Tài liệu Machine design, tập 84, số 04, 2012

March 22, 2012 A Penton Media Publication Tune in to EngineeringTV.com RADIOS IN SPACE: SDRs FOR THE SPACE STATION, page 20 WILL ALUMINUM ION BATTERIES MAKE LITHIUMION OBSOLETE? page 38 A GLIMPSE OF THE FUTURE THROUGH CONCEPT CARS, page 44 ENGINEERING FOR THE OTHER 90%, page 52 RS# 101   &  '    (  RS# 102                                     !        !              "#   $                    !    % !            &                  !    %   ! 

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!  +                     VOLUME 84 ISSUE 4 MARCH 22, 2012 AUTOMOTIVE Concept cars 2012: Chevrolet Tru 140S A glimpse of the future Whether consumers want ecoconscious electric cars, gasburning performance or economy, or a hybrid of the two, the world’s automakers seem ready to build it. FEATURES Scion FR-S Chevrolet Code 130R Authored by: This year’s Detroit Auto Show featured several concept cars, everything from micromini pickups to flashy highperformance hybrids. There was also a good mix of powertrains showcased, including several all-electric cars and vans and a wide variety of hybrids. And conventional gas-powered concepts also held their own. Conventional engines 20 NASA payload will test software-defined radios Space Communication and Navigation Testbed will communicate with both Earth and space-bound radios. The low, sleek FR-S (front-engine, rear-wheel-drive) sport car from Scion could help you forget the boxy designs the company is known for. It carries a 200-hp, 2-liter boxer engine mounted in front, but lower and farther back than other front-engine cars. This gives the concept car a lower center of gravity and a front-to-rear weight ratio conducive to good handling and dynamics. The engine uses direct and port injection for more power — 200 hp — as well as more torque throughout the powerband without sacrificing fuel economy. The flat four mates to a six-speed manual or automatic transmission. Chevrolet is looking to connect with car buyers under the age of 30, hoping to tap into some of their estimated $1 trillion in purchasing power. One concept car they have designed with the younger buyers in mind is the Code 130R, a four-seat coupe. It features a 1.4-liter turbocharged EcoTec engine that can crank out 150 hp or 148 lb-ft of torque, and still get 40 mpg (highway). The car also uses eAssist, a combination of features that include shutting off the engine at stops, regenerative braking, and 44 MACHINE DESIGN.com smoothing torque during accelerations. These features should help balance turbocharged performance with fuel economy. The other youth-targeted concept car from Chevy is the Tru 140S, a streamlined front-wheel-drive sports coupe. The four-seat, three-door hatchback is based on the same platform as the Cruze and Volt. It carries the same engine and powertrain features as the Code 130R. Chevy plans to market both of these cars soon and with the features young car buyers say they want. This includes a price tag under $20k, fuel economy of at least 40 mpg, as well Wi-Fi, smartphone integration, a headsup display, and Chevy’s MyLink connectivity. To get this audience’s opinions on what the interior and dashboard should look like, Chevy will take the cars to several major auto shows, key lifestyle events such as concerts and festivals, and college campuses. There, t he y wi l l us e MARCH 22, 2012 kiosks and other social media to gather opinions and suggestions. The MKZ concept car is the next step in the reinvention of Lincoln, according to that company’s Vice President of Global Product Development, Derrick Katz. Though clearly conservative in design, the MKZ does feature a glass roof that stretches from the windshield back to the rear window and from the left roof rail to the right rail, The four-door, four-seat sedan can be equipped with a variety of front or rear-wheel-drive engines. Many auto observers believe that when the MKZ comes to the showrooms, it will carry a 300-hp, 3.7-liter engine, the same one found in the MKS. It might also have an optional twin-turbo 3.6-liter EcoBoost V6 with about 355 hp. And a hybrid version is also a possibility. The car boasts a continuously controlled damping suspension, which is driver adjustable, and Ford’s lane-keeping subsystem that alerts drivers when the vehicle strays from its lane. And in a retro touch, the car’s Lincoln automatic transmission is controlled MKZ using pushbuttons. Hybrids The NS4 from Toyota uses a nextgeneration plug-in hybrid drive, which should get better acceleration, longer all-electric range, shorter charging times, and be smaller and lighter, compared to the current Prius MARCH 22, 2012 44 to lithium-ion 38 Goodbye batteries? Aluminum is cheap, easy to find, and can be used to devise batteries having a higher energy density than that from lithiumion batteries. 