DesignNews Magazine July 2011

SURF’S UP Firewire Uses CAD to Customize Boards 26

JULY 2011 $15.00

MINIATURE MOTION It’s Spurring Medical Device Design 50

GADGET FREAK Latest Project Rewards Smarts with Gumballs 64

Accelerating Engineering Innovation

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Design for Recyclability Component reduction through modular design and fastener standardization is paving the way for faster disassembly 36

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The Secret To Keeping Electronics Cool! NEMA 12 Cabinet Coolers

The NEMA 12 Cabinet Coolers for large heat loads up to 5,600 Btu/hr. are ideal for PLCs, line control cabinets, CCTV cameras, modular control centers, etc.

A bad choice could cost you thousands! Look Familiar? When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery up and running again. The operator might choose to simply open the panel door and aim a fan at the circuit boards. In reality, the fan ends up blowing a lot of hot, humid, dirty air at the electronics and the cooling effect is minimal. If the machinery starts functioning again, the likelihood of repeated failure is great since the environment is still hot (and threatens permanent damage to the circuit boards). Worse yet, that open panel door is an OSHA violation that presents a shock hazard to personnel.

• Measures 8" (203mm) high • Mounts top, side or bottom • Enclosure remains dust-tight and oil-tight

NEMA 4 and 4X Cabinet Coolers

NEMA 4 and 4X Cabinet Coolers for large heat loads up to 5,600 Btu/hr. They are ideal for PLCs and modular controls. • Enclosure remains dusttight, oil-tight and splash resistant • Suitable for wet locations where coolant spray or hose down can occur

Type 316 Stainless Steel Cabinet Coolers

Type 316 Stainless Steel Cabinet Coolers for NEMA 4X applications are available for heat loads up to 5,600 Btu/hr. • Resists harsh environments not suitable for Type 303/304 • Ideal for food and chemical processing, pharmaceutical, foundries, heat treating and other corrosive environments

The Real Solution! Stop electronic downtime with an EX AIR Cabinet Cooler® System! The complete line of low cost Cabinet Cooler Systems are in stock and can ship now. They mount in minutes through an ordinary electrical knockout and have no moving parts to wear out. Thermostat control to minimize compressed air use is available for all models. All Cabinet Coolers are UL Listed to US and Canadian safety standards.

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Answers for industry. © 2010 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. Teamcenter is a registered trademark of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.

Accelerating Engineering Innovation

Contents

July 2011

vol. 66 no. 7

www.designnews.com

26

36

42

Cover Story 36 Design for Recyclability Component reduction through modular design and fastener standardization is paving the way for faster disassembly. By Doug Smock

Features 42 Putting a New Face on cAD Interoperability While working with multiple CAD systems still raises its share of interoperability challenges, vendors have made strides leveraging new technologies and creating new workflows to facilitate cross-platform design. By Beth StAckPole

46 Boom time for lithium Batteries Higher capacities are enabling cylindrical, prismatic, and flat lithium batteries to move into medical instruments, power tools, and computing applications. By chARleS J. muRRAy

50 miniature motion in medical Devices Solutions offering more compact, mobile, low power, and lightweight motion control help spur advances in medical device design and development. By Al PReSheR

Columns Wolfe’s den

13 Welcome to the New Design News community

As you surf over to Designnews. com, you will notice a new, streamlined look and feel. It’s all about you

— enabling you, the design engineer and engineering manager, to connect with your peers. By AlexANDeR WolFe Made by Monkeys

14 monkeys Designed my Jeep’s Stereo Wiring Monkeys are playing with the stereo wires of this Jeep.

monkeys Don’t Read the owner’s manuel The “no-touch” loader control is causing headaches. Captain Hybrid

16 Was electric car Poll Biased? Fifty-seven percent of Americans say they wouldn’t consider buying an electric vehicle, no matter the price of gas. By chARleS J. muRRAy

continued >

Cover Image: istockphoto/Bosca78

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Contents > continued GadGet Freak

64 Test Your Knowledge, Win a Gumball!

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Supplement

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automation: Networking trends

Here’s a gadget that lets you flip a switch and win gumballs based on your trivia expertise.

In this supplement you will find stories on the optimization of energy usage, strategies for energy monitoring, and how industrial networks can use upgraded technology to address concerns.

Departments 18 engineering Matters It’s Such A Crime

20 Green Scene

Environmental News for Engineers

22 Mechatronics Mechatronic System Design Process

24 data Measurement & analysis

Cables Can Introduce Errors

26 News Trends, Developments, Breakthroughs

These stories also appear online at www.designnews.com.

54 Social engineering

Why Isn’t Embedded More Innovative?

56 design decisions Fiber-Optic or Flexible Coiled Fiber

58 design engineering Products

Best of the Engineering Marketplace

DESIGN NEWS® (ISSN 0011-9407) is published monthly by UBM Electronics, 11444 W. Olympic Blvd., Los Angeles, CA 90064-1549; 310/445-4200; FAX 310/445-4299. Periodicals postage paid at Los Angeles, California, and at additional mailing offices. SUBSCRIPTIONS – Free to qualified subscribers as defined on the subscription card. Rates for non-qualified subscriptions, including all issues: U.S.A., $150.00 one year, $250.00 two years, $300 three years; Canada, $184.90 one year, $314.90 two years (includes 7% GST, GST#123397457); Mexico, $172.90 one year, $295.90 two years; Foreign air expedited $323.90 one year, $579.90 two years. Except for special issues where price changes are indicated, single copies are available for $10 U.S.A. and $15 foreign. For telephone inquiries regarding subscriptions, call 763/746-2792. Email: [email protected]. CHANGE OF ADDRESS – Notices should be sent promptly to DESIGN NEWS® P.O. Box 47461, Plymouth, MN 55447. Please provide old mailing labels as well as new address. Allow two months for change. NOTICE – Every precaution is taken to ensure accuracy of content; however, the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein. POSTMASTER – Send address changes to, DESIGN NEWS® P.O. Box 47461, Plymouth, MN 55447. Canada Post: Publications Mail Agreement 40685520. Return undeliverable Canadian addresses to: BleuChip International, P.O. Box 25542, London, ON N6C 6B2. Printed in U.S.A. Copyright 2010 by UBM Electronics. All rights reserved. Reproduction in whole or part without written permission is prohibited.

