Tài liệu Machine design, tập 84, số 13, 2012

September 6, 2012 A Penton Media Publication Tune in to EngineeringTV.com Private Enterprise in Space page 44 NEW ROLE FOR CIRCUIT INTERRUPTERS: PROTECTING EQUIPMENT, page 54 DIY FABRICATION IS HOT, page 62 COPPER ROTORS BOOST MOTOR EFFICIENCY, page 70 RS# 101 High Accuracy Pressure Transducers Hermetically Sealed Gage Transducers PX409 Series All Models $475 Precision Micro-Machined Silicon Transducers and Transmitters PX409 Series Starts at $475  Hermetically Sealed for the Harshest Environments  Available with Pin or Twist-Lock Connector Outputs  High 0.08% Accuracy  Ranges from 0-100 to 0-5000 psis (Sealed Gage)  316L Stainless Steel Wetted Parts  Shock and Vibration Tested Visit omega.com/px429-sgv All Stainless Steel Pressure Transducers High Performance Silicon Technology Very High Accuracy Digital Pressure Gauge 316 SS Body, Analog Output and Optional Wireless Transmitter Visit omega.com/px309 Visit omega.com/dpg409 PX309 Series Starts at $175 0.08% Accuracy DPG409 Series Starts at $695 Visit omega.com/px409 omega.com ® Νο. ® RS# 102 © COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED VOLUME 84 ISSUE 13 SEPTEMBER 6, 2012 MANUFACTURING A sheet-metal class shows users how to operate equipment. Members learn layout techniques, how to use the hydraulic shear, how to make corner notchers, and how to use the press brake. At the conclusion of that class, these members will be authorized to set up and use the equipment on their own projects. MANUFACTURING for the masses Key points: • Areas such as machining, laser, electronics, and industrial-painting sit off a large central workspace. • The studio has spring boarded several small businesses. Resources: Juan Martinez shows off the prototype of his cargo bike, which he built from the ground up with TechShop software and equipment. FEATURES The holes in the cards were cut out on TechShop’s Epilog laser cutter. The cards are used to program a Jacquard loom. truckin’ with SpaceX 44 Space A private firm develops the first commercial launch vehicle and transport capsule, then proves they can carry payloads into space. Ford Motor Co. and TechShop Studio layout Detroit facility Director Will Brick says as the shops evolve, TechShop personnel are increasingly dialing-in their layout and design to let users work more efficiently. A big central room features several large work tables. All the different technology areas, such as the laser, electronics, and industrial-painting studios, sit off the central room. “This arrangement encourages people to use the central room to work together on projects,” he says. “In fact, many entrepreneurial partnerships have been made between people sitting next to each other at one of these tables.” The computers in the central room each feature more than $20,000 worth of engineering-design software from Autodesk Inc., San Raphael, Calif. Programs include Inventor, AutoCAD, Maya, and Revit. The central room also 62 MACHINE DESIGN.com TechShop member Richard Jeryan is the weaver in the Weaving Shop at The Henry Ford museum, just down the street from the Detroit TechShop. Working with TechShop and other organizations, Ford is helping entrepreneurs commercialize their creations. For example, Ford’s Patent Incentive Program provides Ford employee-inventors who come up with potentially patentable ideas, a three-month free membership to TechShop Detroit. And the company’s Motor City Innovation Exchange will be an open meeting place for inventors to showcase what they create in TechShop. It will provide a way for inventors to negotiate, network, and sell their prototypes to manufacturers, suppliers, start-ups, and research institutions in the automotive industry. SEPTEMBER 6, 2012 Auto Harvest, www.autoharvest.org Autodesk, www.autodesk.com Cable Arm, www.cablearm.com Ford, http://corporate.ford.com Ford Land, http://fordland.com Kickstarter, www.kickstarter.com OpenROV, www.openrov.com Square, www.squareup.com TechShop, www.techshop.ws MACHINE DESIGN, “DIY Manufacturing,” http:// tinyurl.com/26clol7 MACHINE DESIGN, “Rapid Prototyping ‘On the Cheap,’” http://tinyurl.com/ylkdoof MACHINE DESIGN, Fab it Now, http://tinyurl.com/yke88kl For more on rapid prototyping, scan this code or go to: http:// machinedesign.com/ article/rapid-prototypingfor-the-masses-0609 hosts a hotline to the U. S. Trademark and Patent Office through which TechShop users can file a U. S. patent or find out the status of one. The central room also features the now-iconic coffee maker and popcorn popper. The 17,000-sq-ft Detroit facility is clean, spacious, and airy. Many windows face both outside and internally to each of the technology areas, helping make the TechShop a pleasant place to work. The machine shop, one such area, houses a lathe, a vertical-milling machine, and a Tormach four-axis CNC mill that can be fitted with various accessories such as a motorized rotary table or a mechanism which fits on the table top to let users cut intricate forms, tapers, and cylindrical objects. “People use the mill all sorts of ways,” says Brick. “For example, one designer came in to make aftermarket car parts, which he modeled