analysis.
variables along any line through
ers a better understanding of how
The first step in analyzing the
parametric space. Likewise, its
a device behaves over its entire
metadata is to create a surrogate
possible to create contour plots
operating envelope and quickly
model. Like the CFD code itself,
of any variable along any plane in
produces better designs. MD
the surrogate model inputs the
70
MACHINE DESIGN.com
MARCH 8, 2012
SPOTLIGHT CYLINDERS
& VALVES
SafetyMixing/diverting
shutoff valve ball valve
The E828 hazardous-location
safety-shutdown valve is designed specifically for broad
temperature ranges. The automatic safety-shutoff solenoid
valves are suited for heating
equipment, furnaces, ovens,
kilns, boilers, gas generators, incinerators, flare stacks, oil batteries,
tank heaters, and line heaters.
Features include a wide operating temperature range of 40 to 65C; low power
draw of 1.8 W, three voltages 12 and 24 Vdc
and 120 V/60 Hz ac; operating pressure differential of 3 to 30 psi; and tough 316 stainlesssteel construction.
Three high-flow-capacity sizes are available:
-in. NPT 5.8 Cv (3,375,000 Btu/hr capacity);
1-in. NPT 13 Cv (7,575,000 Btu/hr capacity);
and 1-in. NPT 29 Cv (16,875,000 Btu/hr
capacity.
Peter Paul Electronics Co Inc., 480 John
Downey Dr., Box 1180, New Britain, CT 06050,
(860) 229-4884, www.peterpaul.com
RS# 446
Allstainless
cylinders
The All Stainless Original Line Series of cylinders has been expanded to offer 12 bore
sizes 5/16 through 3-in. bore. The nonrepairable actuators feature stainless-steel end
caps, urethane wipers, PTFE-based rod and
pivot bushings, and food-grade synthetic
grease.
Bimba Manufacturing, 25150 S. Governors
Highway, University Park, IL 60484, (708) 5348544, www.bimba.com
RS# 447
r
formation via ou
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Reader Serv
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design.com/rs
ww w.machine
A three-way mixing/diverting
ball valve has a common inlet
port that can be open to
flow with the outlet ports
either individually, for diverting service, or simultaneously, for mixing applications. The miniature ball valve
is made in 303 or 316 stainless
steels, with a variety of available
seal materials. It has excellent corrosion resistance and fluid/temperatures compatibility.
Beswick Engineering Co. Inc., 284 Ocean Rd., Greenland, NH
03840, (800) 354.5014, www.beswick.com
RS# 448
Steam valves
A new range of steam valves with interchangeable coils consists of two valves: the EV215B and EV225B. The valves are
constructed of dezincification-resistant brass, with a floating
polymer disc and a stainless-steel seat, making the valve
bodies extremely resilient.
Users can attach one of three different coils, designed to
cope with temperatures to 140, 160, or 185C. The coils are
clip-on for quick and easy mounting. With an IP65 rating, the
coils resist to aggressive steam and impurities.
The dirt-resistant EV225B is for heating water in
laundry machines and dishwashers. The EV215Bs highpressure resistance makes it suitable for steam-injection applications, such as flat irons and dryers. Both
valves are
suitable for
autoclaves
and steam
sterilizers.
Danfoss
Industrial
Automation, 11655
Crossroads
Circle, Baltimore, MD
21220, (410)
933-6009,
www.danfoss.us/ia
RS# 449
MARCH 8, 2012
MACHINE DESIGN.com
71
SPOTLIGHT CYLINDERS
& VALVES
Valve terminal
The VTUB-12 lightweight valve terminal is designed for localized machinemounted applications. The Series is capable of flowing up to 400 lpm
or 14 scfm with a maximum pressure of 8 bar or 120 psi.
Constructed with a lightweight, high-performance engineered
polymer, the valves are mounted on a durable aluminum profile
that is also lightweight. The valve terminal is available as a multipin
electrical connection; as many as 35 valves can be installed on one
terminal with its single screw and hook method. Available connection
cables allow up to a 10-m separation between the controller and the valve.
Festo, 395 Moreland Rd., Hauppauge, NY 11788, (800) 993-3786, www.festo.com/us
RS# 450
Stepper-controlled
proportional valve
The high-flow stepper-controlled two-way proportional valve features a
bonded elastomeric seat that provides above-average sealing and fine control
at low flow for millions of cycles. Additional features include 2% hysteresis,
2.5% of full scale linearity, 2-msec reaction time, and a 0 to 300-slpm flow range.
Clippard Instrument Laboratory Inc., 7390 Colerain Ave., Cincinnati, OH
45239, (513) 521-4261, www.clippard.com/scpv-m
RS# 451
GRAPHALLOY
BEARINGS CAN
TAKE THE HEAT.
HANDLE HIGH TEMPERATURE AND HARSH