A serious approach to a critical subject. Safety. Innovative Allen-Bradley® Guardmaster® solutions enhance productivity, flexibility, and sustainability–and help do it safely. Work with a single global source, backed by certified expert support. Rockwell Automation. Advanced solutions, single source. Allen-Bradley Guardmaster: Serious Safety. Download your free SERIOUS SAFETY eToolkit: abSeriousSafety.com/DN/5

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Wolfe’s Den

Mechatronics Zone

Siemens Corp. CEO (U.S.) Eric Spiegel says the company is having a hard time finding staff, despite the U.S. unemployment rate of more than 9 percent. However, upon further investigation, and a back-and-forth with someone at the company, it turns out Siemens is actually approaching this with an attitude that should improve perceptions about engineers, as well as their employment prospects.

If you design products that incorporate a bipolar stepper or brushed dc motor, Texas Instruments has some new driver integrated circuits (ICs) that might simplify your driver circuits.

http://bit.ly/koQM9Q

Designnews.com has re-launched with a new, community-enabled site that encourages interaction between you, your peers, and our editors.You’ll also get a heads-up on upcoming live online chats and Internet radio shows with outside engineering experts.

Gadget Freak

Jack Zylkin has taken a number of old manual typewriters and converted them into working USB keyboards.The typewriter plugs into your computer, and you can type simultaneously onto paper.The two main components to his kit are a controller and a sensor board, and installation doesn’t require any permanent modifications to the typewriter. http://bit.ly/lp6kR1 Engineering Materials

Development of the 787 Dreamliner exposed significant weaknesses in the supply chain developed by Boeing to produce the ground-breaking composite-bodied aircraft. http://bit.ly/iTeGI1 CAD/CAM Corner

Building on the foundation laid in Solid Edge ST3, Siemens PLM Software took further steps to enable machine designers and engineers to work within a history-based or direct modeling paradigm depending on what’s best suited for the task within the same product. http://bit.ly/qv7wHV

http://bit.ly/iAkNmY Welcome to the New Design News Community

RESOURCE CENTER DATA ShEET

Miniature Pneumatic Products Create Solutions

If you need a product that fits your application, Clippard has the capability to design or modify its standard products to suit your exact needs. We understand that a standard catalog product may be close, but not be exactly what you need. We have the ability and capacity to give you what you want. Our dedicated staff of engineers, application experts, and manufacturing professionals is devoted to providing you with the best solution available. http://dn.hotims.com/34938-501

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The Best of Gadget Freak

OEM Quick Guide to Surface Finishing

The editors of Design News have handpicked your favorite Gadget Freak cases from over the years, and brought them together in a dynamic digital edition. Download and check out; not only the best gadgets, but accompanying videos, too! http://dn.hotims.com/34938-504 Webcast : Clean Energy: Wind, Solar, or Biofuels?

View now at http://bit.ly/qs0DFl The focus of this Webcast is on the topic of alternative energy’s long-term viability and current application. Digging deep into this topic, our moderator and speaker cover generation and application of energy from solar and wind power technologies; how alternative energy storage issues are being dealt with from a systems engineering point of view; and the role of biofuels in systems design.

CONNECT wITH US

Design News’ System & Product Design Engineering group: http://bitly.com/designnewsLI

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Design News’ general Twitter feed: http://twitter.com/designnews Design News’ Sustainable Engineering Twitter feed: http://twitter.com/awolfe58

http://on.fb.me/fanpagedn Get Design News’ RSS feeds at http://www.designnews.com/rss/ and sign up for e-mail newsletters at www.designnews.com/subscribe.asp.

“A Condensed Resource on Die Cast Part Surface Finishing for OEM Design Engineers & Specifiers” is a preliminary guide that will help design engineers evaluate die-cast surface finishing alternatives for product appearance, durability, and protection to aid in cost-effective specification of parts produced in aluminum, magnesium, and zinc — and ZA8 — die-casting alloys. http://dn.hotims.com/34938-502 WhiTE pApEr

Realistic User Productivity Comparisons for Upgrade Decision Making

While the overall performance of a software program or hardware platform can be measured using standard benchmarks, actual user productivity is a more difficult metric to gauge, since it often includes perceptions of the overall user experience and must account for differences in the methods employed while using the software. http://dn.hotims.com/34938-503

