Electric vehicle conversion - Design Product News

Wave springs eliminate weldsRotor Clip has announced retaining rings for fl uid power assemblies that fi x the cov-er element and eliminate the need to weld or screw down the components. The wave spring between one cover element and the inner tube pre-loads the inner components against each other; possible axial toleranc-es are balanced so no axial play occurs.www.rotorclip.com

PM#

4006

5710

Inside: Power Transmission ■ Motion Control ■ Adhesives & Fasteners

Volume 39 Number 2

DESIGNPRODUCT NEWS

March 2011

Continued on page 6

Sealed USB connectors CONEC has expanded its bayonet locking and IP67-rated series of connectors with a connector compliant with USB 2.0 specifi -cations. Internal components are housed in black plastic and nickel-plated zinc die-cast with a bayonet locking termination.www.conec.com

Pneumatic cylindersAutomationDirect has extended its NI-TRA pneumatic product line to include round body C-series cylinders that feature a type 303 stainless piston rod equipped with Buna “N” O-ring rod seals and sintered bronze rod bushings. The double-acting cylin-ders are available in 9/16- to 3-in. bore sizes and stroke lengths from 0.25 to 4 in.www.automationdirect.com

dpncanada.com

A young man (34) with a mission. That’s Jay Giraud, CEO of Vancouver-based Rapid Electric Vehicles Inc. (REV), who wants to revolutionize the Canadian automobile manufacturing industry by making vehicles powered by internal combustion engines (ICE) obsolete and replacing them with electric vehicles (EVs).

Giraud has started putting his plan into action. Founded in 2008, REV designs, develops and assembles electric bi-directional charging vehicles for non-revenue- generating commercial fleets owned by municipalities, government and the military in Canada and the U.S.

“Non-revenue-generating, hub-and-spoke commercial vehicle fleets, which have repetitive driving patterns, are ideal for electric vehicles,” Giraud said. Such fleets are used, for example, in parking enforcement, parks and

recreation, building inspection and meter reading. “The City of Toronto has 1400 fleet vehicles, of which 700 are in non-revenue service.”

REV (www.rapidelectricvehicles.com) retrofits the Ford Escape SUV and Ford F-150 pick-up truck, the most common North American fleet vehicles, with a 125 kW permanent magnet ac mo-tor and direct-drive gearbox drive systems that deliver 300 Nm of torque to the wheels. Lithium ion batteries, with a life expectancy of over 320,000 km, power the vehicle for up to 192 km on a single charge. Vehicles are charged from a 240 V EV charging station in less than four hours. REV says the vehicles are up to 92% energy-efficient.

“By getting retrofit vehicles into the fleets now, REV is positioning itself to become a new elec-tric fleet vehicle provider by 2012,” Giraud said.

Electric vehicle conversion

eners

Vancouver company wants to transform our automobile industry

Covering the total design engineering function in Canada

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dpncanada.com

Government Funding BlogJason Schwandt & Tracey Wills put SR&ED tax credits into your cash flow

Industrial Design BlogDavid Duncan challenges us to “out innovate” our competitors

EXCLUSIVE ONLINE BLOGS

THIS MONTH ON

dpncanada.com November/December 20074 Design Product News dpncanada.com March 20114 Design Product News

DEPARTMENTS:7 By Design

SAE Hybrid Electric Vehicle Symposium report

8 Energizer “bunny” hops into Welland LED lighting plant

15 CAD Industry Watch Alin Vargatu gets inside

SolidWorks World

16 Bill Fane goes to school at Autodesk University

18 Power Transmission Spotlight

The latest in PT products and technology

21 Automotive Scene The electric supercharger

prepares to go mainstream

In this issue

Design Exchange Awards honor industrial designers

Selecting a lubricant for ball screws

Vehicles move into the bonding age

Handheld scanner analyzes moles for cancer

Miles Kellerman of MKDA Inc. received a 2010 DXA Award of Excellence for his mixed martial arts equipment for Hatashita International. Other award winners included GSMprjct and OHM Industrial Designers.

The right oil or grease lubrication for ball screw assemblies reduces unscheduled downtime for repair by ensuring that the assemblies deliver their expected service life, according to Jeff Johnson of Thomson Industries.

Used by Group Hesse for ambulance bodies, Loctite H8600 Speedbonder was found to be better at joining aluminum pre-painted panels than welding, riveting or screw-fastening could ever be.

An innovation from MedX Health is a device for the early detection of skin cancer and the analysis of melanoma. Known as a MoleMate, the device detects size, shape, color and texture to inform a dermatologist.

Amacoil Inc. ................................... 20ASCO Numatics .............................. 22AutomationDirect............................. 3Baldor Electric Co. .......................... 12Baumer .......................................... 17Bimba Mfg. Co. .............................. 11Bishop Wisecarver .......................... 14Brecoflex ........................................ 10Clippard ......................................... 24Conductix Corp. ............................. 10Festo ................................................ 5Goodyear ....................................... 15Henkel Loctite .................................. 7Lapp Canada .................................... 9Master Bond .................................. 19Nook Industries .............................. 17Nord Gear ...................................... 13Omega ............................................. 2PennEngineering ............................ 21Phoenix Contact ............................. 23Pivot Point ..................................... 22Ringball .................................... 18, 19Rotor Clip ......................................... 6Seal Master .................................... 18Smalley Steel Ring ......................... 20Spirol .............................................. 19

IndexAdvertisers

8 10

14 20

Interactive stuffNotice that as you move your mouse over certain parts of the magazine or over the DPN 3D and video player buttons, in some editorial stories and in some advertisements, a grey box appears. That means you are one click away from a new window opening up that takes you to a website or rich media we’ve linked to.

D I G I TA L E D I T I O NMarch 2011

Please go online to dpncanada.com to fully explore and enjoy the Digital Edition of Design Product News. This user-friendly new format, with every item linked to other websites, videos and 3D PDFs, will help you get even more invaluable design engineering infor-mation from DPN.

DESIGNPRODUCT NEWS

DPN editorial directorMike Edwards

dpncanada.com

To watch what’s going on in the industry visit: dpncanada.com

Design Product News magazine stays on top of the latest developments in the fast-moving world of design engineering. Video highlights from trade shows give you access to top executives and product managers and

clips from technology demos keep you informed and entertained.

SAE 2011 Hybrid Vehicle Technology Symposium

At the SAE 2011 Hybrid Vehicle Technologies Symposium in Anaheim, CA, Alan Soltis, Automotive Program Manager for Opal-RT Technologies demonstrated a hardware-in-the-loop motion simulator.http://ow.ly/451K8

Electronics recycling plant addresses end-of-life for CRTs

Witness the Sims Recycling Solutions e-waste CRT recycling facility grand opening. It will create up to 200 jobs and process 100,000 metric tonnes of waste electronics and electrical equipment annually.http://ow.ly/452ht

PTC Creo anymode 3D direct modeling demonstration

Mike Campbell, PTC’s DVP, Creo Product Development, discusses 3D direct modeling with anymode software. Users are able to toggle between history-based and direct modeling techniques, depending on their needs.http://ow.ly/452Dq

DPN _Mar_2011.indd 4DPN _Mar_2011.indd 4 3/8/11 2:08:05 PM3/8/11 2:08:05 PM

Design Product News 5dpncanada.comMarch 2011 Design Product News 5

By Mike Edwards,Editorial Director

As we go about our business each day, regulatory coordination is of little interest for most of us — until

the moment you try to charge your mobile phone with a borrowed charger or with one left over from previous models.

Until recently across the Atlantic, ac-cording to the Conference Board of Canada (www.conferenceboard.ca), these chargers did not require standardized technology – but now agreement between the European Union and manufacturers of mobile car-riers has eliminated these differences for European consumers.

Adopting common regulations gov-erning mobile phone chargers is one prac-tical example where different standards among nations and products have been overcome for the benefit of consumers, the Conference Board says in a recent state-ment. As a relatively small economy, Can-ada has much to gain from similar regu-latory coordination with trading partners, but little progress has been made, it adds.

A new Conference Board of Canada re-port argues that a practical plan – tailored to specific sectors and focusing on key trading partners – is the best approach to obtain the benefits of regulatory cooper-ation.

“Persistent differences between na-tional standards – many of which so incon-sequential that they are essentially mean-ingless – interfere with the movement of goods, services, capital, and people,” said Kathleen Macmillan, author of Regula-tory Cooperation: A Practical Action Plan, published for the Conference Board’s Inter-national Trade and Investment Centre.

“Proponents of increased internation-al cooperation and coordination are not calling for an end to regulation, but for greater predictability and uniformity in the measures that do apply. Canada’s best chance for success lies in a practical plan of cooperative self-interest, drawing on the successful experiences of the Australia and New Zealand Trans Tasman Mutual Recognition Arrangement, the European Union and other accords.”

In seeking partners, Canada should concentrate on countries with similar ob-jectives for health, safety and environment-al protection and the capacity to oversee and enforce regulations, such as the U.S. and European Union. There are a number of sectors where closer regulatory align-ment with the U.S. makes sense.

Canada should set priority sectors and industries for regulatory alignment where the greatest economic advantages are found. Accord the report, one such sector is motor vehicles – although motor vehicle manufacturing is integrated in North America, Canada and the U.S. maintain

separate safety and operating regulations. Most merely create inefficiencies; that said, a notable and justifiable exception for dis-tinct Canadian regulations might be meas-ures to ensure that vehicles can start in cold weather.