in Inventor. He took a Tormach machine-tool class and then machined his first prototype. We helped him make a fixture so he could produce four or five parts at once. He now has a small business.” Another technology area, the wood shop, features a three-phase table saw, a big wood lathe, a router table, and a pair of CNC wood-router Shop Bots, one with a large 4 × 8-ft work surface and one with a smaller work surface. “The machines have the same spindle, same controls, and same interface,” says Brick. “They just provide two different options for different project sizes.” One of the machines is getting upgraded with a more-efficient vacuum pull-down SEPTEMBER 6, 2012 62 shock: Sensing ground 54 Safety faults in industrial applications Senior Editor [email protected] Twitter @ LeslieGordon • TechShop gives users access to high-end manufacturing equipment and software. DIY fabrication studios let just about anyone make just about anything. Do you have a hankering to make something, but lack access to a laser cutter or machine tool? You might want to check out a local TechShop. Founded in October 2006, TechShop Inc. is a membership-based (about $100/month), do-it-yourself (DIY) workshop and fabrication studio that provides access to more than $1 million worth of high-quality machines, tools, and software, as well as classes and workshops on the technologies. TechShop is open to people of all ages and skill levels. It is based in Menlo Park, Calif., with locations in San Francisco, San Jose, Raleigh, N. C., and Detroit. Locations in Arizona, Pittsburgh, and D. C. are being planned. Authored by: Leslie Gordon  Originally designed to protect people, ground-fault sensing now helps extend equipment life. ELECTRICAL/ELECTRONIC Industry Manufacturing for the masses 62 DIY fabrication studios let just about could take a shine to COPPERROTOR MOTORS Authored by: anyone make just about anything. Trista Baldwin Contributing Editor Edited by Leland Teschler [email protected] Key points: • Rotors made from copper conduct electrical current better than aluminum, thus run cooler with more efficiency. • The process of die casting copper has become economical thanks to recent advances in modeling the casting process. Resources: could take a shine 70 Industry to copper-rotor motors International Copper Association, www.copperalliance.org For more on copper rotors, scan this code or go to: http://machinedesign.com/ article/copper-shines-inmotor-rotors-0818 Better manufacturing techniques may let rotors cast from copper become a mainstay of superefficient motor technology. The stringent efficiency levels now spelled out in NEMA Premium tables have fostered interest in motor architectures that can deliver high efficiency. One of those architectures uses a squirrel-cage rotor cast from copper rather than the traditional aluminum. Copper cuts down on the I2R losses by up to 40% and overall motor loss by 20%, though it increases the weight of the rotor a bit. The motivation for a copper-rotor design stems not only from efficiency considerations but also from a desire to minimize the size of the motor. But until recently, copper rotors were tough to cast because of copper’s higher melting point (1,083°C compared to 660°C for aluminum), and a tendency to oxidize. Now, breakthroughs in copper die casting have made it more economical to mass pro-  Visible in this cutaway view of an induction motor is its copper rotor. Use of copper rotors can let induction motors run efficiently enough to provide the same amount of horsepower as conventional motors that sit in larger frame sizes. New manufacturing techniques make it possible to cast rotors in copper and bring new levels of efficiency to induction motors. 70 MACHINE DESIGN.com SEPTEMBER 6, 2012 70 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 SEPTEMBER 6, 2012 MACHINE DESIGN.com 63 Along with our great prices, you get: Rotary Encoders, ;<):<16/
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quick-disconnects in M8 and M12 RS# 103 www.automationdirect.com Go online or call to get complete information, request your free catalog, or place an order. 1-800-633-0405 ON THE COVER DEPARTMENTS The Dragon space capsule recently traveled to the Space Station and back. For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at [email protected] or visit pentonreprints.com. 8 EDITORIAL Where did ethics go? 10 EDITORIAL STAFF 12 LETTERS 16 SCANNING FOR IDEAS Temperature sensors use Pt-100 technology for accuracy Cyclonic action extends life of hydraulic filter 20 REPORTER’S NOTEBOOK 30 LOOKING BACK 37 SENSOR SENSE Sensor Sense: Automation light grids 38 COMMENTARY It’s been a good summer for space exploration 40 VANTAGE POINT Specialization helps machine builders endure economic uncertainty 42 INVENTOR’S CORNER Surgical dressing restores mastectomy patients’ figures 84 SOFTWARE REVIEW Plug-in imports organic surfaces into CAD 86 PRODUCT SPOTLIGHT Hose & fluid connectors 88 92 93 94 94 95 4 PRODUCTS BUSINESS INDEX AD INDEX CLASSIFIEDS BUSINESS STAFF BACKTALK MACHINE DESIGN.com Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert. 