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Physiology, healthy fungi and photons are likely to be linked in the future. I recently delivered a paper highlighting interesting applications of ultraviolet light and the connection to new high-power UV LEDs. One section dealt with UV LED’s potential role to augment interior solid state lighting. The idea is not to make your DayGloTM tie fluoresce1, nor to have white clothes appear “whiter than white” (due to fluorescent dies commonly added to laundry soaps). Instead, it’s to make folks healthier—by accelerating the synthesis of vitamin D. Vitamin D3 (cholecalciferol) is produced naturally in our bodies when skin is exposed to UV-B (270 - 300 nm). It’s also available in some animal-based foods (fatty fish, egg yolks, lean meat, etc). A related form is vitamin D2, known as ergocalciferol, produced from ergosterol in mushrooms. Ergosterol is a component in mushroom cell walls, just as cholesterol is a component in animal cell walls. Vitamin D plays a pivotal role in many cellular processes as well as skeletal calcium balance. Additionally, some studies have linked vitamin D deficiency to increased cardiovascular risks, type 1 diabetes and elevated colorectal cancer rates2. Although we can synthesize our own D3 with sufficient daily sunlight exposure, many of us are constrained to offices, schoolrooms and other buildings which have little or no full-spectrum sunshine available. Typical window glazing actually filters out UV. Then there’s winter.

Now for the role of high-power UV LEDs and other pulsed UV-B sources. Experiments5 have demonstrated that even post-harvest, exposing cultivated mushrooms to short bursts of UV can catapult their effective D2 levels. 84 g of white button mushrooms were treated with a single pulse from a Xenon Corp SteripulseTM wide spectrum source. D2 rose to 32 µg, with two pulses it rose to 56 µg, and with three pulses to 72 µg. Keep in mind that the RDI is 15 µg, and before UV-B exposure the levels were about zero. Similarly, one pulse raised 84 g of shiitake mushrooms to 49 µg of D2 and oyster mushrooms to 65 µg. High-output pulsed UV is preferred since continuous UV takes longer, tends to discolor the mushroom flesh and adds excess heat to the process. I envision UV-B enhancement of edible cultivated mushrooms will become commonplace. It’s a simple, non-chemical method to transform the health benefits of a readily available and inexpensively grown food source.

How much vitamin D do we need? The National Academy of Sciences’ Institute of Medicine’s recommended daily intake (RDI) is 600 IU3, equivalent to 15 µg. Harvard’s School of Public Health suggests it should be higher, about 20-25 µg. Few people are exposed to enough UV-B to create that amount naturally. In fact, if you live more than 35°north or south of the equator, there is negligible UV-B penetrating the atmosphere for a portion of each year4, the so-called “vitamin D winter”. Most people receive less than 40% of the RDI from sunlight alone.

There’s an opportunity for UV LEDs here, especially since they are easy to pulse, have relatively long and stable outputs, are rugged, compact and quite energy efficient relative to other UV sources. Imagine bringing the benefit of vitamin D enriched food to impoverished nations using “off grid” solar powered processing. Only a few highpower UV LEDs are in the UV-B region today, but that is changing.

In the paper I suggested a controlled, safety-margined and closed-loop introduction of UV-B into some interior lighting environments. UV is potentially dangerous though, so caution and further study is required.

This issue of Light Matters and many others are available on the Avnet LightSpeed website. Questions and comments are welcomed. www.em.avnet.com/ LightSpeed.

We have another interesting option—mushrooms and pulsed UV-B. Most wild mushrooms are rich in ergosterol in their natural growing environment. However cultivated mushrooms, the ones most often encountered on a grocery shelf, are grown in dark places—they receive no UV-B (except incidental light when handling), and thus contain little ergosterol.

Figure 1 – The common white mushroom (photo by Darkone)

DayGlo trademark of DayGlo Color Corp; Steripulse trademark of Xenon Corp http://www.hsph.harvard.edu/nutritionsource/what-should-you-eat/vitamin-d/ Dietary Reference Intakes for Calcium and Vitamin D, National Acc of Sciences, 2010 4 Influence of Season and Latitude on the Cutaneous Synthesis of Vitamin D3, Webb AR et al., J Clin Endocrinol Metab. 1988 5 Vitamin D2 Enrichment In Fresh Mushrooms Using Pulsed UV Light, Kalaras et al., 2008 1 2

Cary Eskow is Global Director of the Solid State Lighting and Advanced LED business unit of Avnet Electronics Marketing. An ardent advocate of energy efficient LED-based illumination, he has worked closely with LED manufacturers, advanced analog IC and secondary optics vendors since his first patent using LEDs was issued two decades ago. Avnet works with customers through their national team of illumination-focused sales engineers who are experienced in thermal, drive stage and optics design. Prior to his LED lighting focus, Cary was Avnet’s technical director and managed Avnet’s North American FAE team. To submit questions or ideas, e-mail Cary at [email protected]

3

To learn more about designing an LED-based illumination system, go to:

www.em.avnet.com/LightSpeed

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Engineers will need to harness new design and manufacturing approaches to address the DoD’s tough new guidelines for ground soldier equipment

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f your company targets the defense market, it’s time to rethink traditional approaches to design. Heavy, cumbersome, unimaginative are out. Lightweight, flexible,

Precision molding technologies hold the key to creating a ground soldier ensemble that is lightweight, ergonomic and dependable.

user-friendly are in. With the military moving increasingly toward a fast-moving, quickstrike strategy, the Department of Defense is taking direct aim at the 80 lbs of gear that the average soldier takes into battle. Today’s desert and urban warfare places tremendous physical demands on troops. All that extra weight not only detracts from the soldier’s performance, but is also potentially life-threatening. To ease the burden, the DoD has challenged the EDGE Network, a consortium of leading defense industry suppliers, to find fresh approaches to trim 20 lbs of weight from the ground soldier’s equipment ensemble (GSE).

