Tài liệu Machine design, tập 84, số 15, 2012

October 4, 2012 A Penton Media Publication Tune in to EngineeringTV.com Getting MOTION SYSTEMS up and running fast page 48 MESHING FOR CFD, page 38 BETTER DIE CASTING, TIGHTER TOLERANCES, page 44 ADHESIVES THAT CURE WITH VISIBLE LIGHT, page 52 [ MOTOR TRUTH #13 ] Are you into belts and chains? If not, then you need SEW’s patented TorqLOC®. Its keyless hollow shaft and taper bushings eliminate inefficient belts, chains, and sprockets thus reducing maintenance and energy costs while enhancing system safety. Mounting Its spacious air gap provides easy mounting. Its tightening bolts provide easy dismounting. No more tight tolerances! No more keys! Need retrofit? No problem. TorqLOC even mounts onto an existing shaft that has a keyway. Visit sewmotortruth.com/truth13 for other ways to save energy. sewmotortruth.com/truth13 864-439-7537 RS# 101 Dismounting &) O M *0 +1 E .. 0 GA 1 (/. 0( 1, $0 .% 1 #0 /0 *  ' 0 /( 0) ##0 -0 -1( )* .1 )" 01 1$ ,) -/, # /, © COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED 1 © Petesaloutos / Dreamstime.com OMEGA 0(*&)1 01 0&-.1&)1$%.-,'0/10/&*0 0/01!++1 0/*0)-1 $,''&--0"1-,1%/1$%.-,'0/. !+++++1 /,"%*-. 1Τεμπερατυρε,πρεσσυρε, στραι ν ανδ φορχε,φλ οω ανδ λ εϖελ ,δατα αχθυι σι τι ον ανδ αυτοματι ον προδυχτσ (.1/"0/&) 1Χαλ λορϖι σι τυσατομεγα.χομ (.-10#&0/ 1Σαμε−δαψσηι ππι νγ ,/#"1$#(..1$%.-,'0/10/&*0 1Φρεε τεχηνι χαλ συππορτανδ λ ι τερατυρε ,'0(*,'11! RS# 102 !+++++10(.%/0'0)-1 /,"%*-. VOLUME 84 ISSUE 15 OCTOBER 4, 2012 OEM SERVICES Authored by: Kenneth J. Korane Die casting the knurled sleeves on quick-connect couplings eliminated several machining operations and substantially reduced production costs. Net-shape castings that eliminate machining operations can cut costs. casting takes on machining 38 From CAD to CFD in 5 minutes How to mesh a real geometry. casting takes 44 Die on machining Engineers often have an important decision to make when they design and source a metal part: Should it be machined or die cast? In the past, a cursory review of production volumes, tolerances, features, and alloy requirements would clearly favor one manufacturing method over the other. Today, the choice is anything but clear. Advancements in die-casting technology now make it possible to cast tight-tolerance features that once would have required multiple machining operations. By eliminating machining steps, near-net-shape casting offers a manufacturability advantage that can reduce the costs of many metal components. The experience of Dixon Quick Coupling, a manufacturer of hose fittings and accessories, offers one such example. The Charlotte, N. C.-based company recently converted a knurled sleeve for a quick-connect coupling from machining to die casting. Converting a proven machined part to a die casting can be a big step, says Cindy Karriker, the com44 MACHINE DESIGN.com Resources: Dixon Quick Coupling, www. dixonquickcoupling.com Dynacast, www.dynacast.com Getting the knurl right Die FEATURES Managing Editor [email protected] pany’s supply-chain manager. “We had to make sure the potential manufacturability benefits of die casting would not come at the expense of durability and quality,” Karriker says. With help from engineers at Dynacast, headquartered in Charlotte, Dixon managed to lower the cost of making its sleeve component while maintaining quality. Here’s some advice they offer others looking to do the same. Pick the right part. Not all machined parts are good candidates for die casting. Low-production volumes, for example, make it tough to justify the expense of hard tooling. Requirements for exotic metal alloys can also rule out die casting. Looking beyond these obvious deal breakers, many parts are excellent candidates for die casting, particularly when net-shape or near-netshape casting replaces machining. At Dixon, eliminating several machining operations tipped the scales in favor of die casting. According to Karriker, the sleeve’s original two-piece design required three machining steps — roughing out the part, adding Adding a knurl to a machined metal part isn’t all that difficult. Any machine shop with the right tools can do it. Knurling gets a lot more difficult, however, when you try to cast it as a surface feature. One concern is that the raised portions of the knurl pattern will interfere with the release and ejection of parts from the tool. The pattern may require slight modifications near the parting line. Typically, pattern changes are barely noticeable on the finished part. Gate vestiges and