44 ELECTRICAL/ELECTRONIC Goodbye to Inexpensive aluminum may hold the key to battery chemistries that pack more punch than today’s lithium-ion cells. Concept cars 2012: A glimpse of the future Here’s a look at what the automotive industry is planning for the future. lithium-ion batteries? Authored by: Leland Teschler Editor [email protected] Resources Cornell University, Energy Materials Center, http://www.emc2.cornell.edu/news/story/ Science%20news.html Oak Ridge National Laboratory, Aluminum Battery Research, http://www.ornl.gov/adm/ partnerships/events/presentations/spark_ aluminum_ion_battery.pdf For more info on lithiumion batteries, scan this code or go to: http:// machinedesign.com/ article/lithium-ionbatteries-get-a-boostfrom-novel-materials-1103 Back to the future? 52 Designing for places that 38 can’t afford high tech. MACHINE DESIGN.com A piece of aluminum has more free energy content than the same amount of either methanol or ethanol. That, succinctly, explains why scientists are now trying to perfect batteries based on chemistry that involves aluminum. Even better, aluminum-ion batteries promise to squeeze more energy into a given space than the lithium-ion batteries that seem to be in the headlines these days for all the wrong reasons. Aluminum is the most abundant metallic element and the third most abundant of all elements on the planet. Most of the countries that mine the bauxite ore from whence it comes are friendly to the U. S. And the metal’s abundance brings the promise of aluminum-based batteries that are relatively cheap. The key quality of aluminum that makes it advantageous in battery chemistry is the fact that it is trivalent, having three valence electrons involved in forming valence bonds. Lithium, in contrast, has one valence electron. The result is that battery charge/discharge reactions (per formula unit) involving aluminum transfer three electrons compared with only one with lithium. So an aluminumbased battery can be smaller than a lithium-ion cell packing the same power: Aluminum-based batteries have a potential energy density of 1,060 W-hr/kg compared with 406 W-hr/kg for those based on lithium ion. Problem is, there are a number of obstacles that have made it tough to devise a practical aluminum-battery chemistry. For one thing, aluminum batteries typically use an aqueous electrolyte and consume water during their discharge cycle. They also give off hydrogen. This behavior has made it impossible to come up with an aluminumbased battery that could be sealed. And aluminum used in the battery anode typically corrodes or forms an oxide film. Both factors reduce the efficiency of battery reactions over time. Unfortunately, these effects can take place so quickly that commercial batteries based on aluminum have been impractical for most applications. MARCH 22, 2012 38 Access our Reader Service Web site to quickly find and request information on the products and services found in the pages of MACHINE DESIGN. www.machinedesign.com/rsc 2 MACHINE DESIGN.com MARCH 22, 2012 Stephen J. Mraz Senior Editor [email protected] Resources: Acura, http://tinyurl.com/76emwt6 BMW, http://tinyurl.com/7mrc2nn Chevrolet, http://tinyurl.com/88wdrvd Infiniti, http://tinyurl.com/mmao8n Lexus, http://tinyurl.com/7oy3zdz Lincoln, www.lincoln.com Nissan, www.env200.com Scion, http://tinyurl.com/7fhzzct Smart car, www.smartusa.com Toyota Motor Sales USA, http://tinyurl. com/7qd5zuy Volkswagen of America, http://tinyurl. com/7tphnon For a look at some of our past features on concept cars, scan this code or go to: http://machinedesign. com/article/conceptcars-over-the-past-tenyears-0331 MACHINE