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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. 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. Can GST #R126431964. Canadian Post Publications Mail Agreement No.40612608. Canada return address: Pitney Bowes, P.O. Box 25542, London, Ont., N6C 6B2. 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. SEPTEMBER 6, 2012 POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O. Box 2100, Skokie, IL 60076-7800. The Truth About Compressed Air! If you think compressed air is too expensive and noisy - read this. The facts will surprise you! Compare these Blowoffs Facts about Blowers There are a variety of ways to blow the water from the bottles shown in the photo below, but which method is best? To decide, we ran a comparison test on the same application using four different blowoff methods: drilled pipe, flat air nozzles, Super Air Knife (each using compressed air as a power source), and a blower supplied air knife (using an electric motor as a power source). Each system consisted of two twelve inch long air knives. The following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff, cooling or drying application. Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of filters, belts and bearings. Here are some important facts: The goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). The compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water off. The blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page summarizes the overall performance. Since your actual part may have an odd configuration, holes or sharp edges, we took sound level measurements in free air (no impinging surface). Drilled Pipe Blower Air Knife This common blowoff is very inexpensive and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed poorly. The initial cost of the drilled pipe is overshadowed by its high energy use. The holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots. The blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and flat air nozzle, but was comparable to EXAIR’s Super Air Knife. The large blower with its two 3" (8cm) diameter hoses requires significant mounting space compared to the others. Noise level was high at 90 dBA. There was no option for cycling it on and off to conserve energy like the other blowoffs. Costly bearing and filter maintenance along with downtime were also negative factors. Flat Air Nozzles EXAIR Super Air Knife As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. The flat air nozzle provides some entrainment, but suffers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers offer flat air nozzles where the holes can be blocked - an OSHA violation. Velocity was inconsistent with spikes of air. The Super Air Knife did an exceptional job of removing the moisture on one pass due to the uniformity of the laminar airflow. The sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and off is possible. Safe operation is not an issue since the Super Air Knife can not be deadended. Maintenance costs are low since there are no moving parts to wear out. Filters must be replaced every one to three months. Belts must be replaced every three to six months. Typical bearing replacement is at least once a year at a cost near $1000. G
Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate effective airflows. G
Poorly designed seals that allow dirt and moisture infiltration and environments above 125°F decrease the one year bearing life. G
Many bearings can not be replaced in the field, resulting in downtime to send the assembly back to the manufacturer. Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often difficult to control since mechanical adjustments are required. To discuss an application, contact: EXAIR Corporation 11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 (800) 903-9247 Fax: (513) 671-3363 email: [email protected] www.exair.com/45/423c.htm The Super Air Knife is the low cost way to blowoff, dry, clean and cool. RS# 104 Blowoff Comparison Comp. Air Type of blowoff Horsepower Required Sound Annual Approx. Annual Purchase Level Electrical Maintenance Price dBA Cost* Cost First Year Cost PSIG BAR SCFM SLPM Drilled Pipes 60 4.1 174 4,924 35 91 $50 $4,508 $920 $5,478 Flat Air Nozzles 60 4.1 257 7,273 51 102 $208 $6,569 $1,450 $8,227 Blower Air Knife 3 0.2 N/A N/A 10 90 $5,500 $1,288 $1,500 $8,288 Super Air Knife 60 4.1 55 1,557 11 69 $518 $1,417 $300 $2,235 *Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year. What’s new online machinedesign.com FREEBOOK Piezos in motion: technology basics, motors, and more The piezoelectrical effect is the ability of piezoceramic materials to generate an electrical charge in response to squeezing or pressing mechanical force or motion when electrified. The effect is leveraged in piezomotors, which are being applied in an increasing number of applications. Learn more in this informative guide from MICROMO, available at http://machinedesign.com/ebook. Nutating engine for UAVs At the 2012 AUVSI Unmanned Systems show, an engineer from Kinetic BEl explains the nutating-disk concept engine. It has the potential to provide twice the power density of two-stroke piston engines and four times the power density of