OPERATING CONDITIONS WITH EASE
GRAPHALLOY bushings,
bearings and components:
Survive when others fail
Run hot, cold, wet or dry
Excel at -450F to 1000F
Corrosion resistant
Self-lubricating
Non-galling
Low maintenance
Ovens, dryers, pumps, valves,
turbines, mixers, conveyors
GRAPHITE METALLIZING
CORPORATION
Yonkers, NY 10703 U.S.A.

ISO 9001:2008
H06a
TEL. 914.968.8400 WWW.GRAPHALLOY.COM/MD

72
RS# 136
MACHINE DESIGN.com
RS# 137
MARCH 8, 2012
High-flow-capacity
solenoid valve
General-purpose and
specialty solenoid valves
A high-density
interface
(HDI) solenoid
valve offers
increased
flow capacity without
sacrificing size
and weight.
The Lo-Lohm
HDI uses a spike and hold voltage drive
to extend flow and pressure ranges (19 to
39 slpm @ 50 psid). Available in plug-in
and face-mount configurations, the valve
measures 1.25-in. long and weighs only
4.5 gm.
The Lee Co., 2 Pettipaug Rd., Box 424,
Westbrook, CT 06498, (800) 533-7584,
www.theleeco.com/EFSWEB2.NSF/51afc74e7
f2112c9852563a9005db170/ec7bb21ff1dee0
868525790400604197!OpenDocument
RS# 452
A 300-page catalog covers the Skinner and Gold Ring lines

of solenoid valves. The companys two, three, and four-way
general-purpose and specialty valves are engineered for a
wide range of applications, including hot water and steam
for industrial dishwashing, industrial laundry and cooking
equipment; NSF certified beverage dispensing; compressors and compressed-air systems, including condensate
drain valves; fuel dispensing; traditional
and alternative-fuel delivery systems;
and medical and instrumentation.
Also included is information on the
Valve Actuation product line, coils and
enclosures reference guide, technical
information, and a safety guide. Download a free copy from the companys
Web site.
Parker Hannifin, Fluid Control Div.,
95 Edgewood Ave., New Britain, CT
06051, (860) 827-2300, www.parker.
com/fcd
RS# 453
No swell
Replaces bronze
Self-lube. No greasing
Enviro friendly
No heavy metals
Extended MTBR
Toll free: 1866 635 7596

vesconite@vesconite.com
vesconite.com
RS# 138
MARCH 8, 2012
RS# 139
MACHINE DESIGN.com
73
PRODUCTS & LIT
r
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design.com/rs
ww w.machine
Rotary positioning
The ServoBelt Rotary 200 (SBR
200) stage can move up to 100-kg
loads. The units huge through-hole
makes it easy to bring utility connections, sensors, and other components to the top of the stage.
The SBR 200 offers a stiff symmetrical drive mechanism that
enhances stiffness and eliminates
backlash, contributing to the units
positioning accuracy.
The rotary stage features a
200-mm through hole; 38-N-m
Continuous-movement cable
Chainflex CF Thermo cable is for use in temperature-sensing equipment where it acts as a
thermocouple extension link. The cable is available in types J, K and T for a variety of different
industries.
CF Thermo features an abrasion-resistant
PUR outer jacket. It can be used in applications
with high mechanical loads, travels up to 164 ft,
and is flame-retardant, as well as oil and coolant
resistant.
igus Inc., Box 14349, East Providence, RI 02914,
(800) 521-2747, www.igus.com
RS# 467
Wi-Fi transmitters
torque; 25 (axial) and 21 kN (radial)