Designs for the modern soldier Meeting that goal requires design breakthroughs in virtually every part of a soldier’s gear: body armor, weaponry, communications equipment and more. With Defense officials calling Magnesium injection molding allows for equipment that is rugged, more production of very complex designs with little or no secondary operations. compact and more ergonomic, it will

take new approaches to realize a 25% reduction in GSE weight. “Engineers need to change their mindset on designing for the military,” says mechanical engineer Tom Rothgery, Defense Market Director for Wisconsin-based Phillips Plastics. “Methods that worked in the ‘70s aren’t sufficient for today’s needs.” Rothgery adds that the most effective way of meeting the DoD’s GSE goals is to replace conventional materials with new technologies. For example, redesigned equipment cases, housings, and internal components can provide significant weight savings, while offering superior water proofing, impact resistance, and overall durability. In addition, new manufacturing methods can reduce parts count in military assemblies, further trimming weight. Component miniaturization offers perhaps the single greatest opportunity for shedding equipment weight. Properly designed and manufactured molded parts can also outperform conventional components, while accelerat-

Wolfe’s

Follow us on:

Den

Alexander Wolfe, Content Director, [email protected]

Welcome to the New Design News Community As you surf over to DesignNews.com, you will notice a new, streamlined look and feel. But the elegant presentation belies the underlying purpose of our site refresh. It’s all about you — enabling you, the design engineer and engineering manager, to connect with your peers. This is peer-to-peer with a purpose. We’ve implemented a commenting system on steroids, enabling you to interact with colleagues both familiar and as-yet unmet. We invite you to join in and become an engaged member of the Design News community. It’s easy; simply register on the site. Not only will you be able to do the online water-cooler thing, but you will also get a heads-up on upcoming live online chats and Internet radio shows with our editors and outside engineering experts. One thing that won’t change is our continued emphasis on the building blocks of design in the core areas of automation and control, electronics and test, materials and assembly, and CAD software and hardware. Our wildly popular Gadget Freak, Sherlock Ohms, and Made by Monkeys sections will of course continue. We do plan to significantly ratchet up the quantity of how-to articles, illuminating the tough trade-offs — and tight bills of materials — designers face in turning rough concepts into manufacturable deliverables. This is all of a piece with the increasingly interdisciplinary nature of the work we do. No longer is it enough to sit siloed in mechanical, electrical, or software niches. We’re typically doing all three, and, oh, by the way, there’s budgeting, scheduling, and keeping up

with emerging technologies, too. Which is where I have the honor of coming into your world. I’m an electrical engineer by training, and spent the first seven years of my career working in embedded design, which remains my first love. I intend to channel that enthusiasm into connecting our Website and magazine tightly with the engineering community, so that we become a daily destination and resource. I’ll also be taking over the automation & control beat, where outgoing editorial director David Greenfield did such stellar work. But to succeed, I’ll need your help, which is why I’ll repeat my call to register on DesignNews.com. I’m also inviting you to contribute your success stories — and perhaps failures — via guest blog posts. Email me at [email protected] to learn more. Most importantly, I urge you to leverage the best resources in the product design community — our crack staff of editors. Reach out to Charles Murray on test, Doug Smock on materials, Beth Stackpole on CAD/CAE, and Rob Spiegel for Gadget Freak, Made by Monkeys, and Sherlock Ohms. You can find their contact information on page 10, and you can interact with them — and your peers — on our live message boards every day. I’ll close with the parting thought that engineering isn’t just a job, it’s a passion, which is always more fun when you can share with like-minded individuals. See you online. DN

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MADE BY

MONKEYS designnews.com/madebymonkeys

Monkeys Designed My Jeep’s Stereo Wiring The monkeys were hard at work when they designed the stereo wiring in my Jeep Cherokee. They placed a hard splice in the middle of the wiring flex between the door and the frame of the Jeep. The splice is two wires in the door to one wire in the main door wiring harness. They even went so far as to use extra heavy heat shrink sleeve with sealant to cover their mischief. Had they placed the splice 3 to 4 inches in either direction it would have avoided the flexing where the wire met the shrink sleeve. You might think this to be an isolated case. Nope. After repairing the stereo wiring on my Cherokee several months ago, I had the misfortune of being rear ended a few weeks back while stopped at a traffic light. The Jeep was totaled. I bought another Cherokee that was manufactured the same year and I was not surprised to find the front speakers did not work. Having an inkling of the problem’s cause, trouble shooting was fast. It again proved to be broken wires just forward of the splice on both sides. Since both vehicles had identical problems, it is clear Detroit has a monkey masquerading as an automotive electrical engineer — unless it was deliberate to create more maintenance fees down the road. – GENE MELTON

Monkeys Don’t Read the Owner’s Manual Panasonic’s newest Blu-Ray player has an interesting feature that is bound to cause some major headaches. The DMP-BD210 has a “No-Touch” loader control. Yes, you wave your hand over the top of the player to open and close the disk drive. Nice feature, right? In the setup menu, this feature can be turned on or off, and a warning is shown in the menu, “do not place any items near the sensor if this feature is activated.” This is fine, assuming the owner reads the owner’s manual to know that this feature can be controlled from the setup menu, and if the owner reads the little note in the setup menu. Many people put disks on top of the player, or put the player in a shelving unit of some type. The shop I work for has already had a unit sent in with the complaint “drive drawer opens and closes at random.” It’s a simple “repair” to turn the feature off, but it looks like there will be a lot of these players coming in for repair with this complaint — or the opposite … “drive doesn’t open when I wave my hand.” – JED MARTIN

Made by Monkeys highlights products that somehow slipped by the QC cops. E-mail your examples to Rob Spiegel at [email protected]. D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

SolidWorks is a registered trademark of Dassault Systèmes. ©2011 Dassault Systèmes. All rights reserved.