fourstroke engines. The positive-displacement unit has multifuel capability, low vibration and bearing loads, and a modular, flexible design. Learn more at www. engineeringtv.com/video/NutatingDisk-Engine-Delivers-H;OnlyEngineering-TV-Videos. EDITOR’S WEB PICKS Ethernet-cable white paper Turck’s new white paper, “Ethernet Cable: A Guideline to Implementing Solid or Stranded Cables,” helps engineers select cables for industrial networks. Content includes understanding Ethernet-cable classifications, their uses, and installation guidelines to ensure reliable performance and best efficiency. Download a copy at www. askturck.com/docs/TURCK-EthernetCable-White-Paper.pdf. 6 Bearing App Rexnord has launched Bearing Mobile Pro, a new iPhone app that gives engineers quick access to technical data on ball and cylindrical bearings. It also offers interchange info for leading manufacturers’ products and technical support via e-mail and phone. Get more details at www.rexnord.com. Threadlocker data A new two-page, at-a-glance information sheet from Henkel provides data on 21 Loctite threadlocker products. A properties chart lists strengths and viscosities of primerless and oil-tolerant formulas, temperature-resistant grades, low-and medium-strength products that disassemble with hand tools, and high-strength formulations. The chart highlights general use, MIL-Spec, food-grade, and health and MACHINE DESIGN.com safety-rated products, and threadlockers for plastic fasteners. Download a copy of “Threadlockers Are Reliable and Removable” (LT-6540) at www.loctitethreadlockers.com. PLC programming courses PLC Programming courses conducted by Omron Automation and Safety (www.Omron247.com) let attendees complete basic, intermediate, and advanced courses in just seven business days. The intensive hands-on sessions cover real-world design and troubleshooting challenges. Students learn to programs PLCs, develops HMI projects, set up networks, simulate system interactions, and configure motion controllers, drives, and temperature controllers. Piezo actuator catalog PI Ceramic’s new 70-page Piezoelectric Actuators catalog covers products such as piezo-ceramic stack actuators, multilayer actuators that have been tested for more than 100 billion cycles, and low-voltage bimorph bender actuators. It also details custom subassemblies and high-linearity materials, as well as drivers, controllers, and charge amplifiers that increase dynamic linearity. A tutorial explains operating and application basics. Download a copy at www.piceramic.com/piezo_news_more. php?newsid=21&on.-prw. SEPTEMBER 6, 2012 WATCH PRODUCT OVERVIEW AND TUTORIAL VIDEOS AT YOUR CONVENIENCE AutomationDirect’s Learn Web site features free industrial control product overviews and tutorials. Topics range from PLCs and HMI to motion control and sensors. Recently added Kickstart product videos include: Buck-boost transformers — can be used as an autotransformer to raise or lower supply line voltage by a small amount; or as an isolation transformer. Watertight wiring devices — industrial-grade watertight plugs, connectors, and receptacles from Bryant are a must in harsh conditions. Cord grips — see the full line of wire and cable strain reliefs, support grips, bus drop grips, and pull grips. Differential pressure transmitters — precision engineered for accurate low differential measurement of positive, negative, and bidirectional pressures. The latest tutorial series gives pointers on configuring our multipurpose counter/timer/ tachometer units. For a complete list of videos, visit http://iearn.automationdirect. com or www.youtube. comlautomationdirect. Become a subscriber and get alerts when new videos are uploaded. Solve your most complex lighting puzzles with    DOWN 1. Weight of an empty container 2. American air gp. 3. Repeated musical phrase 4. Portuguese miracle site 5. Microchip Technology’s lighting solutions provide precise ___ control, regulating the amount of visible light emitted 6. Part of information highway? 7. Fender bender 8. A ___ Microchip Technology lighting solution provides significant flexibility and ability for expansion versus that of pure analog or ASIC implementation 9. Not that                                    42. Greek letters 44. Pass 46. Hosp. areas 47. Smaller Georgia city than 36 Across 49. Orange juice option 51. This complete lighting unit can benefit from lighting-design technology from Microchip Technology 55. Emit 56. Not new 57. A crazy person may be as loopy as one 58. Mount Sinai School of Medicine (abbr.) 59. Offensive or defensive in football 60. Aware of 61. Pitcher Young’s 62. At Microchip Technology, emphasis is focused on reducing costs while developing products with a strong mix of peripherals such as liquid-crystal-display (abbr.) drives, PWM, ADC, comparators, timers and communication 63. 