load capacities; 1,050-N-m maximum moment; 100 arc-sec bidirectional repeatability; 15 arc-sec
unidirectional repeatability;
60 arc-sec accuracy, and 100-kg
maximum payload.
Bell-Everman Inc., 82 Aero
Camino Rd., Goleta, CA 93117, (805)
685-1029, www.bell-everman.com
RS# 465
The wSeries Wi-Fi transmitters, which

communicate on standard Wi-Fi networks, are ac or battery powered. The
battery version comes with two alkaline C-cell batteries that last for two
years, depending on the frequency of
readings. The ac version comes with
a universal adapter that operates on
any voltage (110 to 240 Vac) and also
includes an alkaline AA backup battery. Styles include analog voltage
and current (0 to 10 V, 4 to 20 mA), temperature from digital sensors
and dual thermocouples, humidity, and barometric pressure.
Users can view charts and graphs, as well as monitor and record
readings from virtually any type of transducer, over an Ethernet network or
the Internet from any computer, tablet, or smart phone with a Web browser.
Alarms can be set to notify users by e-mail. The alarm can be sent to
a single user or a group, and include text messages to cell phones. The
wSeries Wi-Fi sensors are protected in a rugged weatherproof, polycarbonate
NEMA-4/IP65-rated housing.
Newport Electronics Inc., 2229 South Yale St., Santa Ana, CA 92704, (714)
540-4914, www.newportus.com/ppt/wseries.html
RS# 468
Power supplies
Power supplies are available for variable-torque electromagnetic brakes and clutches, such as magnetic particle
and hysteresis brakes and clutches. Output current is manually controlled using a potentiometer or a 0 to 10-V control
signal. Output is also scaled by a separate Span Max adjustment, so fine control, even for low current loads, is easy. The
supplies offer outputs of 12-Vdc @ 1.25 A or 24 Vdc @ 0.75 A
and come in enclosed or open versions, with or without an
LCD ammeter.
Placid Industries Inc., 139 Mill Pond Dr., Lake Placid, NY
12946, (518) 523-2422, www.placidindustries.com
R# 466
74
MACHINE DESIGN.com
MARCH 8, 2012
Diaphragm pump
The new Type NF1.25 diaphragm pump handles dosing or transferring liquids
or liquid-gas mixtures at flow rates up to 300 ml/min. The pump is engineered to operate either intermittently or continuously against pressure up to
87 psig. Versions can be developed to handle pressures up to 145 psig.
The pumps have a patented valve and sophisticated diaphragm technology. Users can choose from a wide selection of motors, including iron-core dc,
ironless-core dc, or brushless-dc (BLDC) versions. The BLDC models can be supplied
with simple two-wire operation or with four wires for advanced tachometer output and
speed control input, and a highly linear control curve (flow rate versus control voltage) for use in
closed-loop systems.
These self-priming pumps can run dry, require virtually no maintenance, and offer chemical resistance by
using PP, PTFE, EPDM, and FFMP for components that contact the pumped medium.
Specialized accessories are available, including an antivibration mounting plate that can reduce vibration levels and audible noise. Pumps can be mounted in any position.
KNF Neuberger Inc., 2 Black Forest Rd., Trenton, NJ 08691, (609) 890-8600, www.knfoem.com
RS# 469
Stampings catalog
Dc servomotors
The 2012 Metal Stamping Brochure is