parting lines can also interrupt the knurled pattern, creating a small flat section near parting lines. “Casting in a knurling pattern is harder than it looks,” says Dynacast’s Helmut Wolf. The payoff, however, can be significant if casting the pattern eliminates a machining operation. According to Wolf, there are a few design steps that simplify the task of making knurling a net-shape feature. Consider ejection implications. On the Dixon job, Wolf recommended subtle changes to the geometry of the knurl’s raised sections — rounder edges, fillets, and draft — to ease ejection from the tool. He also slightly changed the pattern near the parting line. These geometry changes cannot be seen or felt by someone using coupling. “They were made only for reasons of manufacturability,” Wolf says. Consider cosmetics. To eliminate disruptions gating can make on the knurling pattern, Wolf was careful to locate gates on the pads formed by raised portions of the knurling pattern. The pattern geometry around the parting line was also slightly altered for cosmetic reasons. surface detail, and cutting the part in half. The die-cast version maintains the two-piece design but the two halves require no machining prior to assembly, making die casting less expensive. “Multiple machining setups can drive a lot of cost,” Karriker says. Add surface detail in the tool. One challenge in Dixon’s switch from machining to casting involved the knurling on the connector surface. This ergonomic feature improves “grip-ability” and is easy enough to machine, notes Karriker. But machining the knurling OCTOBER 4, 2012 Converting from machining (left) to die casting called for subtle changes to the knurled pattern that are imperceptible to most users. on the cast part would have limited the advantages of net-shape die casting. To overcome this hurdle, Dynacast’s engineers worked with Dixon to replicate the knurling pattern on the tooling surface. According to Helmut Wolf, Dynacast’s special projects director, this tooling-based approach requires more upfront design effort. “It can be difficult to get the surface detail right when converting machined parts to die castings,” he says. But adding surface texture in the tool eliminated an entire machining OCTOBER 4, 2012  44 Net-shape castings that eliminate machining operations can cut costs. Comparing knurls speeds valve48 Software terminal commissioning Valve terminals control numerous devices and handle lots of data. New software makes programming and setup much easier. 52 Curing adhesives with “normal” light A new group of light-curing adhesives do not need UV light. FASTENING/JOINING Curing adhesives with “normal” light A new group of light-curing adhesives do not need UV light. A new group of adhesives have been developed that cure under visible light (405-nm wavelength). Traditional light-cure adhesives, by contrast, need ultraviolet (UV) light with wavelengths between 250 and 365 nm. The difference of a few dozen nanometers of wavelength may not seem like a big deal, but it opens up a range of bonding, encapsulation, and sealing applications that were previously unsuitable for light-curing adhesives. On the factory floor, for example, shifting to visible light eliminates the need for expensive UV lighting. Instead, inexpensive light-emitting diode (LED) lamps can handle the job. And eliminating UV lights means A new adhesive from Master Bond cures under visible light (wavelength of 405 nm), not UV light. It can cure in 15 to 30 sec and adheres well to glass, polycarbonates, acrylics, and metals. Authored by: Comparing light-curing adhesives 56 An understanding of oscilloscope Scope this out operations, abilities, and limits improves circuit-design analysis and even troubleshooting.  52 ADHESIVE VISCOSITY AT 75°F (CPS) LED401 100,000 to 150,000 LED401LV 60,000 to 80,000 LED403Med 1000,000 to 150,000` MACHINE DESIGN.com Robert Michaels SHELF LIFE (AT 75°F IN ORIGINAL UNOPENED CONTAINERS) SERVICE TEMPERATURE Clear 6 months 60 to 250°F (51 to 121°C) Clear 6 months 60 to 250°F (51 to 121°C) 6 months 60 to 250°F (51 to 121°C) COLOR Clear Vice President of Technical Sales Master Bond Hackensack, N. J. Edited by Stephen J. Mraz [email protected] Resources: Master Bond, www.masterbond. com OCTOBER 4, 2012 52 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 OCTOBER 4, 2012 MACHINE DESIGN.com 45 From cable to enclosures ... AutomationDirect has some of the best prices available for cables, wire duct and wire, terminal blocks, and even the enclosures to put it all in. Our latest addition of communication data cables are a direct equivalent of popular brands. So check out our prices to see how we can help you stretch your controls budget! 