52 Down athlete     ACROSS 1. Sod 5. Microchip Technology-based solutions can support any lightemitting-diode (abbr.) drive methodology as well as add additional capabilities beyond that of traditional lighting solutions 8. Long-time auto-racing sponsor 11. “Heat of the Moment” was its best-selling song 12. Beast of burden 13. Eight, in Madrid 14. Huck Finn’s transport 15. ___, a plan, a canal, panama 16. Wood fastener 17. Microchip Technology’s lighting solutions provide highly ___ power conversion 19. Otherwise 20. English author A.A. 21, Fed. aviation regulator 22. ___, be all 25. Traditional light shape 26. Through its ___® microcontrollers, Microchip Technology provides solutions for the entire performance range of 8-, 16- and 32-bit microcontrollers, with a powerful architecture, flexible memory technologies, comprehensive easy-to-use development tools, complete technical documentation and post design-in support 27. Abate 30. Ritzy arena location 34. The latest info via the Internet 36. GA big city 37. Principle 38. Scary first name of famed architect Saarinen? 39. Former First Lady of the Philippines 41. Type of motive (abbr.)     Intelligent Lighting & Control solutions from Microchip can meet the technical needs of lighting engineers with a large array of 8-, 16-, 32-bit PIC® microcontrollers, analog, wireless, and human interface products. Visit www. microchip.com/lighting to learn more about our advanced peripheral integration and support.                  10. North or South 12. Common Irish girl’s name 13. Former NBAer Shaquille 18. Shelves at foot of window, the English way 21. Enjoyment 22. Fencing sword 23.Number of players in the field in 61 Across’ sport 24. Nation’s capital resident? 25. Actress Kristen 28. A particular Club for shoppers 29. Fr. Holy woman 31. Where George and Louise Jefferson moved 32. Connects well with another 33. Feminine suffix 35. Lighting and control solutions from Microchip Technology can meet the technical needs of lighting engineers with a large array of 8-, 16- and 32-bit PIC® microcontrollers as well as analog, ___ and humaninterface products 37. Sharp claw 39. Cyclades isle 40. Determine 43. Beyond standard peripherals, Microchip Technology is con- stantly bringing additional value to microcontrollers by developing unique and exclusive peripherals that allow embedded-lighting engineers to simplify designs and create evermore creative applications and products. This innovation is demonstrated by microcontroller integrated peripherals such as high-resolution pulse-wave modulators (abbr.) 45. Of or pertaining to a mechanism that represents data by measurement of a continuous physical variable, as voltage 47. Melodious sound 48. Fix 49. Another state-of-the-art microcontroller peripheral, Microchip Technology’s programmable switch mode controller (abbr.) is an advanced, customizable high-speed 16-bit PWM module 50. ___-daisy 51. Break in the action 52. New Rochelle, New York, college 53. Repetitive teaching technique 54. Organic compound The letters in the shaded boxes spell out the secret word that describes lighting solutions from Microchip Technology Inc. The first 50 respondents with the correct secret word will receive a USB Flash drive wristband. All entries will be entered in a contest for a chance to win an Apple iPad. Contest is open September 6, 2012 – October 31, 2012. Visit www.microchip.com/ lightingcontest to submit your secret code and for official contest rules. For assistance with clues, visit the lighting section of the Microchip website and look under Applications. ——————————— RS# 106 Microcontrollers 
Digital Signal Controllers 
Analog 
Memory 
Wireless EDITORIAL Where did ethics go? When I was in engineering school, tests were never proctored. When we took exams, the instructor never hung around in the room to watch over students and guard against cheating. At the end of the exam, we all signed an engineering honor-code statement saying we had completed the exam honestly. There were only a few infractions of the code every year, and they were dealt with by a jury of students who had the power to bounce offenders out of engineering school. The ethics displayed at my school were probably no different than those at other engineering colleges. Practicing engineers, in general, tend to be highly ethical. Civil engineers, for example, follow a Code of Ethics spelled out by the American Society of Civil Engineers that, among other things, directs them to put public safety and welfare above all other considerations. There is a more-broad-based organization in the U. S. called the Order of the Engineer, which promotes similar ethics. It sprang up in the 1970s and is modeled after a Canadian organization having similar principles. There are now local “links” on 278 U. S. campuses. When someone joins the organization, they agree to be bound to a code of ethics that, in part, says they will “participate in none but honest enterprises” and “pledge to practice integrity and fair dealing, tolerance, and respect.” You might wonder whether these are just empty words to the largely 20-year olds who take the pledge. Do these kids just look at the whole ceremony as a good excuse to go drinking afterwards? Not according to Order of the Engineer Executive Director Paula Ostaff. “They take it very seriously,” she says. Someone taking the obligation gets awarded a ring, which they wear on the little finger of their dominant hand. The ring is supposed to serve as a symbol of their obligation to