an in-depth, eight-page booklet that
details the companys vast, high-quality stamping capabilities.
With its innovative technology and
engineering concepts, the company
accommodates diverse, complex applications, offering such services as
flat blanking and piercings in sizes up
to 12 12-in., metal forming in thicknesses from 0.005 to 0.134 in., and
draws up to 3-in. deep and 8 in. in
diameter.
Also covered is the companys
secondary operations, including deburring,
tapping,
reaming,
counterboring,
spotfacing
and more.
Included
in the
brochure
is a quickreference
guide
complete
with several useful resources, such as a Base
Elements chart, a Decimal Equivalents
chart, and an extensive glossary of
more than 100 industry terms.
Bokers Inc., 3104 Snelling Ave., Minneapolis, MN 55406, (800) 927-4377,
www.bokers.com
RS# 470
The 8540 Series dc servomotors feature improved power

density through the use of
bonded neodymium magnets. The units have approximately twice the continuous
torque rating of previous
motors. The motors measure
1.18 in. (30 mm) in diameter
and come in three lengths
2.114 in. (53.69 mm), 2.585 in.
(65.66 mm), and 3.057 in.
(77.65 mm). Depending on
the model, continuous torque
ratings range from 2.5 to
8.3 oz-in. (0.018 to 0.059 Nm)
without the use of a heat sink.
The motors are available
with eight standard windings ranging from 9.55 to 48 V and have standard
preloaded ball bearings that allow for high speeds, radial and axial-shaft loading, and higher temperatures.
Pittman, 343 Godshall Dr., Harleysville, PA 19438, (330) 673-3452,
RS# 471
www.ametektip.com
Mechanical hardware catalog

The new D810 Inch Catalog is an easy-to-use
book that includes new products, detailed
indexes, and comprehensive technical data.
Over 87,000 components are featured, including an entirely new section of industrial quality
leveling foot mounts. The D810 contains 1,520
pages of newly organized layouts making it
easier to read and locate parts.
Stock Drive Products/Sterling Instrument,
2101 Jericho Turnpike, Box 5416, New Hyde
Park, NY 11042, www.sdp-si.com/eStore
RS# 472
MARCH 8, 2012
MACHINE DESIGN.com
75
ADVERTISER INDEX
RS#. . . . .COMPANY . . . . . . . . . . . . . . . PAGE
116. . . . . .Minnesota Rubber. . . . . . . . . . . . . .19
133. . . . . .Absopulse Electronics Ltd. . . . . . .47
112. . . . . .National Instruments
118. . . . . .Airpot Corp/Airpel . . . . . . . . . . . . . .24
Corporation. . . . . . . . . . . . . . . . . . . . .13
119. . . . . .Airpot Corp/Airpel . . . . . . . . . . . . . .25
102. . . . . .Omega Engineering Inc . . . . . . . . . 1
103. . . . . .Automationdirect.com . . . . . . . . . . 3
. . . . . . . . . .Ondrives.us . . . . . . . . . . . . . . . . . . . . .28
105. . . . . .Automationdirect.com . . . . . . . . . . 5
126. . . . . .Pepperl+Fuchs. . . . . . . . . . . . . . . . . .32
125. . . . . .Avago Technologies U.S. Inc . . . .31
127. . . . . .Pepperl+Fuchs. . . . . . . . . . . . . . . . . .33
Reduce costs
131. . . . . .Avago Technologies U.S. Inc . . . .39
110. . . . . .Precision Paper Tube. . . . . . . . . . . .10
and ensure quality
123. . . . . .Avnet . . . . . . . . . . . . . . . . . . . . . . . . . . .29
114. . . . . .Proto Labs, Inc.. . . . . . . . . . . . . . . . . .15
132. . . . . .Avnet . . . . . . . . . . . . . . . . . . . . . . . . . . .41
115. . . . . .Sapa Industrial
40
years
Advancing Automation
Extrusions, Inc. . . . . . . . . . . . . . . . . . .17

145. . . . . .Baldor Electric Co . . . . . . . . . . . . . . IBC
134. . . . . .Seal Master Corporation . . . . . . . .47
138. . . . . .Beswick Engineering
Company, Inc.. . . . . . . . . . . . . . . . . . .73
146. . . . . .Bimba Manufacturing
Company . . . . . . . . . . . . . . . . . . . . . . BC
108. . . . . .Clippard Instrument
Laboratory, Inc. . . . . . . . . . . . . . . . . . . 9
Simply added value