500’ reels Cat5e STP (Twisted Pairs with overall Shield) Ethernet Patch Cables starting at: $279.00 (L19772-500) 100’ coil starting at: $66.00 (L19772-100) Wire duct and flexible tubing 1000’ reels starting at: $455.00 (L19772-1000) Choose from over 1,600 Hubbell/Wiegmann enclosures across NEMA 1, 3S, 3R, 4, 4X, 6P, 12, 4/12, and 13 ratings High quality, low-capacitance data cables are designed with impedances specific for RS-232/RS-422 and RS-485 communication applications in industrial environments.  ( (&%$$'#("' (&%!&'#(% ("$#&" !  "%($#( %#'#(!%'#!(%&(&%$$'#("' (# %$(% '  "'&'$'("$#&" (%$!&%"$( (
'&  (($#( (&%!&'#(% ('(!&'!  (((((""&('$&!("% ''! For complete details, visit: www.automationdirect.com/data-cables www.automationdirect.com Signal and sensor terminal blocks and power distribution blocks Go online or call to get complete information, request your free catalog, or place an order. 1-800-633-0405 RS# 103 ON THE COVER CPX valve terminal from Festo Corp. DEPARTMENTS 8 EDITORIAL Jobs and the reverse innovation mindset 10 EDITORIAL STAFF 12 LETTERS 16 SCANNING FOR IDEAS Stand-alone lubricator keeps things humming Quick connector simplifies pneumatic and hydraulic testing 20 REPORTER’S NOTEBOOK 30 LOOKING BACK 36 COMMENTARY Stressed at work?— Leslie Gordon 37 VANTAGE POINT Forget college, go to trade school — Mitch Free 66 SOFTWARE REVIEW A “personal factory” that lets you make almost anything 68 PRODUCT SPOTLIGHT Cables & carriers For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at [email protected] or visit pentonreprints.com. 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. 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). 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. 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. 70 PRODUCTS 76 BUSINESS INDEX 77 AD INDEX 78 BUSINESS STAFF 79 BACKTALK 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, $149. 4 MACHINE DESIGN.com OCTOBER 4, 2012 POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O. Box 2100, Skokie, IL 60076-7800. Low Cost Vacuum Generators For Lifting, Clamping, Mounting, Vessel Evacuation and “Pick and Place”! Adjustable E-Vac® or Vacuum Generator E-Vac® Vacuum Generators Modular E-Vac® orr o Vacuum Generator are compressed air powered vacuum pumps that provide instantaneous response and are most commonly used for pick and place operations. These single stage vacuum pumps are a low cost venturi available in a variety of sizes and flows along with a selection of vacuum cups suitable for a wide range of applications. 7
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1/ &$ www.e www. ex xair. air.com/45/480.htm i co ht WATCH THE VIDEO! www.exair.com/45/48045.htm 11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 Phone: (513) 671-3322 Fax: (513) 671-3363 Website: www.exair.com Email: [email protected] Vacuum Cups, Fittings, Tubing, & More EXAIR can provide the accessories you need to build your vacuum system. RS# 104 @EXAIR What’s new online machinedesign.com FREE WEBCAST: DESIGNING EFFECTIVE SAFEGUARDING FOR MACHINES Thursday, October 18, 2:00 p. m. ET Attend this Webinar to learn how to design effective machine safeguarding. Experts from Schmersal will discuss types of hazards, various options for separating guards and devices, different levels of circuit design, and how to engineer a complete safety system. The presentation will also review in detail: • Fixed and movable guards. • Reaching and guard-opening design. • Interlock switches, including limit, keyed, non-contact, locking, and keyexchange versions. Learn more and register at http://machinedesign.com/training. Quarter-scale V8 engine The Stinger 609 is reportedly the world’s smallest production V8 engine. At IMTS 2012, an engineer from Conley Precision Engines discussed lubrication issues with small engines, and how a new honing process overcomes the problem of excessive oil flow. See it at www. engineeringtv.com/video/Stinger609-Quarter-Scale-V-8-E;OnlyEngineering-TV-Videos. EDITOR’S WEB PICKS Motors and motion courses 6 CNC info SMMA – The Motor & Motion Assn. has scheduled three courses on November 6, prior to the start of its Fall Technical Conference. They include Fundamentals of Electric Motor Design, Fundamentals of Brushless Motor Control, and Permanent Magnet Fundamentals. Get more details at www.smma.org. Compression-molding brochure Medical