the engineering profession and to the public. “If they lose that ring, they order another immediately because it means so much to them,” says Ostaff. Now contrast this serious treatment of ethics to the behavior that has been on display in the financial industry. For that we turn to Charles H. Ferguson, winner of an Academy Award for his documentary on the financial crisis and author of a book called Predator Nation, in which Ferguson uses newly released court filings to show “the financial sector has become increasingly corrupt, with the widespread fraud that caused the housing bubble going completely unpunished.” There is one particularly telling incident Ferguson details, which involves the investment bank Goldman Sachs. In late 2006 and 2007, financiers were increasingly waking up to the idea that housing could implode. So the firm was trying to sell off its risky mortgage-related assets but was having trouble finding customers. “Smart people were already out of the question; only fools would do,” says Ferguson. Citing information from the U. S. Senate Permanent Subcommittee on Investigations report “Wall Street and the Financial Crisis,” he relates that, “A salesman pushing one of Goldman’s most-toxic offerings to a Korean client thought he could expand the sale, but wanted a better commission ‘as we are pushing on a personal relationship’ [i.e., I only screw my friends if I am paid well for it].” Ferguson further relates that the salesman got the extra commission. — Leland Teschler, Editor 8 RS# 107 MACHINE DESIGN.com SEPTEMBER 6, 2012 4ALKABOUTABUNDLE OFADVANTAGES
 s%# TECHNOLOGY FROM EBM PAPST GIVESYOUMORECONTROLOPTIONS FOR ADVANCED APPLICATIONS THAN !# TECHNOLOGY AND ITS HIGH EFlCIENCY ALSO SAVES A WHOLE LOT OF ENERGY s&URTHERMOREIT PROLONGSTHESERVICELIFE OFAIR CONDITIONINGAND REFRIGERATIONSYSTEMSAND MAKESTHEIROPERATIONMUCH QUIETER s4HEELECTRONICSARECOMPLETELYINTEGRATEDINTO THEMOTORMAKINGTHESETRULYhPLUGANDBLOWvFANS s/NEMORETHINGOUR%#TECHNOLOGYENABLESYOUTOCREATEANENERGY SAVING BUNDLEOFSEVERALHUNDREDFANSANDCONTROLTHEMFROMASINGLEWORKSTATION &ORAWHOLEBUNDLEOFINFORMATIONVISIT www.ebmpapst.us/hyblade The engineer’s choice RS# 108 EDITORIAL STAFF EDITOR Leland E. Teschler [email protected] MANAGING EDITOR Kenneth J. Korane [email protected] SENIOR EDITORS Leslie Gordon [email protected] Stephen J. Mraz [email protected] ASSOCIATE EDITORS Lindsey Frick [email protected] Robert J. Repas, Jr. [email protected] RS# 109 INDUSTRY COVERAGE: AUTOMOTIVE, PACKAGING, MEDICAL Stephen J. Mraz CAD/CAM, MANUFACTURING Leslie Gordon ELECTRICAL, ELECTRONICS Robert J. Repas, Jr. FASTENING & JOINING, MATERIALS Lindsey Frick FLUID POWER Kenneth J. Korane MECHANICAL Lindsey Frick Kenneth J. Korane EDITORIAL PRODUCTION Denise Greco Editorial Production Manager Randall L. Rubenking Art Director 1300 E. 9th St. Cleveland, OH 44114-1503 10 MACHINE DESIGN.com RS# 110 SEPTEMBER 6, 2012 DŽŽŐŽŵƉŽŶĞŶƚƐ'ƌŽƵƉŝƐĂǁŽƌůĚůĞĂĚĞƌŝŶƐůŝƉƌŝŶŐƚĞĐŚŶŽůŽŐLJ*ƐĞƌǀŽŵŽƚŽƌĂŶĚƌĞƐŽůǀĞƌ ĚĞƐŝŐŶĂŶĚĮďĞƌŽƉƟĐƌŽƚĂƌLJũŽŝŶƚƐĨŽƌŚŝŐŚďĂŶĚǁŝĚƚŚĂƉƉůŝĐĂƟŽŶƐ" ZĞůŝĂďŝůŝƚLJŝƐďƵŝůƚŝŶƚŽĞĂĐŚƉƌŽĚƵĐƚ"džƚĞŶƐŝǀĞůŝĨĞƚĞƐƟŶŐŵĞĂŶƐŽƵƌƉƌŽĚƵĐƚƐĂƌĞĚĞƐŝŐŶĞĚ ĂŶĚŵĂŶƵĨĂĐƚƵƌĞĚƚŽŽīĞƌůŽŶŐůŝĨĞ"tŝƚŚŽǀĞƌϱϬLJĞĂƌƐŽĨĞdžƉĞƌŝĞŶĐĞ*ŽƵƌĞŶŐŝŶĞĞƌƐǁŽƌŬ ƚŽŐĞƚŚĞƌǁŝƚŚLJŽƵƌĚĞƐŝŐŶƚĞĂŵƚŽƐĞůĞĐƚũƵƐƚƚŚĞƌŝŐŚƚŵĂƚĐŚ" >ĞĂƌŶŵŽƌĞĂďŽƵƚDŽŽŐ2ƐƐŽůƵƟŽŶƐĨŽƌƚŽĚĂLJ2ƐĂŝƌĐƌĂŌ"^ƚĂŶĚĂƌĚ*ŽīƚŚĞƐŚĞůĨĚĞƐŝŐŶƐĂƌĞ ƌĞĂĚLJĨŽƌƋƵŝĐŬĚĞůŝǀĞƌLJŽƌƉƌŽĚƵĐƚƐĐĂŶďĞĐƵƐƚŽŵŝnjĞĚĨŽƌLJŽƵƌƵŶŝƋƵĞƉƌŽũĞĐƚƐ" Looking for more? Scan to view our ĐŽŵƉůĞƚĞƉƌŽĚƵĐƚŽīĞƌŝŶŐĂŶĚƐƉĞĐŝĮĐĂƟŽŶƐ DŽƟŽŶdĞĐŚŶŽůŽŐLJ&ŝďĞƌKƉƟĐƐůĞĐƚƌŽŶŝĐ^LJƐƚĞŵƐ нϭϱϰϬϱϱϮϯϬϭϭဒϬϬϯϯϲϮϭϭϮ;h^ ŵĐŐΛŵŽŽŐ"ĐŽŵ www.moog.com/components RS# 111 Aerospace Products:  6 6 6 6 6 ^ůŝƉZŝŶŐƐ dŽƌƋƵĞDŽƚŽƌƐ ĐƚƵĂƚŽƌƐ ZĞƐŽůǀĞƌƐ &ŝďĞƌKƉƟĐZŽƚĂƌLJ:ŽŝŶƚƐ ƵŝůĚdŽWƌŝŶƚ^ŽůƵƟŽŶƐ LETTERS Power to PowerPoint PowerPoint is a just a tool that can be used well or badly (“PowerPoint Can Kill,” June 14). When a mechanic does not correctly fix a car, we don’t blame the tools; we blame the mechanic. The same is true for PowerPoint. If there are any faults with a PPT presentation, the speaker is at fault, not the software. The audience for these presentations — other engineers, management, and customers — are always short on time these days. They don’t have time for disjointed communication or streams of conscience. The speaker should concisely communicate his ideas or project to the audience. Bullet points are one effective way to communicate clearly and they help keep meetings on topic. PowerPoint is just one way to create bullet-point presentation. (Some of us older engineers have even used typewriters to create bulletpoint presentations.) Brian Little I got a good laugh when I read the phrase “festival of bureaucratic hyperrationalism” describing PowerPoint presentations for NASA. It reminded me of a job I had on a space program. But PowerPoint wasn’t the problem. The real cause of the difficulties was the customer’s insistence that report formats were more important than technical content. One of my tasks was to analyze electronic circuits which were poorly designed. I was not allowed to suggest improvements in my report. Instead, the report had to show how good and reliable the circuits were. And it was shocking to discover that “peer