LOOKING FOR DESIGNERS TO PUSH THIS BABY PROJECT 3: HOT ROD BABY BUGGY Help host Jeremy Luchini design the first hardcore baby buggy using SolidWorks®. You’ll share ideas, comment on designs and vote on key decisions throughout the project. If you think you’re ready, let’s go design. Watch. Share. Vote. LetsGoDesign.tv

16

Captain Hybrid designnews.com/blog/Captain_Hybrid

Was Electric Car Poll Biased? Fifty-seven percent of Americans said they wouldn’t consider buying an electric vehicle, no matter the price of gas. By CHARLES J. MURRAY, Senior Technical Editor, Electronics & Test

A recent USA TodAy/Gallup poll has apparently shocked much of the green world. The results, published in May, revealed that many Americans still aren’t interested in pure electric cars. The poll asked 1,024 adults a simple question: “How high do you think gas prices would have to rise before you would buy an electric car you could only drive for a limited number of miles at one time?” Fifty-seven percent of those adults said they would not buy an electric car, no matter the price of gasoline. What’s particularly interesting about the results, though, is the fact that the pollsters broke down the answers by gasoline price and found that as the prices rose, fewer Americans would be willing to buy an electric car. With a gasoline price of under $6 per gallon, for example, 12 percent said they would consider an EV. After that, the percentages dropped: from $6 to $7.99, 10 percent; from $8 to $10, 9 percent; and above $10 a gallon, just 3 percent. Shouldn’t we expect it to be the other way around? If the criteria is the price of gasoline, shouldn’t more Americans say, “Well, if gas hits 10 bucks a gallon, I’ll consider going electric.” What this tells us is that two diametrically opposed camps have formed. On one side we have the EV proponents, many of whom would buy a batteryoperated electric car, even if gasoline were free. On the other side we have 57 percent of Americans who simply won’t consider an EV. This, of course, is confounding for the hardcore electric car crowd. After USA Today published a front-page story headD e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

lined, “Americans say no to electric cars despite gas prices,” some green Websites cried foul. Plugincars.com ran a story saying, “Bias alert: survey says 57 percent would never buy an electric vehicle.” And greenchipstocks.com wrote, “Another anti-electric car article exposed!” But the problem isn’t the article. And it isn’t the poll. The critical passage in the Gallup survey is this: “ … you could only drive for a limited number of miles at one time.” The results tell us that when many Americans see that phrase, they balk. Sure, many have heard the statistics that say 75 percent of Americans drive 40 miles a day or less. And many know that approximately 90 percent of all driving is within the range of EVs. But what about the other 10 percent of our driving? Do we need another car every 10 days? If we deliver the kids to college or take a short vacation, do we have to make a trip to the local Avis first? The problem remains: For many Americans, pure electric vehicles — that is, battery-driven vehicles — still have too little range to serve as a good first car and are too expensive to serve as a backup. In this economy, many consumers can’t plunk down $30,000 or $40,000 on a second car. That’s why GM, in its wisdom, decided to put an internal combustion engine and a gas tank on the Chevy Volt. Like it or not, the Volt teaches us that gasoline is still an important part of the energy mix. American consumers recognize that, and they have every right to. Yes, we could say they’re biased, but they’re merely biased toward financial responsibility. DN

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1818

ENGINEERING MATTERS Focus on the Future of Engineering

It’s Such A Crime New technologies are offering creative avenues for criminals. WE ALL KNOW THERE are unintended conse-

quences that come with technological progress. Both unanticipated and undesired, some are so significant that they have a major impact on our society. I was just in the DC area visiting a secured facility to learn more about one of the most troubling consequences of modern technology: the widespread use of computers, cell phones, and commercial electronics to perpetuate crimes. The range of these crimes is breathtaking, from the expected white-collar crimes of fraud, trade secret, and intellectual property Geoffrey C. Orsak theft, to terrorism, extortion, exploitation of children, and even homicide. With the widespread deployment of every imaginable form of technology throughout business, national infrastructure, and social networking, there has been an explosion of crime by individuals, groups, and nation states. What is particularly concerning is it appears that many of these criminals might not perpetuate these crimes if it were not for the apparent ease, anonymity, and emotional distance that comes from the online world. The old bumper sticker “guns don’t kill people, people kill people,” while dubious in traditional crimes, may actually have some relevance to the online criminal community. In this new world, wouldbe bank robbers don’t need to risk approaching a bank teller with a gun and a note. With a little expertise these individuals can use the same beneficial technology they use to write memos for work, send photos to grandparents, and reserve hotel rooms for family vacations, to quietly access someone’s account and transfer the funds to undetected foreign accounts. Within some amoral circles, this is nothing more than a victimless crime with insurance picking up the tab. The FBI has created a national network of Regional Computer Forensics Labs, where the normal foren-