nonwovens The new Victrex Compression Molding Guide discusses how to form large and intricate parts out of advanced thermoplastics. It discusses processes that can deliver void-free moldings and explains materials options for making high-performance parts that lower overall costs in demanding oilfield, transportation, electronics, and medical applications. Learn more at www.victrex.com. MACHINE DESIGN.com Fanuc FA America has launched a Web site (www.fanucfa.com) offering detailed info on the company’s CNCs, drives, lasers, and engineering support. An expanded Industries section tells users more about requirements for aerospace, ag and construction, automotive, energy, job-shop, medical, metal-fabrication, mold-and-die, and woodworking applications. Fabrico is hosting a discussion on medical nonwovens on its www.fabricoforum.com site. Design engineers can learn about nonwovens’ advantages over traditional woven textiles, pose question, and seek the advice of experts. The FabricoForum is an open dialog where design engineers and others interested in materials and product assembly can read opinions and weigh-in on various topics. OCTOBER 4, 2012 VIDEOS TELL ALL ABOUT NEW DOMORE PLC AutomationDirect’s newest controller, the Do-more H2 Series, is a “supercharger” for the industry proven DirectLogic 205 PLC hardware. Learn Do-more’s story with this video series: The Overview hits the highlights, and compares the Do-more H2 CPUs to the current DL205 models. The Quick-Start video demonstrates the steps to create a simple program with the new Domore Designer software. The Math Instruction video details the use of the Math function block, which offers capabilities from simple formulas to statistical functions. Other topics address helpful hints for configuring and programming, serial port use, Data View and Trend View windows for troubleshooting, and use of the built-in PLC simulator. To view the Do-more PLC video series, visit http://learn. automationdirect.com and look under the PLCs tab. Or find them at: www.youtube. com/automationdirect. Become a subscriber and get alerts when new videos are uploaded. Technology by THE INNOVATORS Generic Motion Control ` Maximum system productivity through exceptional performance and system synchronization ` Supports advanced manufacturing technologies by integrating CNC, robotics and motion control with integrated safety technology ` Easy implementation of machine options because of software compatibility across all drive technologies ` Supports all machine topologies through the use of centralized and decentralized drive technology Booth 4337 ` 5HGXFHGKDUGZDUHFRVWVDQGVLPSOLÀHGVHUYLFH Perfection in Automation RS# 106 www.br-automation.com EDITORIAL Jobs and the reverse innovation mindset When GE CEO Jeffery Immelt signed on to head up the President’s Council on Jobs and Competitiveness, he began encouraging U. S. manufacturers to export their goods as a way to promote U. S. job growth. Trouble is that for most manufacturers, exporting involves a lot more than just finding a distributor and shipping products overseas. In truth, it might be easy for companies the size of GE to think about exporting, but obstacles in foreign markets can be close to insurmountable for the average manufacturer. To understand the problem, consider reverse innovation, today’s trendy idea for U. S. manufacturers. Its basic premise is that you do the innovating in emerging markets, then somehow morph the resulting technology into something that can be sold here. Manufacturers must take this tack, we’re told, because Indian and Chinese consumers aren’t interested in buying low-end or lightly modified goods that western manufacturers make. If true, that pretty much kills the idea that we can generate jobs in the U. S. just by exporting to emerging markets. What kind of innovation do you need to sell stuff in places like India? An example is the ChotuKool refrigerator made in Mumbai. It lists for $69 and relies on a Peltier module for cooling, so there is no compressor or plumbing to boost the cost. This technique is only good for cooling to 36°F below the ambient temperature, but thanks to high-quality insulation, it is good enough for the low-income consumers it targets. The fridge can also run on batteries if need be because of the notoriously unreliable grid system in India. The lesson of the ChotuKool, says Vijay Govindarajan, a business professor at Dartmouth College, is that western appliance makers could undoubtedly come up with similar offerings, but never by customizing