10 times more added value
for your automation
For more information:
Call:
1-800-Go-Festo
1-800-463-3786
www.festo.com/us/addedvalue
124. . . . . .Smalley Steel Ring

Company . . . . . . . . . . . . . . . . . . . . . . .30
135. . . . . .SolidWorks Corporation . . . . . . . .65
107. . . . . .Spirol International
101. . . . . .EBM-Papst . . . . . . . . . . . . . . . . . . . . . IFC
Corporation. . . . . . . . . . . . . . . . . . . . . . 8
104. . . . . .Exair Corporation . . . . . . . . . . . . . . . . 5
113. . . . . .Trim-Lok Company . . . . . . . . . . . . .14
117. . . . . .Fabco Air, Inc. . . . . . . . . . . . . . . . . . . .23
139. . . . . .Vesco Plastics Sales . . . . . . . . . . . . .73
140. . . . . .Festo Corporation . . . . . . . . . . . . . .76
120. . . . . .W.L. Gore & Associates Inc . . . . . .26
129. . . . . .Goodfellow Corp. . . . . . . . . . . . . . . .36
121. . . . . .W.L. Gore & Associates Inc . . . . . .27
136. . . . . .Graphite Metallizing Corp . . . . . .72
106. . . . . .Wirestone/Nvidia . . . . . . . . . . . . . . . . 7
130. . . . . .Helical Products

Company, Inc.. . . . . . . . . . . . . . . . . . .37
141. . . . . .Intech Corporation . . . . . . . . . . . . .77
Global manufacturer of process control
137. . . . . .Kepner Products. . . . . . . . . . . . . . . .72
and factory automation solutions
109. . . . . .Lee Company. . . . . . . . . . . . . . . . . . .10

111. . . . . .Lubriplate Lubricants Co. . . . . . . .11
142. . . . . .Magnetic Brakes System. . . . . . . .79
144. . . . . .Magnetic Component
Engineering, Inc. . . . . . . . . . . . . . . . .80
143. . . . . .Master Bond, Inc. . . . . . . . . . . . . . . .79
RS# 140
128. . . . . .Simrit Group . . . . . . . . . . . . . . . . . . . .35
While every effort has been made to

ensure the accuracy of this index, the
publisher cannot be held responsible for
any errors or omissions.
ader Service
Access our Re
ickly find and
Website to qu
ation on the
rm
fo
in
request
rvices found
se
products and ACHINE DESIGN.
M
in the pages of
c
design.com/rs
w w w.machine
BUSINESS INDEX
3D Systems Corp. . . . . . . . . . . . . . . 30
Agilent Technologies Inc. . . . . . . 26
Agilent Technologies Inc. . . . . . . 58
Arktos Developments Ltd. . . . . . 66
Autodesk Inc.. . . . . . . . . . . . . . . . . . 66
AutomationDirect . . . . . . . . . . . 6, 30
B&R Industrial Automation . . . . .
Balluff. . . . . . . . . . . . . . . . . . . . . . . . .
Barron Lighting Group . . . . . . . . .
Beswick Engineering Co. Inc. . . .
Bimba Manufacturing . . . . . . . . .
30
30
25
71
71
Central Piedmont Community