Other sectors which the Conference Board identifies as potential beneficiaries of greater regulatory coordination are R&D intensive sectors and professional licensing.

A broad range of options for coordina-tion exist – from fully harmonized stan-dards to joint assessments and information

Renderings

sharing among separate regulatory agen-cies. Where differences are inconsequential or pose little risk to Canadians’ health or well-being, Canada could simply adopt foreign standards. Canada could also work with other jurisdiction to harmonize stan-dards or recognize the equivalence of other countries’ regulations (mutual recognition). Maintaining unique regulations should be a rare exception, and the onus should be on Canadian regulators to justify distinct standards.

Finally, provinces and territories should redouble their efforts to eliminate internal

regulatory differences. The International Trade and Invest-

ment Centre is intended to help Canadian leaders better understand what global economic dynamics — such as global and regional supply chains, barriers to trade, U.S. policies, or tighter border security—could mean for public policies and business strategies.

The time has come for Canada to improve regulatory coordination

Adopting common regulations benefits

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Untitled-12 1 3/2/11 3:37:16 PM


Cover Story

Internal combustion engine vehicles convert to electric

The company’s EVs have many advan-tages over ICE vehicles, he explained.

“They’re quiet, have a glass-smooth ride, faster acceleration and more torque,” Giraud said. “And, be-cause the electric drive train has less than 10 moving parts, there’s little wear and tear. The result is reduced main-tenance – and zero tail-pipe emissions.”

Retrofitting the ve-hicle to electric takes place by removing the hardware of an ICE vehicle – 80 litre gas tank, engine, transmission, fuel lines and exhaust pipe – and replacing it with an

electric drive train, high-voltage wiring and a battery pack. The entire process takes a total of nine to 12 hours to complete. The retrofitted vehicle’s centre of gravity re-mains the same, although it is about 150 lb heavier than the original.

The company is new, but there is already considerable interest in its technology. REV has taken orders for 10 ve-hicles; with more in the pipeline. The company recently received an or-der for four EVs from

the U.S. Army Tank Automotive Research Development Engineering Center (TAR-DEC) Micro-Grid for the delivery, test-ing and demonstration of a micro-grid at Wheeler Air Base, Hawaii. (A micro-grid is a local grouping of electricity sources and loads that are connected to and synchronized with the main power grid through a common coupling. It can also disconnect from the main grid and oper-ate on its own, depending on electricity demand and supply.)

Giraud says the TARDEC project rep-resents the next generation of EV technol-ogy – the convergence of the automobile and electrical generating industries. The company’s EVs are part of its AutoGrid, a two-way communications network that connects the vehicle battery packs to the power grid in such a way that aggregated battery packs from a fleet of EVs help to balance electrical supply and demand on the grid.

“Our technology enables the power stored in the vehicles’ batteries to be used in equipment, buildings and homes when-ever and wherever the vehicle is plugged in,” Giraud said. “In effect, it turns the ve-hicle into a mobile power supply.”

To enable the remote control and flow of on-board electricity, REV’s system communicates through a built-in virtual private network router connected in real-time to a network server. This allows fleet operators to export power from the bat-teries for 240, 480 or 600 V applications.

Giraud says REV will start to pro-duce EVs “in volume” in early this year. He aims to set up a vehicle assembly line in southern Ontario and to make 10,000 vehicles a year there by the end of 2013.

“I’m positioning the company to be a national automotive brand that that will rejuvenate the car industry in Canada,” Giraud said.

“Over time, electric vehicles will be-come multi-functional modes of trans-portation and mobile power supplies. And gas-powered vehicles will go the way of the horse and buggy.”

dpncanada.com November/December 20076 Design Product News dpncanada.com March 20116 Design Product News

Untitled-6 1 2/10/11 4:56:45 PM

The REV transmission retrofit for the Ford Escape SUV and Ford F-150 pick-up truck, the most common North American fleet vehicles, includes a 125 kW permanent magnet ac motor and direct-drive gearbox drive systems that deliver 221 ft lb of torque to the wheels.

The Global Market for hybrid and electric taxi vehicles (above chart) is set to explode. “By getting retrofit vehicles into the fleets now, REV is positioning itself to become a new electric fleet provider by 2012,” according to Rapid Electric Vehicles Inc. CEO Jay Giraud.

From Front Page

REV has passed a micro-grid test at Wheeler Air Force

Base in Hawaii


By Randy Frank

The annual SAE Hybrid Vehicle Technologies Symposium made its debut in Anaheim, CA, after

being held many years in San Diego. In addition to the change of venue, the sym-posium specifi cally addressed recently in-troduced electric vehicle (EV) and plug-in hybrid vehicle (PHEV) technologies.

Toyota’s Prius continues to overshad-ow the entire fi eld of hybrid electric ve-hicle (HEV) offerings, those from other manufacturers as well as its other HEVs. Still, vehicles with any form of electric propulsion are only 3% of the total sales in the U.S. However, vehicles with new electric propulsion systems could soon challenge the Prius’ dominance.

Tetsuya Takahashi, general manager, Powertrain Product Development, Nis-san Motor Co., Ltd., discussed the hybrid propulsion of the 2012 Infi niti M35h. Using a single 50 kW motor, two clutch parallel hybrid system, a seven-speed au-tomatic transmission without a torque converter, and a 3.5-litre Atkinson cycle V-6 engine, the M35h gets 27 mpg city and 32 mpg highway mileage. The re-cently introduced Nissan Leaf EV was also discussed later in the symposium.

Seok-Joon Kim, senior research engi-neer, HEV System Test Team, Research & Development Division of Hyundai Motor Company presented technical aspects of the 2011 Sonata Hybrid. Using a parallel architecture with an Atkinson cycle 2.4L, 4-cylinder engine and 270V Li-polymer battery powering a 30 kW motor, the So-nata Hybrid delivers 35 mpg city and 40 mpg highway mileage.

Pete Savagian, director Hybrid Pow-ertrain Systems Engineering and Electric Motor Release Centers, General Mo-tors discussed how eAssist on the 2012 LaCrosse (above) allows the vehicle to achieve 25 mpg in city driving and 37 mpg on the highway. He also discussed the Chevy Volt extended range EV in the added technical session on Friday.

The eAssist system is a new name for the belt alternator starter (BAS) system previously introduced in the 2007 Sat-urn Vue Green Line. Using a higher volt-age (115 V instead of 42 V), the eAssist’s higher power 15-kW electric motor and Li-Ion battery provide a value optimized mild hybrid powertrain that will be of-fered at the same price as the base V-6 engine model. GM feels the term eAssist is more consumer friendly than BAS and other hybrid terminology.

Infi neon was one of the exhibiting suppliers. Dusan Gravoc, senior manager, Head of Product Marketing for Infi neon Technologies AG knows the importance of high power modules in electric propulsion.

“We build all of our power systems so they are scalable throughout the power range and also though out the voltage classes,” said Gravoc.

For those applications with a high battery voltage, Infi neon has introduced

1200 V IGBTs in its HybridPACK.Increased IGBT operating tempera-

tures can be expected in the future. “It is our goal in the future to have 175°C op-erating temperature as a standard,” said Gravoc.

Battery cell balancing is essential to optimum performance and battery life in all classifi cations of electric powered vehicles. Cuyler Latorraca, an applica-tions engineer for Linear Technology demonstrated how the LTC6803-2 and -4 multicell battery stack monitoring IC can address three different types of cell technologies.

Today, every car company is working on EV, HEV or PHEVs and in some cases all types. Perhaps, Nissan’s Takahashi’s summary for his paper serves as an appro-priate summary for the Symposium: “The next challenge is to reduce the cost.”

The eAssist system on the 2012 Buick LaCrosse provides a mild hybrid that cost effectively increases mileage by optimizing the battery size.

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Untitled-2 1 10/28/10 10:41:13 AM

By Design

EVs and PHEVs add to annual Hybrid Vehicle Symposium

dpncanada.comMarch 2011 Design Product News 7

Every car company is working on EV, HEV or PHEV models, or all of

the above


dpncanada.com March 20118 Design Product News

By Design

Abbott Point of Care (www.ab-bottpointofcare.com) of Ottawa was among four Ontario employers to be honored for an exceptional commitment to apprenticeship training.

The annual Ontario Minister’s Ap-prenticeship Employer Recognition Awards (http://ow.ly/43v92) celebrate employers that show leadership in train-ing apprentices, support the apprentice-ship training system and promote careers in skilled trades.

The 2011 edition of the biannual Plant Maintenance and Design Engineering Show (www.sme.org/pmds) in Montreal will feature new products and technology for plant maintenance, equipment and systems design, safety and logis-tics. Presented by the Society of Manufacturing Engineers, it will showcase technology from assembly, bar coding and process control to robot-ics and rapid manufacturing. Vendors exhibiting

include Avdel Canada, Designfusion, Creaform 3D, Fluke Electronics Canada, SolidXperts and Vibratech.

Montreal set to welcome PMDS event

The CRS Electronics production facility in Welland, ON, will manufacture a suite of LED lighting products under the brand name Energizer. Inset: CRS president Scott Riesebosch.

NKK expands distributionNKK Switches (www.nkkswitches.com) has announced its SmartSwitch product line of OLED and LCD switches and displays is now avail-able through all of NKK’s authorized distributors in the U.S. and Canada. The expansion adds 20 addition-al distributors to sell and support SmartSwitch products.