one of their existing refrigerators. ChotuKool developers went through several iterations working with rural Indians and Indian financial institutions involved with microfinance to come up with a product appealing to households earning about $5 a day. That sort of collaboration is only possible by having a team on the ground in India. And that’s why it probably seems out of reach to midlevel U. S. manufacturers that can’t fund multiyear expatriate assignments in the developing world for their key employees. The problem of resources becomes even clearer by considering the effort Deere & Co. had to put into developing an agricultural tractor for India. As Govindarajan reports, all Deere’s machines were too heavy and expensive for Indian farmers. The tractor maker came up with a model having a mere 35 hp, but it was far from being just a low-end knock-off of an existing vehicle. After two years of market research in India — which included disassembling six rival tractors — Deere eventually came up with a design that addressed complaints from Indian farmers about maintenance by incorporating new clutch technology developed for more-expensive models. More to the point, Deere had to use a product-development process that employed about 120 people with many of them from Deere’s Indian operations. And manufacturing takes place in Pune, India, not here. The magnitude of these reverse-innovation efforts might seem reasonable to manufacturers the size of Deere or GE. But it’s not clear how any of this will result in U. S. jobs, let alone products useful for U. S. markets. And so it is with all but a handful of reverse innovations, despite the cheerleading by Jeffery Immelt. — Leland Teschler, Editor RS# 107 OCTOBER 4, 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] INDUSTRY COVERAGE: AUTOMOTIVE, PACKAGING, MEDICAL RS# 109 Stephen J. Mraz &RQWURO6ROXWLRQV7KDW$FWXDOO\*LYH> 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 The question asked in the title is a great one. I think the article effectively addresses technical aspects of natural-gas-powered vehicles and some of the challenges but misses the overpowering issues. The current generation of cheap natural gas is mentioned but not discussed. Fracking has significantly reduced the cost of natural gas. Electricity generated using natural gas costs about half that of electricity generated using coal because of fracking. While many people wouldn’t think there are any problems from this, some have polluted water and land that was fracked. When a company says it is pumping proprietary chemicals under my house for fracking, I get a little concerned why they can’t tell me what is going into the ground under my house. But the cost advantages of fracked gas are so compelling that these and other issues will have to be resolved. My answer to the question posed by the title is: absolutely yes. Unfor tunately, the companies selling me gasoline refined from crude at $4/gallon are not interested in selling me the equivalent in natural gas at $2/gallon or less. If they were, it would have happened years ago. Jeffrey Anntman Fund research, not politicians Since LPO was created and directed by political appointees and has been used as a way to funnel money to political supporters, it is no wonder the program received the lion’s share of funding and has had the lion’s share of corruption (“ Two Sides of a Green-Energy Failure,” Aug. 9). ARPA-E, on the other hand, 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] appears to actually require engineering and studies, as well as industry-savvy reviews and competitive approval based on potential market impact. These are difficult to “justify” based on expected ROI. But ARPA-E’s basic R&D into prototypes that work, along with initial attempts to scale up into marketable products and systems, are exactly what we need and find so hard to fund. Name withheld by request Rise of the Machines 5)&