sic science of fingerprints, blood splatter patterns, and DNA give way to IP addresses, destroyed hard drives, and encrypted passwords. The field of digital forensics employs computer and electrical engineers and computer scientists just like the traditional crime labs employ biologists and chemists. One of the main challenges the FBI faces comes from the drive to innovate by commercial enterprises. This competitive necessity produces such rapid changes in the technological infrastructure that would-be criminals can exploit countless vulnerabilities before they are even known to the manufacturer or designer. These cases don’t always make it into the public sphere, but one crime which appears on the official FBI Website shows just how sophisticated this underworld has become. It all starts with three young eastern Europeans and an unnamed criminal who goes by the name “Hacker 3.” As the FBI Website reports, “working together, the four hackers cooked up ‘perhaps the most sophisticated and organized computer fraud attack ever conducted.’” It began when a man from Moldova discovered a weakness in the computer network of a major credit card processing company. He passed that information to a hacker living in Estonia who monitored the network before sharing this information with a Russian hacker. “The Russian reverse-engineered the PIN codes from the encrypted system, and raised the limits on the amount of money that could be withdrawn from the prepaid payroll debit cards,” according to the FBI. A global network of hackers then used counterfeit cards to simultaneously hit more than 2,100 money machines in more than 280 cities on three continents for $9 million. Months of digital forensics work by law enforcement and engineers ultimately led to the criminals. So we learn again that engineers, particularly those whose work is propelling our digital economy, now have one more thing to worry about: our unintended role in crime. DN

Geoffrey C. Orsak is Dean of the SMU Lyle School of Engineering. He can be reached at [email protected]. D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

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GreenScene Environmental news engineers can use \\\ By Rob Spiegel, Senior Editor

Toyota’s Prius Goes Versatile with the ‘v’ Toyota has introduced the Prius v, the newest member of the company’s hybrid family. The “v” stands for versatile since the vehicle blends fuel efficiency with advances in storage space and connectivity. While the v is a mid-size vehicle, it is designed to offer compact-car efficiency, with estimated EPA fuel economy ratings of 44 mpg city, 40 mpg highway, and 42 mpg combined. The vehicle incorporates Hybrid Synergy Drive, the company’s thirdgeneration hybrid system that does not require recharging. The Prius v will go on sale this fall.

The Prius v extends Toyota’s hybrid family.

Wireless Headset Doubles Battery Life Texas Instruments has doubled the battery life of its PurePath Wireless CC8530, an environmentally friendly device that drives multichannel audio streaming on up to four channels. This headset reference design was created to double battery life compared with offerings currently on the market. It is aimed at consumer, portable, and high-end audio applications. The 2.4Ghz

radio frequency system-on-chip transmits uncompressed wireless audio over a robust RF link. TI has also introduced a headset development kit as part of the PurePath Wireless audio family. The design comes with a total electronic bill-of-materials cost of less than $5 in high-volume production, and is designed to achieve a 22-hour life on a 465 mAh battery. Texas Instruments’ PurePath wireless headset.

GREEN UPDATES

PackageSmart Software Thinks Sustainable Packaging EarthShift has launched PackageSmart, a software tool designed to help design professionals create sustainable packages. This lifecycle assessment program evaluates the environmental impact of packaging, and is designed to allow packaging designers to build and analyze several design ideas simultaneously. Designers can add custom end-of-life recycling rates for individual materials. EarthShift is allowing a two-week trial through the company’s Website. Go to http://www.earthshift.com/ software/packagesmart for more information.

For regular updates on sustainable engineering news, follow Content Director Alexander Wolfe at http://twitter.com/awolfe58.

D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

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Mechatronic System Design Process A model-based design approach from concept to working system.

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System Design and Performance Specifications START HERE

Mechatronic System Design Process

Simplifying Assumptions

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Concept Physical Model

Engineering Judgment Past Experience & Experiments

Real World

Apply Laws of Nature

Expected Component and Open-Loop System Response

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Model Parameters Re-evaluate Physical Model NO Assumptions & Parameters

Solve Equations: Analytical & Numerical

Predicted Open-Loop System Response

Agreement? YES

Control System Design

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NO Re-evaluate

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Build and Test Physical System designnews.com Visit the Mechatronics Zone for the latest mechatronics news, trends, technologies and applications: http://mechzone. designnews.com

Simulation World

THE TOP TWO drivers in industry today for improving development processes are shorter product development schedules and increased customer demand for better-performing products. As engineering systems are becoming ever more multidisciplinary and complex, can these two goals be achieved at the same time? Challenges inhibiting mecha- Kevin C. Craig, Ph.D., Robert C. Greenheck tronic product development fall Chair in Engineering into two categories: the multi-do- Design & Professor of main nature of the complete system Mechanical Engineerand integration of the domains, ing, College of Engiand fi nding errors early in the de- neering, Marquette University. velopment cycle and testing before hardware is available. Once a system is in development, correcting a problem costs 10 times as much as fi xing the same problem in concept. If the system has been released, it costs 100 times as much. The Mechatronic System Design Process addresses these challenges. Through system modeling and simulation, it facilitates understanding the behavior of the proposed system concept; optimizing the system design parameters; developing optimal control algorithms, both local and supervisory; testing control algorithms under various scenarios; and qualifying the production controller with a simulated version of the plant running in real time (hardware-in-theloop testing), before connecting it to the real plant. The Mechatronic System Design Process provides an environment that is rich with numerical and graphical analysis and design tools that stimulate innovation and cooperation within design teams. It aims to reduce the risk of not meeting the functional requirements by enabling early and continuous verification throughout the entire design workflow. DN

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DATA MEASUREMENT & ANALYSIS

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Cables Can Introduce Errors WHEN MOST OF US make a measureInsulation

V

Unity Gain Buffer

RCG

RGS

IGS

Guard Shield

A potential difference between the center conductor and a guard lets small currents flow through the insulation (RCG) and distort low-level signals. Driving the guard shield with the buffered unknown voltage lets current flow only through the guard-to-outer-shield path (RGS), which doesn’t distort the unknown signal, V.