College. . . . . . . . . . . . . . . . . . . . . 38
Clippard Instrument Laboratory
Inc.. . . . . . . . . . . . . . . . . . . . . . . . . 72
DoEs Pacific Northwest National
Laboratory . . . . . . . . . . . . . . 26, 27
Danfoss Industrial Automation . 71
Dept. of Energy . . . . . . . . . . . . . . . . 27
Dept. of Labor . . . . . . . . . . . . . . . . . 38
Dordan Manufacturing . . . . . . . . 20
Eastern Michigan University. . . . . .8
Energist Group . . . . . . . . . . . . . . . . 62
Entrepreneur . . . . . . . . . . . . . . . . . . 30
Fabrico. . . . . . . . . . . . . . . . . . . . . . . . 25
Festo. . . . . . . . . . . . . . . . . . . . . . . . . . 72
FIRST Robotics Competition. . . . 34
GreenBiz Group . . . . . . . . . . . . . . . 48
Groschopp . . . . . . . . . . . . . . . . . . . . . .6
IDI Composites International . . . 42
IDI Composites International . . . . .6
ITW Formex . . . . . . . . . . . . . . . . . . . 25
Industrial Equipment Div.,
Baldwin-Lima-Hamilton
Corp. . . . . . . . . . . . . . . . . . . . . . . . 28
Infinite Z Inc. . . . . . . . . . . . . . . . . . . 63
Packaging Machinery
Manufacturers Institute . . . . . 30
Parker Hannifin,
Fluid Control Div. . . . . . . . . . . . 73
Pepperl+Fuchs . . . . . . . . . . . . . . . . 33
Peter Paul Electronics . . . . . . . . . . . .6
Peter Paul Electronics Co. Inc. . . 71
PolyPlane.com . . . . . . . . . . . . . . . . . 64
Princeton University Plasma
Physics Laboratory. . . . . . . . . . 28
Rittal Corp. . . . . . . . . . . . . . . . . . . . . 18
Sandia National Laboratory . . . . 24
Sensable . . . . . . . . . . . . . . . . . . . . . . 67
Service Machine Co. Inc. . . . . . . . 27
Siemens. . . . . . . . . . . . . . . . . . . . . . . 38
Siemens PLM Software. . . . . . . . . 62
Simrit . . . . . . . . . . . . . . . . . . . . . . . . . 27
Social Science Research Council . .8
Society of Manufacturing
Engineers . . . . . . . . . . . . . . . . . . 38
Steinmeyer. . . . . . . . . . . . . . . . . . . . . .6
Sterling Instruments . . . . . . . . . . . 30
Stock Drive Products/
Sterling Instrument . . . . . . . . . . .6
Sustainable Packaging Coalition 22
Tecplot Inc. . . . . . . . . . . . . . . . . . . . . 68
TerraCycle Inc. . . . . . . . . . . . . . . . . . 20
TV SD America Inc.. . . . . . . . . . 26
U. S. Green Building Council. . . . 48
Underwriters Laboratories . . . . . 48
Valmont West Coast
Engineering . . . . . . . . . . . . . . . . 66
Walmart. . . . . . . . . . . . . . . . . . . . . . .
Web Industries . . . . . . . . . . . . . . . .
Westinghouse Electric Corp. . . .
Whole Foods Market Day 20
Wittenstein. . . . . . . . . . . . . . . . . . . .
20
30
28
16
York University . . . . . . . . . . . . . . . . . .8
LXI Consortium . . . . . . . . . . . . . . . . 59
Lee Co., The . . . . . . . . . . . . . . . . . . . 73
MTI Systems Inc. . . . . . . . . . . . . . . . 27
Manufacturing Institute. . . . . . . . 38
MICROMO. . . . . . . . . . . . . . . . . . . . . . .6
Millennium Jet Inc. . . . . . . . . . . . . 28
NASA . . . . . . . . . . . . . . . . . . . . . . . . 111
National Association for PET
Container Resources . . . . . . . . 20
Ohio University . . . . . . . . . . . . . . . . . .8
Z Corp. . . . . . . . . . . . . . . . . . . . . . . . . 30
This index includes all significant

references to parent companies
mentioned in feature editorial material
within this issue of MACHINE DESIGN. It
doesnt cite companies listed solely
in the Products and Lit Section. Page
numbers listed refer to the pages where
the articles begin.
MARCH 8, 2012
RS# 141
MACHINE DESIGN.com
77
CLASSIFIEDS
BUSINESS STAFF
PRODUCTS/SERVICES
THE ORIGINAL
INSTANT
THUMBSCREW
In most cases, advertisements contained in