Orbite produces aluminaExploration Orbite of Montreal (www.explorationorbite.com) has an-nounced that it has produced its fi rst ton of high purity alumina ahead of schedule and on budget. The fi rst ton was produced at the company’s pilot facility in Cap-Chat, QC.

Xtronics chosen as repSherborne Sensors (www.sherbor-nesensors.com) has added Concord, ON-based Xtronics (www.xtronics.ca) as an authorized sales representa-tive organization in North America. Xtronics will represent the company’s inclinometers, accelerometers, force transducers and associated products.

April 4-8, 2011. Hannover, Germany. Hannover Messe 2011 trade fair has pavilions dedicated to Industrial automation, motion and drives, energy and mobile technologies (www.hannovermesse.de).

June 21-23, 2011. Toronto. PackEx Torontotrade show and conference for designers

and suppliers to the packaging industry (www.canontradeshows.com/expo/packex11/). Co-located with Automation Technology Expo Canada, Plast-Ex, and Design & Manufacturing Canada shows.

October 17-20, 2011. Toronto. Canadian Manufacturing Technology Show 2011includes live demonstrations of automation technologies and machine tools (www.sme.org/cmts).

News in Brief

Douglas Backman heads Vacon Canada

CRS Electronics signs agreement with Energizer

General Magnaplate awards Dynaloy license

WELLAND, ON – CRS Electronics Inc., an inventor, developer and manufacturer of LED lighting, has announced an ex-clusive agreement with Eveready Battery Company, Inc. a subsidiary of Energizer Holdings, Inc., for CRS (www.crselec-tronics.com) to manufacture a suite of LED lighting products under the brand name Energizer.

The initial LED suite of products includes the MR16, PAR 20, PAR 30 and PAR 38. Future products devel-oped by CRS may also be considered by Energizer.

This agreement brings together the power of the Energizer brand with CRS Electronics’ leading technology in LED light bulbs. Energizer branded LED lights will be distributed through com-mercial and leading retail networks, and will fl ow through major lighting agents in North America. Shipping of the new products is expected to com-

mence in the third quarter of 2011.“We are honored to be working

with the Energizer brand name. Part-nering with a premium, trusted brand validates our efforts and gives us a competitive edge in the marketplace,” said Scott Riesebosch, president, CRS Electronics (inset above). “This agree-ment expands our product reach from the commercial space to retail, and from one product line to four, representing a signifi cant growth opportunity for the Company. We are thrilled with the op-portunity and will continue to develop new LED products to support our rela-tionship with Energizer.”

Said Jim Olsen, vice president of marketing for Energizer North Amer-ica. “CRS was selected for their com-mitment to excellence in LED lighting technology capabilities and their his-tory of innovation in the LED lighting industry.”

Douglas Backman has been appointed managing director for Stratford, ON-based Vacon Canada (www.vacon.com). The lo-cation includes offi ces and distribution services. Backman (left), who is fl uent in both English and French, will be responsible for operations throughout Canada which include sales, marketing and after-market services. Vacon, Inc. is a global manufacturer of ac drives, with R&D and production facilities in Finland, the U.S., China and Italy.

Operating in Ottawa since 1995, Ab-bott Point of Care produces medical diag-nostic instruments used all over the world. The company has 346 employees in mi-croelectronics apprenticeship training.

Participants attend class at work, on work time, and over a three-year period will earn 19 college credits toward their apprenticeship certifi cation. Main part-ners include the Ministry of Training, Colleges and Universities (MCTU) who oversee the provincial standards of the trade and Algonquin College who is ac-countable to the Ministry regarding the academic integrity of the program.

This year, 240 of these employees will graduate with a Microelectronics Cer-tifi cate from Algonquin College (www.algonquincollege.com). In November 2009, the Conference Board of Canada recognized this training in a case study.

There are more than 120,000 appren-tices in Ontario learning a skilled trade today, which is nearly 60,000 more than in 2002-2003. Since the awards began in 2002, more than 140 employers have been recognized for their commitment to training apprentices.

General Magnaplate Corp. (www.magnaplate.com) of Linden, NJ, has awarded a license to Grimsby, ON-based Precision Sur-face Technologies (www.precisionrolls.com) for its Dynaloy en-hanced proprietary chrome process. The process protects any base metal part (except magnesium) against wear, galling, friction and corrosion. Ed Aversenti, COO of General Magnaplate (right), said “parts can be processed at any stage of their service life with-out the need for expensive machining operations to follow.”

Calendar

Catherine Lewis, project manager, Abbott Point of Care (left); Robert Dupuis, director, Eastern Region, Employment and Training Division, MTCU; Kris Koolstra, program coordinator – Microelectronics Manufacturer, Algonquin College.

TORONTO – The Design Exchange(www.dx.org) has announced the 2010 DXA Award of Excellence win-ners. Projects were chosen from hun-dreds of applicants across Canada. GSMprjct of Montreal (www.gsm-prjct.com) was honored with a Staff Award for its Behold Telescope (above) that can be found on the 124th fl oor of the tallest building in the world in Dubai. Industrial design awards went to Miles Kellerman of MKDA Inc.(www.mkda.ca) in Toronto for mixed martial arts equipment for Hatashita International and OHM Industrial Designers (www.ohm.ca) for its Sharx safety whistle commissioned by Fox40 International Inc. View all the winners http://ow.ly/43s2v.

Ontario ministry honors Abbott for apprenticeship training

GSMprjct’s award-winning Behold Telescope can be found on the 124th floor of the world’s tallest building in Dubai.

Canada’s National Design Exchange Awards


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Feature: Power Transmission

By Jeff Johnson

Lubricants maintain the low friction advantage of ball screw assemblies by minimizing the rolling resistance between balls and grooves and sliding

friction between adjacent balls. A ball screw assembly must be thoroughly cleaned to

remove all contaminants before lubrication and re-lubri-cation. Contamination is a leading cause of premature failure of ball screws.

Proper lubrication helps keep most contaminants out, which greatly reduces the damage foreign particles can cause. Rust preventative oil is typically used for shipping and storage of the components and should be wiped clean before application of the fi nal lubrication selection.

There are several methods of delivering lubricant to a ball screw assembly, and several methods to retain the lubricant in the lubricated assembly. For example, a grease lubricated ball nut may have a grease fi tting on the nut fl ange (if there is a fl ange) or on the nut body.

The installation of wipers or seals is used to contain internal lubrication and repel external contamination. Oil systems require a pump, fi ltering system and applica-tion method.

Lubricants are often taken for granted (hundreds of choices are available and many provide near identi-cal performance, contact a lubrication expert or ball screw manufacturer to narrow the selection), but the right choice for each application ensures a ball screw that performs properly for its calculated life. Both oil and grease provide corrosion protection, but lubricant choice depends on evaluation of the advantages and disadvantages of each in the given application.

You can apply oil at a controlled fl ow rate directly to the point of need, and it will clean out moisture and other contaminants as it runs through the ball nut. It

can also provide cooling. Oil disadvantages you must consider include:• Possibility of excess oil contaminating the process,

such as mixing with the cutting fl uid in a machining application.

• Cost of a pump and metering system to apply oil properly.

• Grease is less expensive than oil to apply and requires less frequent application, and it does not contaminate process fl uids. On the other hand:

• Grease is hard to keep inside the ball nut and has a tendency to build up at the ends of ball nut travel, where it accumulates chips and abrasive particles.

• Incompatibility of old grease with re-lubrica-tion grease can create a problem. Be sure to check compatibility.With regard to lubricating with oil, operating

temperature, load and speed determine the oil viscosity and application rate needed for each installation. If the oil is too viscous or if you use too much, heat may be generated.

If the oil viscosity is too low or you use too little, parts may not be coated adequately; fric-tion and wear may result. The selection of the oil lubrication will directly infl uence the tempera-ture rise of the ball screw and the life of the assembly.

With regard to lubricating with grease, ball screws must be lubricated to operate properly to achieve the rated life. Greases can be applied directly to the screw threads near the root of the ball track or pumped directly into the ball nut if lube holes are provided. It is recommended that wipers be utilized to contain the lubricant within the body of the ball nut.

Speeds that are high for ball screws are no problem

for grease, so speed is not a criterion for selection. For example, grease is the accepted lubricant for machine tool spindles with dn (bearing bore, mm x rpm) values as high as 1,000,000. For ball screws, dn values rarely exceed 100,000.

The right oil or grease lubrication for ball screw assemblies reduces unscheduled downtime for repair by ensuring that the assemblies deliver their expected service life.

For more detailed technical information and lubri-cant selection criteria read the complete version of the article at http://ow.ly/45PLQ.

Jeff Johnson is Product Engineer at Thomson Industries, Inc.www.thomsonlinear.com

Factors in selecting a lubricant for ball screws

Untitled-12 1 2/24/10 3:56:00 PM

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Untitled-6 1 2/24/11 11:15:17 AM

The right oil or grease lubrication for ball screw assemblies reduces unscheduled downtime for repair by ensuring that the assemblies deliver their expected service life.