path between an unknown voltage and your instrument. Because the same potential now exists on the center conductor and the guard shield, no current f lows between them and you obtain a better measurement. Your double-shield cable, called triaxial cable, will still have some leakage between the guard, held at the voltage of the input signal, and the grounded outer shield. But the buffer amplifier provides enough current to maintain the inner shield at the input-signal potential or close to it. Sourcemeasure instruments, electrometers and custom-built apparatus that measures low-level signals often use triaxial cables and a buffer amplifier. If you plan to create a measurement system, National Instruments offers a guard and current-amplifier module, PXI-4022, you can use with other PXI-based measuring devices. You can use the guarding technique

Jon Titus, a former designer and chief editor of EDN and Test & Measurement World magazines, remembers when “fast” signals operated at 10 MHz and programs came on paper tape. D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

Outer Shield

+

ment with an electronic instrument, we grab for a scope probe or coaxial cables with a BNC connector on one end and test clips on the other. But as mentioned in the previous column, “Resistances Affect Voltage Measurements,” when you measure small voltages you must take into account shunt resistances in the measurement circuit. Even Jon Titus though the insulation in a coaxial cable provides a very high resistance, it can affect measurements, too. Some current will flow, or leak, between the center conductor and the shield. The high resistance that allows this leakage exists in parallel with the resistance inherent within the measuring instrument. Suppose you have a DVM with a 1,010-ohm input impedance in parallel with a test cable that provides a 109-ohm conductor-to-shield resistance. Ohm’s Law yields a 9.1 x 108-ohm resistance across the DVM, which can cause a measurement error when you measure small voltages or currents. To help eliminate this type of error use high-quality cables with high leakage resistances. You cannot eliminate insulation leakage completely, so for more sensitive measurements, you might need an instrument that can drive an inner guard shield at the same potential as your unknown voltage (see diagram). The outer shield still provides a ground, or return,

–

24

with test fixtures, too. Place a device or sensor undergoing tests on insulators connected to a guard plate or platform insulated from ground. Then, the driven guard greatly decreases leakage current that could flow from the tested device to ground through the insulators. And it eliminates current flow from one test lead to the other through the insulators. DN

For More Information 1. “Cable Insulation Resistance Measurements Made During Cable Fire Tests,” Nuclear Regulatory Commission: http://dn.hotims.com/34938-505 2. “Low-Level Measurements Resource Kit,” National Instruments: http://dn.hotims.com/34938-506 3. “Low Current Measurements,” Application Note 100, Keithley Instruments: http://dn.hotims.com/34938-507 4. “Resistances Affect Voltage Measurements,” Design News, June 2011: http://dn.hotims.com/34938-508

Name Dr. Dennis Hong Job Title Associate Professor of Mechanical Engineering, Virginia Tech Area of Expertise Robotics LabVIEW Helped Me Convey and respond to vast amounts of data in real time Latest Project Design and prototype a car that can be driven by the blind in just 4 months

NI LabVIEW

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Find out how LabVIEW can make you better at ni.com/labview/better

©2010 National Instruments. All rights reserved. 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. 2784

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26

News

Other Stories

Low Power Mixed-Signal MCU 30 Controllers for Small Applications 31 Plastic Part Supports Movement of Solar Panels 34

Trends \\\ Breakthroughs \\\ Developments

Firewire Surfboards target hardcore surfers who want boards that are custom-shaped to order.

Surf’s Up on Custom Board Design Firewire Surfboards and partner ShapeLogic leverage NX CAD tools to deliver an online, 3-D customization system that lets customers directly drive board design. What do you get when you marry 30 years of 3-D CAD experience with a passion for surfing? If you’re Bruce Pettibone, a founder of Siemens PLM Software technology partner ShapeLogic, you come up with a patent-pending online customization solution built around NX that’s being deployed to sell custom-designed, high-end surf boards. The boards come from Firewire Surfboards, a 5-year-old company that made a name for itself in surfing circles by leveraging high-tech materials like expanded polystyrene (EPS) foam, aerospace composites, epoxy resins, carbon D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

rod suspensions and bamboo decks never before used in the business. The application of those state-of-the-art materials enabled Firewire Surf boards to produce boards that were lighter, stronger and more responsive than the traditional polyurethane foam mass-produced offerings, making them appealing to the high-end surfing audience. The problem was while Firewire wanted to offer custom design capabilities on top of its use of unique materials, the design approach put an undue strain on its engineering staff. They couldn’t keep pace with the hours-long effort required to fine-tune the CAD model for each individual custom design to maintain the precision required by Firewire’s CNC (computer numerically controlled) machine-driven manufacturing operation. As a result, Firewire was building custom boards for its international team of surfers, but was hamstrung to offer the same capabilities for

the general marketplace. “The idea of offering customized surf boards to the average surfer created a massive bottleneck in the business with CAD developers,” says Mark Price, CEO of Firewire Surf boards. “We couldn’t afford enough CAD guys to build the custom files.” In addition to automating the behindthe-scenes CAD development, Firewire wanted its system to ensure reuse and replication. Specifically, the development process had to allow for the exact reproduction of the custom-designed board so customers could replace it with the same model at a later date or make slight modifications to the design when making their next board purchase. “Just like when you like a particular tennis racket or snowboard, you can buy another at any point in time. We wanted to bring that degree of sophistication and precision to (custom) surf board making,” Price says.