MACHINE DESIGN employment section indicate
that the companies are equal opportunity
employers. The Federal Civil Rights Act of
1964, and other laws, prohibit discrimination
in employment based on race, color, religion,
national origin, sex, or for any reason other
than lack of professional qualification for
the position being offered. It should be
noted that employment advertisements in
MACHINE DESIGN are published for the readers
convenience and, in no way, to the best of our
knowledge, promote unlawful discrimination.
To Advertise in
MACHINE DESIGNS
Classieds Section,
Bill Baumann,
Vice-President/Market Leader
Dennis Jensen,
Associate Publisher
Larry Berardinis,
Business Development Director
Virginia Goulding,
Online Sales & Marketing Manager
Julie Ritchie,
Research Manager
Jane Maloney Cooper,
Marketing Manager
Debbie Brady, Audience

DevelopmentManager
Carey Sweeten,
Group Production Manager,
913-967-1823
Courtney Denison,
Production Coordinator, 913-967-1738
Denise Donaldson,
Administrative Manager/Sales Support
216-931-9403
Corporate Officers
Bob MacArthur, Senior Vice President
Nicola Allais, CFO
Advertising Sales
Mike Hancock
International Sales Director,
mike.hancock@penton.com
Ph: 011-44-1372-824284,
Fax: 011-44-1372-824322
AZ, CA, ID, OR, NV, UT, WA, British

Columbia: Jim Theriault,
jim.theriault@penton.com,
Ph: 408-857-0322, Fax: 925-736-8705
AL, AR, FL, GA, KS, LA, NM, MS, MO,
OK, TX: Franny Singleton,
franny.singleton@penton.com,
Ph: 678-947-8563, Fax: 913-514-6884
CO, IA, S. IN, KY, MN, MT, NE, ND,
S. OH, SD, TN, WI, WV, WY:
Dennis Jensen,
dennis.jensen@penton.com,
Ph: 952-368-0018, Fax: 913-514-6627
IL: Melinda Hurley,
melinda.hurley@penton.com,
Ph: 847-784-9825, Fax: 847-784-9826
N. IN, N. OH, MI, NY, PA, Ontario:
Bill Rodman,
bill.rodman@penton.com,
Ph: 216-931-9636, Fax: 216-621-8469
DE, DC, MD, NJ, NC, SC, VA:
Brandy Bissell,
brandy.bissell@penton.com,
Ph: 919-773-1875, Fax: 913-514-6357
contact Larry Berardinis at

(216) 931-9393,
CT, ME, NH, MA, RI, VT, Quebec:

Liz Stott, liz.stott@penton.com,
Ph: 857-636-9737, Fax: 913-514-6914
larry.berardinis@penton.com
78
MACHINE DESIGN.com
United Kingdom, Scandinavia,

France, Spain, Portugal :
Stuart Payne,
stuart.payne@husonmedia.com
Ph: +44 (0)1932 564999
Fax: +44 (0)1932 564998
Belgium, Netherlands, Luxemburg: Rodric
Leerling, rodric.leerling@husonmedia.
com, Ph:011-31-229-841882 , Mobile 31683-232625,
Germany, Austria, and Switzerland:
Christian Hoelscher,
christian.hoelscher@husonmedia.com
Ph: 011-49-89-95002778,
Fax: 011-49-89-95002779
Italy: Cesare Casiraghi,
Casiraghi Pubblicit Estera,
Ph: 011-390-31-261407,
Fax: 011-390-31-261380
Tokyo, Japan:
Yoshinori Ikeda,
Pacific Business, Inc.,
Ph: 011-81-03-3661-6138,
Fax: 011-81-03-3661-6139
1300 E. 9th St., Cleveland, OH 44114-1503,