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            RS# 113 14 MACHINE DESIGN.com OCTOBER 4, 2012 quietly thrives in harsh environments Extreme durability meets low db performance. Outperforming. Outlasting. Outstanding. Workhorse strong and church-mouse quiet, our complete line of vane pumps are built to outperform and outlast sensitive piston pumps in the most challenging situations. Our patented Walking Ring and Hydrodynamic Journal Bearings maximize your pump life for the lowest cost of ownership. With Direct Spring-to-Load Sensing and Torque Limiting Control, our vane pumps deliver the control your operation demands. The Pressure Balanced Thrust Plates improve pump efficiencies, and the variable volume and pressure compensated construction simplifies circuit design, while reducing heat and noise to make even harsh work environments less harsh. PUMPS VALVES POWER UNITS RS# 114 952. 895. 6400 | www.continentalhydraulics.com SCANNING FOR IDEAS Edited by Stephen J. Mraz Stand-alone lubricator keeps things humming Keeping machinery well lubricated is a critical step in ensuring equipment runs troublefree. But some lubrication points can be difficult to access. They’re either in spaces too tight for service staff to easily get to, or in a hazardous area. For these situations, engineers at SKF (www. skfusa.com), with U. S. headquarters in Lansdale, Pa., have designed the System 24 LAGD 125, a single-point lubricator. The battery-powered lubricator automatically sends grease to a lubrication point for one to 12 months, depending on the amount of grease and frequency of lubrication. It uses a gas generator to create an inert gas that pushes a piston down into the 4.25-fl-oz (125-ml) container of grease. The piston’s downward stroke forces out the grease. Technicians set the dispensing rate by adjusting the electric current going from the battery to the gas generator. This is done using a simple dial mounted on top of the container. Ambient temperature affects the dispensing rate. So if temperatures top 105°F, the unit runs twice as fast, and a 12-month setting will empty the container in six months. And at 15°F, the unit runs half as fast, so a six-month setting empties the container in 12 months. If space is particularly tight, a smaller, 2-fl-oz (60-ml) LAGD 60 container is available. Both versions can be mounted away from the lubrication point and use hoses to deliver the grease. RS# 401 16 MACHINE DESIGN.com Time-setting slot lets technicians adjust flow rate. Gas cell generates a pressurized, inert gas used to dispense lubricant. Piston ensures all lubricant gets used as container empties. Container is clear, letting technicians visually monitor dispensing rate. Filled with lubricant Base of container matches piston profile, which lets the piston squeeze out practically all of the lubricant. r formation via ou Request free in Web site at ice rv Se er Read c design.com/rs ww w.machine OCTOBER 4, 2012 Cartridge neck screws into lubrication point or accessories. Ingenious solution, Build handling systems faster Exactly For faster, easier, more economical development of handling systems, Rexroth’s EasyHandling approach is exactly what today’s deadline-driven OEMs and systems integrators seek. EasyHandling combines systematic and seamless integration of all drive and control technologies with linear actuators, standardized mechanical and electrical interfaces, all supported by new start-up and commissioning tools to dramatically simplify the automation process. Reduce development time by up to 80% and enable a more efficient and cost-effective engineering process. Bosch Rexroth Corporation www.boschrexroth-us.com/linearsystems RS# 115 SCANNING FOR IDEAS Quick connector simplifies pneumatic and hydraulic testing The FasMate FN Series of connectors from FasTest Inc., Roseville, Minn. (www.fastestinc.com), makes it easier for technicians to test pneumatic, vacuum, and hydraulic circuits, as well as perform filling, flushing, and performance evaluations. A Termination port split-collet assembly quickly makes airtight connections Actuation balls Main seal to internally Test piece threaded ports without any thread sealants or tools. It also does not damage threads in the port. Wetted parts are made of Tapered Gripping Pressurestainless steel Cartridge assisted grip center pin collets and the housassembly and seal ing is anodized. The unit is rated for 5,000 psi. It works with threaded ports ranging from / to ½-in. NPT, as well as SAE, BSPP, and metric sizes. Pressure-assisted sealing securely locks the FasMate to ports. This improves safety for the technicians using the device. The connector can be set up to be triggered one of three ways. A squeeze lever provides simple, intuitive activation (shown in the illustration). A pneumatic thumb valve is another ergonomic choice that lets technicians insert or remove the connector by pushing a button. And a pneumatic pilot lets technicians have free use of both hands. It does require a separate air hookup, however. It is easy to switch between these three trigger mechanisms without using tools. 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