DESIGN.com 45 tick tock Less downtime with every valve. Power. Precision. Performance. Continental Hydraulics knows that time is money, that’s why we offer a complete line of Proportional Directional Valves with integrated digital electronics for maximum precision, durability and reduced hysteresis. Our high performance valves are available in all standard NFPA mounting patterns and flow ranges. The on-board microprocessor provides fast response times, seamless interchangeability among valves and supports software-based, hydraulic parameter modifications to ensure optimal load movement. Factory calibrated for time-savings, output range assurance and easy valve-to-valve exchange, our proportional valves offer a smooth, shock-less motion and precise position control to reduce down time, increase production rates and make every second count. RS# 103 PUMPS VALVES POWER UNITS 952. 895. 6400 | www.continentalhydraulics.com ON THE COVER DEPARTMENTS The e-NV200, Nissan’s allelectric concept van. 8 EDITORIAL A Nobel Prize for … engineers? Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert. Microfilm copies available from National Archive Publishing Company (NAPC), 300 N. Zeeb Rd., P.O. Box 998, Ann Arbor, MI 48106-0998, Ph: 734-302-6500 or 800-420-NAPC (6272), extension 6578. 10 EDITORIAL STAFF 12 LETTERS 16 SCANNING FOR IDEAS Rugged CNC router is easy to use Compressed gas keeps circuits cool 20 REPORTER’S NOTEBOOK 28 LOOKING BACK 35 COMMENTARY Do we need a sustainability standard? 36 ADVANCED MANUFACTURING Electron-beam melting builds titanium parts 58 ORR ON ENGINEERING How secure is your job? 59 SOFTWARE PRODUCTS 60 PRODUCT SPOTLIGHT 62 PRODUCTS 66 DATA FILES 68 AD INDEX 69 BUSINESS INDEX Subscription Policy: MACHINE DESIGN is circulated to research, development, and design engineers primarily engaged in the design and manufacture of machinery, electrical/electronic equipment, and mechanical equipment. To obtain a complimentary subscription see our Web page at submag.com/sub/ mn. For change of address fill out a new qualification form at submag.com/sub/mn. Printed in U.S.A., Copyright © 2012. Penton Media, Inc. All rights reserved. MACHINE DESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January, February, June, July, and December by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212. Can GST #R126431964. Canadian Post Publications Mail Agreement No.40612608. Canada return address: Pitney Bowes, P.O. Box 25542, London, Ont., N6C 6B2. 70 BUSINESS STAFF Digital subscription rates: U.S.: one year, $69; two years, $99;. Canada/Mexico: one year, $79; two years, $119; All other countries: one year, $99; two years, $149. 71 BACKTALK MACHINE DESIGN.com Permission to photocopy is granted for users registered with the Copyright Clearance Center (CCC) Inc. to photocopy any article, with the exception of those for which separate ownership is indicated on the first page of the article, provided that the base fee of $1.25 per copy of the article, plus $.60 per page is paid to CCC, 222 Rosewood Dr., Danvers, MA 01923 (Code No. 0024-9114/12 $1.25 + .60). Paid subscriptions include issues 1-18. Issue No. 19 (OEM Handbook and Supplier Directory) is available at additional cost. Rates: U.S.: one year, $139; two years, $199;. Canada/Mexico: one year, $159; two years, $239; All other countries: one year, $199; two years, $299. Cost for back issues are U.S. $10.00 per copy plus tax, Canada $15.00 per issue plus tax, and Int’l $20.00 per issue. Product Locator, $50.00 plus tax. Prepaid subscription: Penton Media (MACHINE DESIGN), P.O. Box 2100, Skokie IL 60076-7800. Periodicals Postage Paid at Shawnee Mission, Kans., and at additional mailing offices. Enclosures 4 For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at [email protected] or visit pentonreprints.com. MARCH 22, 2012 POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O. Box 2100, Skokie, IL 60076-7800. No other controller can do this! Use the technology built into the Productivity3000 programmable controller to make your job easier. Don’t pay extra or take up valuable rack space for communications modules. With its industry-leading seven built-in communication ports, this CPU has phenomenal cosmic power in an itty-bitty living space! .