Bimba_DPN_SeptOct10.indd 1 8/25/10 11:15:12 AMDPN _Mar_2011.indd 10DPN _Mar_2011.indd 10 3/4/11 11:25:43 AM3/4/11 11:25:43 AM

Design Product News 11dpncanada.comMarch 2011

After more than 50 years of pneumatic leadership, Bimba introduces

its fi rst ever rod-type electric actuator—the Original Line Electric

(OLE). Designed, built and tested to provide the greatest durability,

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Just like Bimba’s trusted Original Line pneumatic cylinders, OLE

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tical fi lter for the iCure AS200 thermal spot curing system. Using thin-fi lm tech-nology, the company says it has created an optical fi lter that eliminates all vis-ible wavelengths except for a mild red pointer glow to provide infrared energy above 800 nm. The system is said to accelerate the curing of two-part glues without affecting heat-sensitive thermo-plastics.www.icure-irphotonics.com

Video website for adhesives

Fabrico announced a website video about low surface energy adhesives. This video addresses its ability to help design engi-neers identify, select, and use adhesives specially formulated to work with LSE plastics. The company sources and con-verts LSE plastics and adhesives, includ-ing liquid adhesives, adhesive tapes and thin fi lm/foam bonding systems. The products are formulated to create strong bonds with LSE plastics that are impact-, shock-, and fatigue-resistant.www.fabrico.com

Adjustable metric hinges

J.W. Winco has introduced series GN 238 zinc die cast adjustable alignment hinges with cover caps. The RoHS-com-pliant, metric sized hinges are designed to provide alignment of the door to its frame. Units are available with both sides adjustable (Type BJ), one side ad-justable (Type EJ), and fi xed hole type (Type NJ). The plastic cover hides the adjustable bushing and screw to prevent dirt from entering.www.jwwinco.com

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Untitled-4 1 2/23/11 9:26:46 AM

vulcanized rubbers and many plastics. The epoxy also resists chemicals includ-ing water, oil and many organic sol-vents.www.masterbond.com

Spot curing systemIRphotonics has announced a visible op-

lants, sealants, molding compounds and cleaners. The products are said to com-ply with relevant standards of the PV in-dustry and are widely used in a range of applications from silicon wafer produc-tion to installation of large solar arrays.www.henkelna.com/solar

Two-component epoxyFormulated for structural applications with temperatures from -80° to 425°F, Master Bond Supreme 33 provides resis-tance to thermal cycling, thermal shock and impact. The two-component epoxy is said to offer high structural bond strength to a wide variety of substrates including metals, glass, ceramics, wood,

Products: Adhesives & Fasteners

Solar cell and module

Henkel Corp. has introduced a line of products for photovoltaic manufactur-ing and installation. The products in-clude structural adhesives, elastomers, thermally and/or electrically conductive materials, die attach adhesives, encapsu-

djustab e et c ges

Untitled-7 1 2/24/11 2:00:59 PMDPN _Mar_2011.indd 12DPN _Mar_2011.indd 12 3/4/11 11:25:45 AM3/4/11 11:25:45 AM


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Visit www.bwc.com today to learn more about our wide range of products, watch HD videos, download white papers and CAD files, view and print catalogs, read customer application stories, utilize our equations toolbox and much more.Visit www.bwc.com today to learn more about our wide range of products, watch HD videos, download white papers and CAD files, view and print catalogs, read customer application stories, utilize our equations toolbox and much more.

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Untitled-12 1 2/22/11 2:15:26 PM

Feature: Adhesives & Fasteners

and also engine parts in cars, are being assembled with adhesives. Direct glaz-ing of windshields and rear windows increases the structural integrity of car bodies – and enables vehicle designs with better aerodynamics, which considerably improve fuel economy.

Adhesive systems are also highly dura-ble. Whereas conventional spot welds are prone to fatigue and plastic deformations when highly loaded – which is one of the reasons why car doors may no longer close properly when a car is parked with two wheels on the curb – engineering adhesives distribute the load better.

Unsealed seams also offer a path for moisture to penetrate. This was a prob-

Every successful vehicle manufacturer nowadays has to look for produc-tion streamlining opportunities, and

has to come up with innovative ideas to create better looking, more durable, stron-ger and lighter platforms that appeal to the market.

Chemical bonding with adhesives has long since become a well-established key technology in many different industry seg-ments besides classic vehicle and car manu-facturing and is increasingly replacing other joining techniques, especially mechanical fasteners. There are many reasons for this.

Particularly in crash tests, bonded cars generally perform better than welded con-structions. As a result, many car bodies,

Vehicles move into the bonding age

lem facing one of the oldest and largest truck body manufacturers in the U.S. Group Hesse, which now manufactures in Granby, QC, produces a wide range

of general-purpose and specialized bod-ies for service and delivery vehicles, including a line of ambulance bodies for a well-known manufacturer of emer-gency vehicles.

Quality specialists had noted that skip-welding resulted in unsightly buck-ling of the outer skin, and that the spaces between welds represented a second path through which moisture could penetrate the joint. The entire welded-assembly design appeared to be problematic, and it was hoped that these problems could all be eliminated by switching to adhe-sive assembly.

The adhesive bond (produced with Loctite Speedbonder H8000 from Henkel) between body panels and door frames is stronger than the welded connection. The redesigned ambulance bodies support 55,000-lb test loads on the roof and sides, exceeding federal standards by more than 200%. In addition, the full-length bond provides a resilient, watertight seal against moisture penetration. This eliminated the problems of paint separation and corro-sion, and drastically reduced the ambu-lance maker’s warranty costs.

Group Hesse has also done extensive testing, including building up a test fl eet of beverage trucks, using Speedbonder H8000. After monitoring these trucks for more than 18 months in the extreme tem-peratures and highly corrosive environ-ment of Quebec roads, the adhesive was found to have a positive effect on the life of the painted graphics on the vehicles. In the past, corrosion that degraded the paint started at the rivets. With rivets eliminated, there is no more potential for corrosion and this problem has been completely eliminated.

“The next step for us is the drastic reduction of welds in our designs. We did many road tests with more exten-sively bonded designs and have gained a high level of confi dence in Speedbonder H8000,” said Martin Barrette, chief engi-neer, Group Hesse. “It’s obvious to me that welds will be used less and less in our designs, being replaced by stronger, more effi cient technologies like Speedbonder.

“Even though we may not see a car, a truck or a bus fully bonded together with no welds or rivets in the near future, adhesives are increasingly fi nding favor with manufacturers,” said Sylvain Caron, material and process engineer for Henkel.

“Fast curing, production friendly structural adhesives are key contributors in assisting our business partners adhere closer to lean manufacturing principles.”The article was contributed by Henkel Loctite ([email protected]).www.henkel.com

Group Hesse’s Parco trailer sports an attractive appearance. Formerly a white plastic rail was installed around the perimeter of the front and back walls to cover the rivets, and create a cleaner look. This effort is no longer necessary when the outside walls of the beverage trucks are bonded.



Falcon HTC® can replace the problematic chain drive with a clean and quiet rubber compound belt that delivers exceptional performance under higher torque and lower speed applications.

Exceptional tensile strength, superior resistance to fl ex fatigue and less noise mean that now you can expect the same long-lasting, low maintenance performance in your low speed drive that you get with the rest of your drive system.

The GOODYEAR (and Winged Foot Design) trademark is used by Veyance Technologies, Inc. under license from The Goodyear Tire & Rubber Company. Goodyear Engineered Products are manufactured and sourced exclusively by Veyance Technologies, Inc. or its affi liates. ©2009 Veyance Technologies, Inc. All Rights Reserved.

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T H E D R I V E S Y S T E M H A S E V O L V E D

F A L C O N H T C ®

LET US INTRODUCE YOUR DRIVE TO

F A L C O N H T C ®F A L C O N H T C ®F A L C O N H T C ®

LET US INTRODUCE YOUR DRIVE TOLET US INTRODUCE YOUR DRIVE TOLET US INTRODUCE YOUR DRIVE TO

T H E D R I V E S Y S T E M H A S E V O L V E DT H E D R I V E S Y S T E M H A S E V O L V E DT H E D R I V E S Y S T E M H A S E V O L V E DT H E D R I V E S Y S T E M H A S E V O L V E D

Untitled-1 1 10/21/10 2:28:36 PM

to meet to try their designs online. Apparently these products are just

the tip of the iceberg. Jon Hirschtick, the founder of SolidWorks said that more new products will be launched in the next 2 years than in the past 16.

Hirschtick reminded everyone that as a founder of SolidWorks he is often asked what it was like in the old days, what it was like in the beginning, when SolidWorks was getting started. His answer: “Today, now, this is still the beginning! Today, now, we are just getting started!”

Alin Vargatu is Senior Applications Engineer at Javelin Technologies (www.javelin-tech.com) and both a Certified SolidWorks Profession and Certified SolidWorks Expert. His blog for DPN is available at www.dpncanada.com/blog/Alin-Vargatu.html.

By Alin Vargatu

F or SolidWorks fans there is noth-ing more exciting than SolidWorks World – the annual users’ confer-

ence of Dassault Systèmes SolidWorks, which, this year, was hosted by San Antonio, TX (no farther than a musket shot from the famous Alamo Mission).

I mentioned excitement, but there was also a lot of apprehension in the user base before the start of this year’s conference, related mostly to the new “SolidWorks-in-the-Cloud paradigm shift” which was the main story for 2010. When the shift was revealed at SolidWorks World 2010 by Jeff Ray, then CEO of SolidWorks, it turned quickly into a PR debacle when it became clear that SolidWorks was unable to answer all the questions from concerned users.