Ph: 216-696-7000 Fax: 216-696-0177
MARCH 8, 2012
BACKTALK
NASA teaches kids math

Sector 33 is a free app from NASA that helps kids understand math by solving simulated air-traffic-control problems. The apps developers also hope it will inspire students
to pursue careers in aeronautics. Using an interactive game
to spark their interest, while at
the same time teaching them
fundamental math concepts, is
a perfect way to help cultivate
the next generation of engineers
and technologists, said Leland
Melvin, NASAs associate administrator for education.
Players work a sector of airspace spanning Nevada and California, adjusting each airplanes
path and speed to move as fast
as possible while maintaining
separation and avoiding thunderstorms. Every minute a plane
a plane is delayed, that delay is passed on to all the planes flying behind it. Although time is of
the essence, to assure safety, the planes must never violate minimum spacing requirements.
Go to Apples app store to download the app: at http://itunes.apple.com/us/app/sector-33/
id486953105?ls=1&mt=8. MD
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www.masterbond.com
RS# 142
MARCH 8, 2012
RS# 143
MACHINE DESIGN.com
79
BACKTALK
SMARTEST DESIGN ENGINEER CONTEST UPDATE
Congratulations to Robert Strobel, Jr., who has earned the
title of MACHINE DESIGNS 2011 Worlds Smartest Design
Engineer. Mr. Strobel received the Grand Prize of $1,500!
Finishing out the 2011 challenge are the five winners of
$100 American Express Gift Cards Marcel Ipince,
Robert Grieger, Mark Sterrett, Bill White, and
Adam Kellada.
The quest continues in 2012. Winners of the January
contest are Edward Laconto, Marshall Renicks,
Don Schimizzi, Robert Strobel, and Gary Thrall.
Each will receive a $25 Visa Gift Card.
Congratulations to all!
SIGN IN TO PLAY THE

2012 WORLDS SMARTEST DESIGN ENGINEER
CONTEST AT:
WWW.SMARTESTDESIGNENGINEER.COM
80
MACHINE DESIGN.com
RS# 144
MARCH 8, 2012
READER SERVICES
Letters to the editor: Please
include your name, address,
and daytime phone number.
Letters may be edited for brevity
and to focus on essential points.
Mail: Letters, MACHINE DESIGN,
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E-mail, Editorial:
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Online forums: To comment
on articles, editorials, and other
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Questions about articles:
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com or visit pentonreprints.com.
List rentals: Marie Briganti,
877-796-6947,
mbriganti@meritdirect.com
All Applications Accepted
Special flange, foot or face-mount configurations,

custom shafts, custom windings, unique performance
requirementswhatever the application, Baldor can
often build and ship your motors in two weeks or less!
With decades of experience and more than 250,000
different custom motor specifications under our belts,
you spec it and well build it faster and better than
anyone in the industry.
baldor.com
Energy Efficient
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Made in the USA
479-646-4711
2011 Baldor Electric Company
RS# 145
MAKING A
BIG SPLASH
IN WASH-DOWN APPLICATIONS.
INTRODUCING MORE ALL-STAINLESS STEEL
BORE SIZES THAN ANY OTHER MANUFACTURER.
Go to bimba.com/washdown to:
t Save up to 50% with the Bimba sampling program*
t View the Preventing Contamination webinar
t Download the Corrosion Resistant Products catalog
www.bimba.com
1-800-44-BIMBA
2012 Bimba Manufacturing
RS# 146
* One piece sample orders are available for any standard model at 50% off the catalog list price.

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March 8, 2012

A Penton Media Publication

The engineers choice

Industrial Pressure Gages

Very High Accuracy Digital

General Purpose Digital Pressure

Industrial Digital Pressure Gages

DPG 2001B Series

Because of transmission frequency regulations, these wireless products may

Digital Pressure Gages

COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

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Pneumatic Blow Guns

A geometry being created in a

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The Truth About Compressed Air!

Facts about Blowers

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Blower Air Knife

This common blowo is very inexpensive

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Flat Air Nozzles

EXAIR Super Air Knife

As shown below, this inexpensive air

The Super Air Knife did an exceptional

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Flat Air Nozzles

Blower Air Knife

Super Air Knife

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