review” consisted of a manager making sure the paragraphs were lined up in a rigid fashion. This meant some technical details were deleted so that each page would look “professional.” The result of all this nonsense was that spacecraft got delayed on the launch pad, a situation which cost millions 12 MACHINE DESIGN.com Don’t blame the tool Readers are still commenting on an editorial that talked about PowerPoint software. They blame the speakers for less than compelling presentations, not the tool used to create them. Other readers commented on recent blog entries. (The media always report this as a “computer glitch” at launch.). I suspect PowerPoint isn’t the problem at NASA, it’s the bureaucracy. Darrell Hambley If you are conducting a meeting using Powerpoint (or any other software) please, please, PLEASE don’t read your powerpoint slides to me. I already know how to read. Use PowerPoint to illustrate your ideas, and layout the details behind your ideas on handout notes attached to each slide. Chris Gordon I have never attended a PowerPoint presentation where the speaker didn’t read verbatim every slide. It seems to be a constitutional weakness among those creating PPT shows. If that’s how it’s being used, printed handouts of the same views would save time, eyestrain, and sleepiness. John Olstand Grounding the GFCI Don Heim pointed out in a letter (May 24) that a ground connection might not trigger a GFCI even if there is a ground fault in plumbing that uses nonconductive plastic water and drain pipes. As you pointed out in your comment on that letter, if there’s no ground connection, then there’s no electrocution and the GFCI doesn’t trip. While this is probably true, GFCIs are rather sensitive. And although tap water is not generally considered to be a good con- SEPTEMBER 6, 2012 ductor, it’s likely to have enough conductivity to trip a GFCI even though it might not be enough to cause a shock. It would, at least, tell you that your appliance or some other electric device had a ground fault. Other readers have commented on a couple blog entries. Brooks Lyman Everyone loves L. A. In a recent blog (“Suppliers Look for Engineers in Detroit,” May 9 in the blog “From the Editor ’s Desk”), the video shows a Nissan spokesperson talking about the company’s need for engineers. Well, it ’s no surprise they are looking for any and all types of engineers. They recently moved their headquarters from Los Angeles to Franklin, Tenn. Only 42% of Nissan’s L. A. workforce made the move with them. That’s because smart, prosperous people like engineers don’t want to live in second-rate locations. That’s why California has the sixth largest economy in the world even though it has some of the highest corporate tax rates in the U. S. What was the latest innovative breakthrough that came out of Tennessee? Has there ever been one? What was the latest breakthrough that came out of California? Ever heard of an iPod, iPad, or iPhone? Two lessons here: If you’re an engineer and willing to move to Franklin, Tenn., there’s probably a job for you there. But if you want to hire the best peo- All the Tools you Need for Embedded Measurements and Control, in one rugged box. Q Graphical Software Q Custom Triggering Q Sensor Connectivity Q Actuator Connectivity Q Signal Analysis Q Embedded Storage Q Control Algorithms Q Industrial Networks Q Custom Timing Q Expansion Systems The NI CompactRIO hardware platform can handle your embedded measurement and control applications, and do it in a way that outperforms other off-the-shelf systems so you don’t have to spend time developing a custom solution. The range of high-quality measurements, coupled with an extremely rugged design and the ability to modify the hardware using NI LabVIEW system design software, gives you all the benefits of customization with the convenience of an off-the-shelf platform. >> To learn more about CompactRIO, visit ni.com/compactRIO 800 891 2755 RS# 112 ©2012 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 05312 LETTERS ple in the business, don’t locate your headquarters where people don’t want to live. Mitchell Bosler how they can legally go about it. You shouldn’t trash the lawyers. Everybody already hates them. Paul Ryan Is your view of Tennessee base on a bad experience or simply anecdotal evidence? Costs were obviously a factor in Nissan’s decision. California, which certainly has many positives, is simply becoming a place too expensive for heavy manufacturing. Richard Gianotti At one company I worked at, job postings for U. S. engineers to replace foreign hires were posted on an inside wall of the CEO’s office. That way, hardly anyone other than the CEO would see them. Keith Frantz Lawyers aren’t the problem I’d blame the CEOs more than the lawyers (“Why We Hate Lawyers: Reason #16,258,” in the blog A Skeptical Engineer, March 9). They’re the ones hungry for cheaper imported engineers and technicians. Management just asks the lawyers to fill in the details for The video just shows a case of legal arbitrage and the CEO or management just assigned a workforce (in this case, lawyers) to find a way for the company to work within the law while sidestepping the intent