The main bone of contention was the interpretation given to one of Ray’s affir-mations that sooner or later all users will be forced to switch to the cloud solution – when the pain of having a local instal-lation would become too hard to bear. As a result, some people started wondering if SolidWorks would neglect its the stand-alone solution in favor of a cloud version.

It appears that these concerns had been heard loud and clear by SolidWorks,

because during the first General Session, Bertrand Sicot, the new CEO of SolidWorks, affirmed: “Last February we committed on supporting 3 plat-forms: desktop, online and mobile. We have been hearing a lot of conversations about moving the SolidWorks applica-tion online and what it means for the future of the desktop application.

“Here I want to say in front of you: it will never be an either/or choice for you. It’s a decision that you, our customer, will make for yourself. We will always, I repeat, we will always offer locally installed applications desktop CAD, data management or simulation. […] All we want is to have options ready when you tell us you are ready!”

Customers use SolidWorks for a wide variety of design applications. SolidWorks World 2011 demonstrated some of these customer applications – from drills rede-signed in three days and used for saving Chilean miners, to incubators made from car parts to be serviced by any mechanic for saving newborn’s lives in remote regions; from miniature robot controllers that can fit on a robot’s arm to cutting edge technol-ogy that permits patients to walk after knee replacement surgery in just 2 hours.

Discussion at the conference included n!Fuze is a new SolidWorks cloud-based data management product using familiar social networking concepts. The product is in beta testing and will be available as a commercial solution later on this year.

Post3D, another Dassault product that blurs the distinction between the real world and the virtual universe, will be avail-able to SolidWorks users this year. With Post3D, designers can upload their CAD data in virtual environments like confer-ence rooms or factory floors and their sales team can invite potential customers

CAD Industry Watch

SolidWorks World 2011: last year’s “cloud” lifts

Hollywood stuntman and amputee Casey Pieretti (centre) of Discovery Channel’s Bionic Builders displayed his propeller leg prosthetic that provides enhanced water transport.

More products coming in next two years than in last 16



simple text. As a result, the early trade shows tended to focus on graphics cards from a dozen or so brands, often with AutoCAD-specific cards and driver soft-ware, as well as digitizer tablets. That all changed when Windows came along.

Now we come to some of the points you can use to justify going. For start-ers, you can use the slogan we use at the AUGI (Autodesk User Group International) CAD Camps: You don’t know what you don’t know. You may have been doing your job very well for a number of years without even realizing that there is now a faster, easier, more accurate way of doing it.

Autodes University gives you a chance to catch up on the latest or even just on existing alternatives. You had better investigate them, because if your compe-tition discovers them before you do…

This year about 400 instructors (including myself) presented 746 classes on about 500 different topics in three days. These ranged from one-hour presen-tations through to 3-hour hands-on labs.

In addition, 148 different sessions were presented online. They were gener-

topics that were derived from a Web sur-vey of 1000 AU attendees:

The Cloud: This has become the hot-button topic any time two or more com-puter nerds get together. If you haven’t heard the word in this context, it basi-cally refers to storing data and running applications from servers somewhere on the Web.

You don’t know exactly where, it’s just up in the clouds somewhere. Check out the sidebar below for more thoughts on this topic.

Mobility: As mobile devices become ever more prevalent, powerful, and per-vasive we’ll see them being used more and more in the context of design soft-ware.

You will probably not want to do heavy-duty design work directly on a tablet, but collaboration and data exchange will definitely increase. HP is already equipping its printers with email addresses so you don’t need to print out things that you might need for a meet-ing; instead you just print to the closest printer when and where you need it.

Input: Touch screens are definitely on the increase. Other input technology that was envisioned included a meeting room of the future that would automatically sense who’s there, put the right people on the conference phone, and bring up the correct data on the projector.

The conference also features and industry trade show, where hardware and software vendors show off their wares.

Software products that have become quite prevalent in recent years at Autodesk University include CNC machining post-processors and digital prototyping analysis software, along with specialty products aimed at much smaller, more specialized niche markets. Hardware displays include a large vari-ety of 3D printing devices, while the recent emphasis on photo-realistic ren-dering has brought graphics cards back into the limelight.

In the early days of AutoCAD, it was one of the few PC applications that made use heavy use of graphics, as opposed to most other applications that just used

By Bill Fane

O ver 8000 users of Autodesk products migrate annually from all over the world to Las

Vegas in early December for Autodesk University (AU).

The keynote presentations took on a slightly different twist at AU 2010 held in the Mandalay Bay resort and casino. In the past they have often focused on gee-whiz wow-factor displays that push the upper limits of the technology, and even step over the line a bit with canned demos to show what might be available in the future.

This year, however, the focus was on The Power Of The Possible. Autodesk CEO Carl Bass asked “Why do we do what we do?” and answered that we want our work to have a positive impact on our company, our community, and even the world.

Bass then introduced seven different speakers who each did a presentation on how they are using Autodesk software to help them achieve this goal. Their work includes helping students at a failing high school, a space craft, highway and rapid-transit visualizations, the Tesla electric car, the film Tron: Legacy (right, and custom prosthetics for amputees.

Similarly, each of the industry-specific keynotes featured users who were push-ing the limits of their industry but not of the software. Everything they showed is possible with current software.

The one keynote that did step into the future was the Technology Main Stage, whose theme, not unexpectedly, was What’s New, and What’s Going to be Cool. This was a panel discussion mod-erated by Autodesk with panelists from Dell, HP and Intel. They discussed three

CAD Industry Watch

Autodesk University: Power of the Possible

ally repeated at least once to accommo-date various time zones; I did one at 6:30 a.m. and again at 9:00 p.m.

Another reason is networking. You will be with your peers, and often the informal gatherings can be as useful as the official classes. At lunch one day two attendees were discussing their jobs.

Although they were in different indus-tries, it turns out that they had a com-mon problem for which one of them had found a solution. After hearing the explanation the other attendee said “I don’t need to attend any other classes; what I just learned will more than pay for my trip!”

So start working on your boss now to send you to AU. This year it will be moving back to the Venetian in Las Vegas from November 29–December 1. Check out http://ow.ly/3ZXKa for details.

Disclaimer: Autodesk covered my AU expenses and paid me to teach five sessions.

Bill Fane ([email protected]) is a software reviewer and retired mechanical engineer-ing instructor at BCIT in Burnaby, BC.

Having a positive impact on our company,

our community, and even the world

A popular keynote was the one for media and entertainment, even to people not in the industry, because it showed a sneak preview of excerpts from the film Tron:Legacy.

Cloud computing: arguments for and against

As indicated in the main article, “the cloud” (as in cloud com-puting) is a hot topic. As such

it has stirred up some pretty strong feel-ings both for and against.

Some of the reasons presented in favor of the cloud are:

• Users can run powerhouse appli-cations on cheaper, less powerful machines. Photorealistic ray-tracing renderings in particular, like those created for Avatar, become more via-ble. Complex stress analysis and fluid flow calculations could benefit from using the cloud.

• Users will always be running the lat-est version of the software with the latest service packs.

• I can rent time as I need it, and avoid capital expenditures.

• Properly done, on-line storage should be much more secure. Redundant backups will be kept, and profes-sional security specialists will guard against outside attacks.

• Real-time world-wide collaboration becomes quite viable. For example, check out my previous article about AutoCAD WS.

Now we come to some of the arguments against:

• Most design and engineering applica-tions don’t have the extreme render-ing needs of a movie studio.

• Is running the latest version always a good thing? Do you want to arrive for work one morning with a dead-line looming on a major project only to discover that the cloud provider has switched to a newer release with a totally-different interface and file format?

• Okay, the short-term-use argument

could be pretty hard to beat, but note my next comment.

• How do I know that the on-line sup-plier is following proper procedures? What is their financial status? Who owns the files that I store there? Will I have to keep on paying software rental time to access my files, even if I have stand-alone copies of the program?

• Will I always have access to the soft-ware? How about if I want to work at my cabin at the lake, or in an air-plane?