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%&$($$!' http://bit.ly/p3000 RS# 104 What’s new online machinedesign.com Free Webcast: Understanding permanent-magnet motor technology March 22, 2012, 2:00 p. m. EST Over the years, motor technology has changed to provide better capabilities and performance, but no motor works for every application. Engineers are continually forced to compare and contrast options to document benefits and protect their projects from potential pitfalls. Leeson Electric is presenting a condensed technical course on permanent-magnet motors to help engineers assess that technology. Topics include: a technical overview of PM motors, energy efficiency, power density, and control requirements, followed by a Q&A session. The Webcast will also be archived for on-demand viewing. Learn more at http://machinedesign.com/content/understanding-permanent-magnet-motortechnology-0302. Jewel bearings at www.ia-na.com September 10 - 15, 2012 McCormick Place, Chicago, Illinois For more information, please contact Aryan Zandieh at (312) 924-1688 or [email protected]. Organized by: 6 Partner: MACHINE DESIGN.com EDITOR’S WEB PICKS Bearings made of synthetic ruby or sapphire are exceptionally hard and rugged. They run with low friction, handle high temperatures, and are chemically inert, nonmagnetic, and surprisingly economical. An expert from Bird Precision explains the basics of jewel bearings and where they’re best applied at www.engineeringtv.com/video/ Jewel-Bearing-Performance-from;OnlyEngineering-TV-Videos. MARCH 22, 2012 NPE microsite Energy savings estimator PolyOne’s NPE microsite (npe. polyone.com) previews topics it will feature at the NPE show, including barrier technology, bioplasticizers, trends in appliance and electronics design, and sustainability. Users can also schedule meetings at PolyOne’s booth or request immediate technical advice on specific problems. There’s also a free guest-pass registration area, live Twitter feed, and blog. Siemens Drive Technologies Div. has an online Energy Savings Estimator that lets users of drives, motors, couplings, and gearboxes estimate potential energy savings across the entire drivetrain. Given data on the application — horsepower, motor speeds, and gearbox reduction ratios — the Estimator evaluates potential savings and ROI of the recommended upgrade. For more info, visit www.usa.siemens. com/energysavingsestimator. Product catalog app Bosch Rexroth’s GoTo Products iPad App offers ready access to product information in its print catalogs, including technical data, dimensions, and specification tables on thousands of linear motion, hydraulic, pneumatic, electric drive, and control products. It also includes video clips and links to the company’s Facebook page, Twitter feeds, and YouTube channel. For more information, visit www. boschrexroth-us.com/gotoipadapp. Automation eLearning Omron Industrial Automation has expanded its eLearning education portal (www.omron247.com/elearning) with 10 introductory courses in eight different languages on automating machines and processes. Topics include an introduction to factory automation, as well as courses on general-purpose relays; photoelectric, proximity, and fiberoptic sensors; power supplies; and temperature controllers.   
   
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'IN6I=6C9 circuits cool Decentralized Servo Drives iX offer unprecedented freedom in mounting options: Cover plate Cavity spacer Thermal load < ¸On the Motor < ¸On the Machine Frame <In the Drive Cabinet The Advantages for the OEM are in plain sight: Heat-transfer plate n EtherCAT and Sercos III Gas inlet and outlet n Continuous Power up to 5 kVA n M23 Powerconnectors (daisy chain) n Reduced Wiring n Functional Safety n No Distribution Box n No Hybrid Cabels n Local I/O n IP 65 18 RS# 115 MACHINE DESIGN.com The thin-cavity fluidic heat exchanger from Third Millennium Engineering, Plano Tex. (www. tmeplano.com), uses highvelocity gas flow to form a thin boundary layer that keeps circuits cool and isolated from possible contaminants or EMI/RFI. According to its developers, this heat exchanger is technically positioned between fans and heatsink methods of cooling, and waterbased cooling subsystems. The device consists of a heattransfer plate, a cavity spacer, cover plate, and a gas inlet and outlet. Heat produced by circuitry or any other thermal load is conducted to the heat-transfer plate, which can be flat, round, or MARCH 22, 2012 any other shape. A gas, typically compressed air, is sent into the thin (0.01 to 0.001-in.) gap created by the cavity spacer mounted between the cover plate and heattransfer plate. Tests show that the thinner the gap, the better the cooling. And placing cooling fins and channels in the gap make the cooling device less efficient and less reliable. The air carries the heat away when it exits the cavity through the outlet. According to the developer, the compressed air can be replaced with nitrogen, oxygen, Freon, or similar gases, and the gas can be hot, cold, or room temperature. RS# 402