or spirit of the law for financial gain. Or as the blog stated “It may be legal, but it’s certainly slimy.” John Lamber CEOs have a fiduciary duty, not to mention a self-interest, to reduce RS# 113 14 MACHINE DESIGN.com SEPTEMBER 6, 2012 costs. So why be shocked when they do things like this? Laws should be written to prevent or at least make it difficult to evade the intent of the law. Doing otherwise is a sign of incompetent or collusive legislators. John Linstrom Correction In the July 29 issue, the Web address for Nanometrics (pg. 28) was incorrect. It should read www. nanometrics.ca LETTERS TO THE EDITOR Please include your name, address, and daytime phone number. Letters may be edited for brevity and to focus on essential points. Mail: Letters, MACHINE DESIGN, 1300 E. 9th St., Cleveland, OH 441141503, Fax: 216-621-8469 E-mail, Editorial: [email protected] COMPLETE ENGINEERING SOLUTIONS Start here. "The navigation and ordering process are easy to work. Thanks." – Richard, Newark element14 customer At Newark element14, all your engineering needs come together in one source—vast product range from world-class brands, fast online search, seamless purchasing tools, resources and services, one-on-one support, and a community of experts. Here, you’ll find simpler, smarter and faster ways to do business. HOW MAY WE HELP YOU TODAY? COMMUNITY: element14.com WEBSITE: newark.com PHONE: 1.800.463.9275 LEARN MORE: newark.com/together RS# 114 SCANNING FOR IDEAS Edited by Stephen J. Mraz Platinum fine-tunes temperature sensor’s accuracy The TS400 and TS500 temperature sensors from Turck, Minneapolis (turck.us), use platinum-resistance temperature detectors and Pt-100 technology for quick and accurate temperature readings. The sensor’s Pt-100 device uses a platinum wire patterned as a thin film so that it undergoes minimal differential expansion. A controller measures changes in the wire’s resistance, which changes with temperature. (The hotter the wire, the higher its resisStainless-steel tance becomes.) The housing sensors are accurate to within 0.4°C at 50°C. Remote cordset The sensors are built to handle harsh operating environments and Stabilizer are relatively immune to Remoteelectromagnetic interference. The stainless-steel mounting housing carries an IP67 ratsensor ing. The sensors can withstand vibrations up to 20 g Compression (9 to 2,000 Hz) and shocks of fitting 50 g. They are also protected Directagainst short circuits and reverse polarity. mounting Technicians can program sensor the sensors using pushbuttons, an LED display, and a Thermowell simple programming format. Operating range is –58 to 932°F (–50 to 500°C). The units are available with two switch points, an analog current, and voltage outputs. The TS500 probe has Probe a housing and display that can rotate; the TS400’s housing is fixed r formation via ou Request free in Web site at in place. Both can be directly or ice rv Se er Read remotely mounted. sign.com/rsc w.machinede ww RS# 401 16 MACHINE DESIGN.com SEPTEMBER 6, 2012 SM YOU’LL CALL IT the most technologically advanced process for customer-focused solutions in extruded aluminum. Sapa innovation turns visions into leading end-use products with advanced engineering, technical competencies and unprecedented resources. -
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)))%#$"'#" ! RS# 115 SCANNING FOR IDEAS Cyclonic action extends hydraulic-filter life The new series of in-line filters developed by Bosch Rexroth, Charlotte, N. C. (boschrexroth-us.com), the 110 LE(N) Series, has a filter head that uses the cyclone effect to keep heavier particles away from the filter, which keeps the filter from becoming clogged as quickly as filters in traditional designs. This extends the life of the filter and reduces maintenance. Incoming hydraulic fluid gets diverted away from the filter and toward the outer wall of the aluminum bowl, creating a downward spiral or cyclone of fluid that forces heavier contaminants away from the filter and towards the bottom of the bowl where they collect. Keeping larger particles from clogging the filter lets the filter last 6 to 8% longer than those in conventional in-line devices. A spring holds the six-layer, glassfiber-paper filter in place, which prevents swirling fluid from damaging it while keeping the filter from vibrating. The filter bowl is shaped so that fluid flows down and around the filter with uniform pressure. This means all filter surfaces do the same amount of work in removing particles. The filter is rated for particles ranging from 3 to 100 μm. The filter works in temperatures from –22 to 212°F. Maximum operating pressure is 1,595 psi. A differential-pressure contamination sensor measures how dirty the filter is. When the filter needs to be changed, the sensor activates a mechanical maintenance indicator, as well as an electrical indicator on top of the housing. When technicians replace the filter, a spring lifts it off its centering pivot inside the bowl, which simplifies the task. RS# 402 18 MACHINE DESIGN.com Contamination indicator Mechanical/ optical indicator Earning signal Input Output Filter spring Filter head SEPTEMBER 6, 2012 Filter