ISO 9001 compliance

TrainingTracking.net has launched its web-based training, tracking and compliance solution. The cus-tomizable TrainingTracking.net contains the features QA manag-ers, training managers and HR executives need, such as reporting and automatic email notifi cation. The intuitive dashboard highlights all critical issues that could jeop-ardize compliance with ISO 9001, 13485, 1400, 19011 and 22000; AS9100, TS 16949, SQF 2000, OHSAS 18001, QS 9000, QS, QA, GMP, OSHA and HIPAA.www.trainingtracking.net

Business intelligence, analysis tool

Altair Engineering has released ver-sion 6.0 of HiQube, its simulation-driven business intelligence (BI) and data analytics solution. HiQube 6.0 is said to expose its multi-dimen-sional data engine to business ana-lysts through a new, self-service Web client, customizable dashboards, un-balanced hierarchical data manage-ment, and embedded mathematical optimization for higher-level what-if analysis. Enterprise accessibility to HiQube also has been expanded to the latest Windows, Red Hat and Ubuntu desktop and servers.www.hiqube.com

Factory layout optimization for AutoCADAutodesk has announced the availability of Factory Layout Optimization for Au-toCAD software, a free technology preview available on Autodesk Labs (http://

ow.ly/3XsDF) enabling industrial engineers and layout designers to devise more effi -cient factory layouts for material handling. The AutoCAD plug-in helps manufacturers adopt leaner manufacturing methods, de-creasing waste and improving overall fac-tory effi ciency.www.autodesk.com

CAD Chronicle

NX supports Visual Reporting

NX product design software, from Sie-mens PLM Software, now supports High Defi nition 3D (HD3D) and Visual Re-porting. The capabilities are said to make critical product information much more useful by visually delivering PLM data as part of the product model, enabling design teams to quickly gain knowledge about a product and visualize its impact directly within the context of the NX 3D design session. www.siemens.com/nx

p

gy p

l h l d

3D concept design, visualizationDesign software developer solidThinking Inc.has released its latest 3D concept design and visualization software, solidThinking 8.5 and solidThinking 8.5 Inspired. Aimed at industrial designers, concept engineers and architects, the solidThinking 8.5 releases introduce more than 900 new features, enhancements and updates, including: modeling with a faster workfl ow and functional performance; data ex-change/CAD Collaboration with direct import for several native formats; and, a real-time photorealistic rendering options.www.solidthinking.com

Finding 3D parts from SolidWorks PDM

3DSemantix has announced that 3DPartFinder geometry-based search engine for SolidWorks has been integrated to SolidWorks Enterprise PDM software and PDM Workgroup software. Launch 3DPartFinder from SolidWorks and suitable matches are displayed in a SolidWorks assembly using the 3D space in a unique and intuitively understandable manner. www.3dpartfi nder.com

S i h d h

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Rugged, Accurate, ProgrammableUnparalleled Flexibility

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Field programmable resolution and output voltage

HS35 Motor Feedback Encoder

Untitled-11 1 2/22/11 2:08:05 PM

Untitled-2 1 3/4/11 11:15:34 AM

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Sub-miniature manifoldsClippard Instrument Laboratory has in-troduced a series of sub-miniature mani-folds for the 10 mm and 15 mm solenoid valves. The single-sided units are avail-able with 2, 4, 6, 8, 10, 12, 14 and 16 stations.www.clippard.com/10-15mm

PM#

4006

3602

Inside: Mechanical CAD Power Transmission Sensors Hydraulics & Pneumatics

Volume 37 Number 1

DESIGNPRODUCT NEWSCovering the total design engineering function in Canada

January/February

2009

Continued on page 10

Multifunctional monitoring The Novotechnik MAP 4000 Series fea-tures include programmable input selec-tion and mathematical functions, as well as up to four limit switches, and ana-log outputs. Units can perform up to 40 measurements/s.www.novotechnik.com

PAP Registration No. 10773

N eglected sealed lead acid (SLA) batteries pose an annual headache for mo-torcycle, scooter, snowmobile and boating enthusiasts. However, designed-in-Canada desulfater-chargers are available to refresh these deep discharged batteries so owners can get on their way when they first turn the igni-tion key.

TecMate North America (www.tecmate.com) of Oakville, ON, manufacturers a wide range of electronic diagnostic tools and char-gers for the 6-, 12- and 24-V battery market. For over a year now, it has contracted Oakville-based product design specialist ORSeS Inc. (www.orses.ca) for mechanical redesign and packaging of its products.ORSeS services include an experienced industrial design consultancy, through Brad Schilling, its chief technical officer. Schilling has more than 20 years of industrial design experi-ence, including at GE major appliances, and

more than 15 years of PTC

Pro/ENGINEER 3D modeling experience, in-cluding advanced surfacing, sheet metal and plastic package design. All the external packaging of the products have been redesigned and modeled by ORSeS using Pro/E. The electrical components and PCB design has been done under the supervi-sion and guidance of Martin Human, CTO for TecMate. According to Mike Cooper, TecMate di-rector of sales in North America, “The new designs have included a number of important design specification changes, which are driven by customer requests. Changes include a var-ied color scheme and new sealed shapes for the product range and an improved, simpler man-ufacturing process, which in turn has helped reduce the product costs.” Much of this has been enabled due to the use of 3D modeling, as well as the experience of ORSeS.

Multi-loop PID controllerWatlow has introduced the EZ-ZONE RM – a DIN-rail mounted, confi gurable multi-loop PID temper-ature/process controller. Units can be confi gured with between 1 to 16 mod-ules controlling from 1 to 64 loops.www.watlow.com

d anap to 40

-, -

beod-

bile and boating

5CD n-cluding advanced surfacing,

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ed A)

se an che for mo-bile and boating

more than 15years of PTC

Pro/ENGINEER 3Dmodeling experience, including advanced surfacing

TecMate refreshes lead-acid batteriesBy Mike Edwards

dpncanada.comDPN Jan_Feb 09indd.indd 1DPN Jan_Feb 09indd.indd 1

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Food and Beverage Products Guide

Untitled-6 1 3/3/11 3:08:09 PM

Compact gear reducer

The IronMan E series gear reducer from Grove Gear operates at 90% effi ciency. The product has a compact housing de-sign that offers a direct replacement to traditional worm gear reducers. By uti-lizing helical-bevel gear technology, the series has up to 60% more torque than many brands’ worm gear designs, the company says. With mounting base kits, the series can drop-in and replace mul-tiple sizes of worm gear speed reducers. www.grovegear.com

Grounding bearing isolator

The Garlock SGi Shaft Grounding Bear-ing Isolator is said to be the fi rst seal to protect bearings from electrical dam-age as well as from lubricant loss and contamination. It is suitable for motors controlled by variable frequency drives (VFDs) running pumps, fans, high-speed spindles, and other equipment in “se-vere-duty” applications such as mining and the processing of pulp/paper, food, pharmaceuticals, chemicals, and water/wastewater.www.garlock.com

Bearing protection ring

The AEGIS SGR bearing protection ring from Electro Static Technology protects the bearings of VFD-driven motors from electrical damage, and the AEGIS Universal Mounting Kit (U-Kit) simpli-fi es its mounting on different ac mo-tor shafts. The kit includes the AEGIS grounding ring and mounting hardware for most motor designs. Ordered based on the NEMA “u” shaft diameter, the kit contains the correct size ring for the motor and four styles of brackets with bolts and lock washers that can be used in various confi gurations.www.est-aegis.com

High temperature bearing

igus iglide A350 polymer plain bearing material can handle long-term tempera-tures up to 356°F. It is suitable for ap-plications in the food, packaging and bottle-fi lling industries. The blue-tinged material delivers low coeffi cients of friction and is resistant to a variety of chemicals and other liquid media. The plain bearing is also corrosion-resistant, lubrication- and maintenance-free.www.igus.com

High torque servo motor

Baumüller has introduced DST torque synchronous motors that offer a higher power density, in addition to a wider range of available speeds and torques than previous models. Extension of the motor series to include a 400-size motor means that rated torques up to 20,000 Nm and maximum torques up to 32,000 Nm are possible. The product line also requires less installation space, thereby reducing the contact surface for machines, the company says.www.electromate.com

Brushless dc servo motors

The BX4 line of brushless dc servo mo-tors from Faulhaber has added a 22 mm module. The 2232/2250 BX4 CSD/CCD is said to be the world’s smallest brushless motor with integrated motion controller in uniform-diameter construction. The company says it combines all the advan-tages of BX4 technology in a tiny pack-age: long service life, high non-cogging torque and freedom from adhesives. This makes them ideal for use in demanding application areas such as robotics, au-tomation, medical technology, specialty machinery and the aerospace industry.www.faulhaber.com

Products: Power Transmission

Motor survives the depths

Maxon motor has launched the EC22 HD (heavy duty) motor, a 22 mm-di-ameter brushless motor said to outper-form other commercial electric drives on shock, vibration and temperature toler-ances. The electronically commutated motor was developed in collaboration with the oil exploration industry and is designed to operate at depths of around 16,000 ft and in boreholes up to 36,000 ft long. The motor operated at tempera-tures up to 240°C and under atmospheric pressure conditions from high vacuum to 25,000 psi. www.maxonmotor.com

Drives double axial thrust

RG3 linear drives from Amacoil-Uhing are now available with an extra bearing option which doubles the axial thrust capacity of the drive unit without sig-nifi cantly increasing the length of the drive box, the company says. RG4 model drives are also said to be an economical solution because increasing thrust with the 4-ring option is less expensive than scaling up to a larger size RG3 drive. Nine RG3 sizes are each available with the 4-ring option. www.amacoil.com



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Untitled-2 1 2/24/11 9:26:36 AM

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Linear Ball Bushing® Bearings

Thomson invented anti-friction linear technology over 60 years ago and has continued to lead the industry ever since. The Thomson brand is recognized and trusted as the global leader in linear motiontechnology.

Thomson offers the widest range of ballscrew products in the industry – includingrolled and ground thread screws in bothimperial and metric sizes.

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500 Series Ball Linear GuideThomson 500 Series Ball Linear Guides provide longlife, exceptional rigidity, high dynamic and static loadcapacities, accommodation for high moment loads,high running accuracy, multiple sealing options and multiple lubrication inlet options.

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Untitled-6 1 3/3/11 3:08:09 PM

Manual motor controllers

The Bryant line of manual motor con-trollers (MMC) now available through AutomationDirect is UL listed as “suit-able as motor disconnects.” Bryant’s controllers feature thermoset bodies, to provide high resistance to electrical arc tracking, and AC-rated silver alloy contacts for excellent conductivity and extended life. The compact devices are available in NEMA 1, 3/3R and 4X en-closures; each controller has lockout/tag out capability. Bryant Toggle AC manual motor controllers feature quick-make/slow break operation to provide reliability and long life.www.automationdirect.com

Soft starter with AAC

Danfoss VLT Drives has introduced the VLT Soft Starter MCD500 with Adap-tive Acceleration Control (AAC). The soft starter is available in 23 models and fi ve different frame sizes, from 21 to 1600 A (7.5 to 800 kW). The G1 frame size is IP20 rated, and G2 to G5 frame sizes are IP00 rated. The unit is also said to be signifi cantly smaller than its MCD3000 predecessor.www.danfossdrives.com

3-phase motor control

STMicroelectronics has announced a customizable motor-control module that is small enough to mount directly on the motor, in addition to providing connection via industrial Ethernet. The SPIMD20 can drive brushless 3-phase motors up to 2 kW, and combines ST semiconductor technologies, including 1200 V/40 A IGBT power switches and the TD352 gate driver. A real-time com-munication interface supporting proto-cols such as EtherCAT and CANopen DS402 is also provided.www.st.com

Profi le rail linear guides

Thomson has introduced the 400 series profi le rail linear guides. The series is available in 4 m lengths, in sizes from 15 to 45 mm in 5 mm increments, that is said to offer extended joint-free rail transfer, even in smaller-sized applica-tions. Double-faced ball track bearing arrangements allow for compliance to simplify installation, and enable equal load carrying capacity in all directions. The series is available with standard or ball cage carriages that use the same rail design.www.thomsonlinear.com

Products: Motion Control

DIN mountable controller

With a new range of powerful and high-ly compact DIN-rail-mount controller hardware, Bosch Rexroth now offers its IndraMotion MTX CNC solutions with multi-Ethernet protocol support. The company says that end-users and OEMs can take full advantage of major Ethernet protocols such as SERCOS III Ethernet motion including I/O, as well as Profi bus, Profi Net or Ethernet/IP for Fieldbus con-nections. www.boschrexroth.ca

Linear stepper motors

Johnson Electric has introduced the Saia ULE series linear stepper motors. Avail-able in unipolar or bipolar confi gurations, the motors provide constant positioning force to 400 N over full travel lengths to 300 mm in ambient temperatures rang-ing from -15° to 60°C. Units have a 55 x 55 mm design envelope and NEMA 23 mounting fl ange. www.saia-motor-usa.com

Untitled-3 1 3/3/11 11:32:50 AM



LP-108-A.ai 1 9/1/2009 2:18:31 PM

Smalley_DPN_Mar_10.indd 1 3/2/10 10:47:07 AM

For many cases there is no early warn-ing that the destructive process of cancer is underway, but physicians

can now have the means to corroborate suspicions of skin cancer with technology.

MedX Health Corp. of Mississauga, ON, is a designer, manufacturer and dis-

tributor of low level laser and light therapy technology for use in numerous medical settings that provide patients with non-inva-sive, drug-free alternatives for improving clinical results. MedX (www.medxhealth.com/) laser/light therapy devices improve the standard of care for tissue repair and pain relief, as well as for help in diagnosing pigmented skin lesions in dermatology.

Low level lasers, also referred to as cold lasers, have a long history of well docu-mented use in a wide variety of conditions. There is a wealth of published articles and research studies showing that light energy can be absorbed into cells resulting in increased tissue repair, wound healing and significant reduction of pain.

Studies have shown 20 to 40% accelera-tion in tissue repair, and the cascade of bio-chemical reactions that occur to the focused light lead to the release of serotonin, which is the body’s natural pain reliever.

An innovation from MedX Health (www.medxhealth.com) is a device for the early detection of skin cancer and the analy-sis of melanoma. The device, known as a MoleMate, refers of course to the body mole (not the subterranean rodent that wrecks the garden).

People are not generally born with moles. They develop in infancy and one’s personal mole quota usually levels off at puberty. Factors such as puberty, pregnancy and sun exposure may increase the size and pigmentation of moles.

Moles are not necessarily cancerous but they can be indicators. Size, shape, color and texture can all be significant and to a dermatologist they can be helpful factors in sifting the ‘OK’ from the bad and the suspi-cious. This is where MoleMate plays an invaluable role because it can see what the human eye can’t see.

MoleMate is non-invasive hand held device for skin analysis. It is supported by a technology known as SIAscopy and the skin analysis system is called a SIAscope. SIAscopy (spectrophotometric intracutane-ous analysis) provides color bitmaps called ‘Siascans’ that show the relative location of blood, collagen and pigment in a lesion on the skin. There are several versions of proprietary software to aid a dermatologi-

cal analysis. The SIAscope operates by illuminat-

ing the skin with LEDs and measuring the intensity of remitted light.

Unlike a biopsy, SIAscopy is non-inva-sive and provides an array of quantitative measurements of the skin that are displayed in graphical form creating a synthesized image – the SIAscan. Each SIAscan isolates four critical features (pigment, dermal pig-ment, blood supply and collagen) viewed over an 11 mm diameter area and displays it in conjunction with a magnified ‘derma-toscope’ view of the lesion. This data is extremely useful as an adjunct in the clini-cal diagnosis of skin lesions and other skin conditions, as well as a valuable asset in planning their treatment.

MoleMate and its related technologies are currently available and being used by physicians in the UK and Australia.

The technology has been evaluated in three clinical trials which have recruited more than 1500 patients assessed with MoleMate. In a substantial UK primary care trial, the rate of sensitivity (true posi-tives) and specificity (true negatives), the key yardsticks of diagnostic tests, were 96% and 83% respectively, and compared favor-ably on both measures with benchmark rates from general practitioners using con-ventional techniques.

Mark Sunderland is President of Ottawa-based BioMedical Industry Group ([email protected]).

Handheld scanner analyzes moles for cancerBy Mark Sunderland

Medical Engineering

Mole shape, size, color and texture offer

cancer clues to the dermatologist

MoleMate is a non-invasive hand held device for skin analysis.

Zero backlash. Jam-proof design.

For positioning & reciprocating motion applicationsSmooth movement; ultra-low maintenanceUhing® Rolling Ring linear drives have zero play when the shaftis rotated – even during reversal. The threadless shaft won'tclog or jam. If the system is somehow overloaded, the shaftsimply slips instead of churning and grinding.

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CPT says its system is ready for use on production vehicles. Bill Vance is an automotive journalist & author (www.billvanceautohistory.ca).

Published by

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Ajay Bajaj, Rotator Products Ltd. (rotatorproducts.com) and Power Transmission Distributors’ Association (ptda.org)

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Electric superchargers about to go mainstream

er operates independent of engine speed and provides instantaneous response – the electric motor accelerates the low inertia turbine from 5000 to 70,000 rpm in <0.35 s – CPT says that when it is fitted in series with a fixed geometry turbocharger, which they recommend, it fills in the turbo lag by providing imme-diate boost up to 3000 crankshaft rpm.

The system gives a seamless surge of close to an additional 20 hp within one second. There is virtually no para-sitic loss, it can operate on regular 12 V automobile electrical systems and can be fitted to gasoline or diesel engines.

CPT says its system will allow auto-makers to not only reduce engine size, but use much “taller” fuel-saving gear ratios to achieve significantly lower highway revolutions, possibly as low as 1000 rpm. Normally this low crankshaft speed would not produce enough torque to keep high-gear passing and hill climb-ing ability at acceptable levels, but the immediate interim boost from VTES compensates until the turbo spins up.

CPT has run tests with a Volkswagen Passat with a 2.0 litre gasoline engine and registered approximately 20% lower CO2 emissions. The company is working on integrating its stop-start “SpeedStart” technology with CPT to gain even lower emissions and fuel consumption.

In keeping with the “greening” trend that is bringing ever tightening leg-islation on fuel consumption and

emissions, particularly CO2, auto manu-facturers are exploring every possible avenue to meet these and avoid stiff non-compliance fines.

A major measure is reducing engine size, sometimes by as much as 50% in extreme cases. But this has to be compensated for because motorists will continue to expect the same passing and hill climbing performance, as well as the ability to keep up with traffic flow they had with larger engines.

Many manufacturers are accomplish-ing this by using forced induction, in other words, pumping more air into the engine than it would breathe normally. This supercharging is either by a positive displacement supercharger (an air pump) rotated by a belt from the engine crank-shaft, or a turbocharger comprised of a small, high speed exhaust-driven turbine spinning a centrifugal supercharger.

While both increase power, they also have disadvantages. Belt-driven super-chargers incur a constant parasitic drag on the engine – although this is starting to be addressed by clutched drives. And turbochargers have a momentary lag between the demand for power and when the turbo rotor spins up fast enough to

By Bill Vance

Automotive Scene

produce boost. And both add consider-able cost and complexity to an engine.

To address these disadvantages a UK company, Controlled Power Technologies (CPT) of Laindon, Essex, working with AVL List of Austria (www.avl.com), pro-ducer of powertrains and other products, has developed a new type of supercharger powered by an electric motor. The motor, in effect, takes the place of the exhaust turbine in a turbocharger and drives the centrifugal compressor, the “cool” end of the turbocharger.

The two companies are not alone, although they must be the most thor-ough. Many aftermarket companies offer off-the-shelf, bolt-on electric supercharg-ers but their promise of instant power at low cost is often more hype than performance.

CPT (www.cpowert.com) is an auto industry supplier specializing in, among other technologies, fitting 12 to 24 V electrical devices to automotive power-trains. It works closely with manufactur-ers’ engineers to adapt their products to specific applications. The CPT electric supercharger, which it calls a Variable Torque Enhancement System (VTES), has been under development for around 10 years.

Termed a “micro-hybrid” applica-tion, it promises to be much less costly than the questionable economics of a full hybrid system comprised of an electric motor and battery pack teamed with an internal combustion engine. CPT’s micro-mild approach is a kind of interim step between non-hybrid and full hybrid, and in addition to lower cost, has the advantages of being light, compact and easy to package under the hood.

VTES is intended to facilitate the trend to smaller engines by keeping the same level of performance that motorists are used to. Since an electric turbocharg-

An electric turbocharger operates independent of engine speed and

provides instantaneous response

The Controlled Power Technologies supercharger powered by an electric motor.



From idea to implementation, leading

engineers choose Numatics as their single source for

quality fluid power components and technologically-

advanced design resources. Just as important, they

know our industry-leading Numatics Express Cylinder

shipping program will get NFPA Interchangeable cylinders

on the job site – fast.

Visit www.asconumatics.ca today and discover

the difference superior quality and unprecedented service

can make to your next project.

From our site to yours. Fast.

How fast is fast? Order up to 5 of the same

cylinders from the Numatics Express brochure

by 3 p.m. EST and we’ll guarantee shipping in

two business days – or we pay the freight!

For product information: www.asconumatics.ca Tel: 1-866-696-1601 [email protected]

From our site to yo two bu

O d up to 555 of tthehee saammme

Speed or quality. Why not choose both?

Untitled-15 1 2/22/11 3:04:12 PM

Programmable inclinometersTurck has enhanced its line of inclinom-eters with the introduction of a single axis device with dual programmable set points. Like all Turck inclinometers, the device uses MEMS (micro-elec-tro-mechan-ical system) technology to solve feed-back require-ments. The offering re-places the traditional analog output with two discrete outputs and is programmable for settings such as on or off points, span and hysteresis. Users can program the in-clinometer using a teach adapter. Single axis inclinometer sensors incorporate an adjustable measuring range of 360°, are IP68 rated and have a temperature range of -30° to 70°C.www.chartwell.ca

Products: Editor’s choice

PCB, fi xed terminal Blocks

FCI has expanded its electronics product portfolio with printed circuit board plug-gable and fi xed terminal blocks. The PCB signal and power terminal blocks are avail-able in pluggable and fi xed confi gurations in various pitch-sizes and wire sizes. The proven rising-cage clamp technology is said to ensure long life and reliable connections. The terminal blocks come with the support tools to facilitate easy design-in, such as the web-based Terminal Block Product Se-lector that includes 3D mechanical model downloads.www.fciconnect.com/terminalblocks

Vacuum suction cups

Anver Corp. has introduced Vacuum Probe Cups that feature button probe valves which remain closed to save air and energy and are actuated when they touch the load, providing faster attach-and-re-lease than conventional cups, the company says. Suitable for continuous duty and for large pick-up arrays used in high cycle automation equipment, the units prevent leakage caused by suction cups that missed the load or are not being used. The Delrin button probe protrudes slightly from the centre, is spring-loaded to remain closed, and opens instantly when it touches a load to permit vacuum fl ow.www.anver.com

Power distribution blocksThe Edison power distribution line from AutomationDirect now includes the HPB series open-style power distribution blocks, designed as a convenient way to manage power distribution needs. The distribution blocks maintain a high SCCR rating of 200 kA, with proper fusing, and are suitable for both factory and fi eld wir-ing. Available in single-pole and three-pole

models, the series is available in 175 and 310 A blocks.www.automationdirect.com/power-blocks

Inclinometers with DeviceNetPosital Accelens inclinometers from Fraba are now available with a DeviceNet elec-tronic interface to permit connection with

embedded control units (ECUs) and pro-grammable logic controllers (PLCs). Single axis (360°) or two-axis (±80°) models are available. Molded polyurethane enclosures provides IP68 or NEMA 6 environmental protection, while internal components can withstand shock loads of up to 100 g and vibrations as high as 20 g.www.fraba.com

SLICK? SLICK?[ maybe ]

U.S. PatentNo. 6,872,039Foreign PatentsPending

With a Self-Locking Implanted Cotter, it’s a pin and cotter all in one! COST SAVING. QUICK LOCKING. SECURE. If you’re using labor intensive pins, cottersor clips, try something SLIC.

SLIC Pin™

DEFINITELY.

NEW

BOW-TIELocking Cotters™WORKS LIKE A HAIR PINCOTTER BUT LOCKS ITSELF ON.

RUE RING™LockingCottersSURROUNDS THE SHAFTAND LOCKS ITSELF ON.

U.S. PatentNo. 4,592,689

U.S. Patent No.6,135,693 and D431,181

Positive Lock PinsPUSH BUTTON,DUAL BALL SECURITY.

Nylon Lanyards™NYLON TETHER IS 1/3 THECOST OF STEELLANYARDS.

U-Lock StyleU.S. Patent No.5,784,760

SPECIALS - Our Specialty!

N O N - T H R E A D E D FA S T E N E R S O L U T I O N S

920-349-3251800-222-2231

www.pivotpins.comHUSTISFORD, WI, USA

Now available withoptional T-handle.

AUTOMATED ASSEMBLYMEANS WE CAN OFFERPRICING COMPETITIVE WITH IMPORTS!

Steel LanyardsBall Detent PinsWE’RE THE EXPERTS IN BALLDETENTING TECHNOLOGY!

Numerous styles and configurations available.

PivotPoint_DPN_Mar09.indd 1 2/12/09 12:27:33 PM



Phoenix

The PSR Safety Portfoliofrom PHOENIX CONTACT –Simplicity in Safety!

When it comes to safety technology,

safety relays must be easy to use and

safe – this is the basis for the PSR series

from Phoenix Contact.

A combination of innovative connection

technology, compact, space-saving design

and clear layout offers fast and simple

implementation of your safety applications.

Certified safety offers the highest standard

of quality and reliability. PSR safety

switching devices are developed and

certified in accordance with the latest

functional safety requirements for control

systems in machines and systems.

CAT/EN 954-1PL/ISO 13849-1SILCL/IEC 62061SIL/IEC 61508cUL ListedGL

For additional information please contact:

Toll Free: (800) 890-2820E-mail: [email protected] visit:

www.phoenixcontact.ca/safety

© PHOENIX CONTACT 2011


Clippard Maximatic® Solenoid & Air Pilot ValvesClippard all-new Maximatic 3-way, 4-way, single and doublesolenoid, 3-way and 4-way air piloted valves are available inmany sizes and variations for a wide range of applications.Specified, tested and backed by Clippard, these quality manu-

factured imported valves are available in sizes from #10-32 to 1/2”, and pressureranges from 0 to 150 psig, depending on the valve and model.

The Maximatic line offers a comprehensive valve series that maximizes flow, arecompetitively priced, and will provide Maximum Value and Maximum perform-ance.

Call Clippard today at 513-521-4261 or visit www.clippard.com/maximatic-b torequest a free Maximatic catalog.

EXPANDED!ClippardPush-QuickFittingsClippard’s Push-

Quick Fittings speed tube insertion forassembling pneumatic circuits. The fit-tings provide a simple method to con-nect pneumatic components and acceptboth flexible hoseand rigid tubing.Many configura-tions, threadoptions and tubingsizes offered.

Thread Sizes#10-32, M5, 1/8” NPT, R1/8, 1/4” NPT,R1/4, 3/8” NPT, R3/8” and 1/2” NPT

Tube Sizes1/8”, 5/32”, 6 mm, 1/4”, 5/16”, 3/8” and1/2”

Visit www.clippard.com/catalog-b torequest a free catalog.

NEW! Clippard Full-LineCatalogClippard’s new 350+ page catalog,with technical information, productapplications, and more, is now avail-able. It includes features, specifica-tions, color photographs, and techni-cal drawings for over 5,000 standardproducts. It's your complete sourcefor miniature fluid power products.Request your free copy today!

Call Clippard today at 513-521-4261or visit www.clippard.com/catalog-bto request a free catalog.

Clippard Brass ValvesClippard offers poppet or

spool designs; 2-, 3-or 4-way functions,in sizes from #3-56

and #10-32 through1/8” NPT ports; and for pressures up to300 psig. They are available with sole-noid, air pilot, manual and mechanicalactuators. Mounting styles includeinline, panel mount, manifold mount orclearance holes for mounting screws.When you are looking for a valve,Clippard’s minimatic line of valves pro-vide a complete range of sizes andstyles.

Call 513-521-4261 to request a free catalog.

NEW Interchangeable

Design!

Clippard Maximatic® FRLsFor the maximum operating efficiency ofpneumatic equipment, FRLs are avail-able with port sizes from #10-32 to 1”.Filters, regulators and lubricators areavailable as individual components aswell as complete FRL combination units.Some of the many features of this all-newline include various bowl and drainoptions, large selection of mountinghardware, easy-to-read gauges and sightglasses, and much more.

Call Clippard today at 513-521-4261 orvisit www.clippard.com/maximatic-b torequest a free Maximatic catalog.


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Electric vehicle conversion - Design Product News