Name Dr. Laurel Watts Job Title Principal Software Engineer Area of Expertise Chemical Engineering LabVIEW Helped Me Control multiple instruments operating in harsh conditions Latest Project Engineer the ultimate storm chaser

NI LabVIEW

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©2010 National Instruments. All rights reserved. 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. 2802

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28 News Customer-Driven Customization Enter Pettibone, an engineer with a background in designing custom golf clubs. Tapping his acumen around pushing 3-D CAD to tackle complex surface shapes, and his knowledge and interest in surf ing, Pettibone began developing highly parametric and f lexible models of Firewire’s base surf board models in Siemens PLM Software’s NX — a challenge in its own right. Typically, much custom f inishing of high-end board design is handled by seasoned craftsman who painstakingly detail each unit by hand. “Surf boards have long, f lowing curves that are not that easy to subtly model in a CAD system,” Pettibone explains. “You have to build fairly complex models — almost like a mini-sculpture.” In addition to creating sophisticated parametric models of the boards, Pettibone leveraged key features of NX to devise a new online customization solution called ShapeLogic Design-To-Order Live! for NX. The solution, at the heart of Firewire’s soon-to-be released Custom Board Design system, essentially consists of an Internet-enabled user interface with intelligent parametric models and advanced 3-D CAD tools to establish a customer-driven customization system. Pettibone leveraged the NX Open application programming interface (API) with ASP (Active Server Page) scripting to create the dynamic, interactive Web application, along with NX’s Product Template Studio (PTS), a tool for creating reusable design templates. The latter was used to prototype the online ordering system interface. The NX Open APIs, in particular, serve as that critical link between the browser interface and routing the consumer-requested dimensions directly to the parametric model. Design rules are embedded in the base parametric 3-D CAD models in the CBD system, allowing customers D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

to change only certain parameters around length, nose and tail width, and thickness, for example. This lets them achieve their desired board shape, yet doesn’t compromise the complex interrelationships within the model that affect performance. From there, a 3-D PDF is created, which includes the custom board model, the 3-D parametric model of the board’s base design, along with all of the exact board dimensions. Users can visualize their board onscreen before committing to a purchase, and they can also download a lightweight version of the 3-D model in the JT data format to share with friends and solicit additional input. Board designs can be stored online for future purchase. (Firewire has already built 30 custom boards based on CBD orders and has somewhere between 3,000 and 4,000 board designs saved in the online system, Price says.) Once customers hit the order button, the system generates a precise CAD solid model of the custom board, which is fed directly to CNC machines in Firewire’s factory for production. Unlike other online conf igureto-order systems, which allow users to tailor cars or sneakers, Firewire’s CBD is a true engineer-to-order system that works on live 3-D models over the Web. “You can go on a Nike site and design your own shoes, but what you’re doing is replacing colors and trim on an existing shape — you can’t have the width changed to f it your foot,” Price explains. Firewire’s CBD, which is live in a pre-launch version, will formally debut this month and include the Taj Pro surf board model. — Beth Stackpole, Contributing Editor, Design Hardware & Software

For More Information: Firewire Surfboards: http://www.firewiresurfboards.com/

Name Peter Simonsen Job Title Design Engineer, Embedded Software Area of Expertise Renewable Energy LabVIEW Helped Me Perform real-world simulations with total control of the application Latest Project Develop a test architecture for verification of wind turbine control systems

NI LabVIEW

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SIMULATE real-world systems

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30 News Electronics & Test

Mixed-Signal MCU Targets Medical Apps

Low-power design aimed at portable sensing applications A&A Polyclutch Ad_4.5x7.5 (Design that require high precision.

A new mixed-signAl microcontroller (MCU) promises higher accuracy and lower power draw for applications ranging from blood glucose meters to fitness monitors to home thermostats. The Q32M210 mixed signal MCU, as it’s known, is targeted at portable sensNews).pdf 1 4/12/11 AM high preing applications that 11:41 call for

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cision. It incorporates an ARM Cortex M3 processor, dual 16-bit analog-todigital converters (ADCs), and three 10bit digital-to-analog converters (DACs). ON Semiconductor, maker of the new MCU, says the device’s real advantage is its ability to offer high precision while operating at just 400 µA/MHz. “It’s about efficiency,” says Todd Schneider, vice president of conversion and control technologies for ON. “It’s about providing performance over the entire battery life, right down to the very end, and doing it at the lowest possible power consumption.” ON engineers say they designed the new MCU in response to greater demand for standard 32-bit architectures and for lower power in embedded products. Makers of medical sensing systems are also pushing for higher accuracy, particularly in products such as blood glucose measurement devices. “We’re seeing a real demand for improved precision,” Schneider says.

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Source: ON Semiconductor

ON Semiconductor’s mixed-signal MCU is targeted at portable sensing applications that require high precision.

31 The new device is contained in a 140pin, 10 x 10 mm package. The package incorporates memory, power management, USB interface, and precision ADCs that can be hooked up to temperature and humidity sensors. The device’s low power draw also makes it a candidate for applications that employ small lithium cells that are typically thrown away without being recharged. “It’s good for the consumer and it’s good for the end application because you don’t have to change your battery as often,” Schneider says. “It’s also good for the environment because you’re not going to be throwing away as many batteries.” — Charles J. Murray, Senior Technical Editor, Electronics & Test

For More Information ON Semiconductor: http://www.onsemi.com/

Automation & Control

Micro800 Component-Class Controllers

Allen-Bradley controllers and Connected Components Workbench software offer solutions for nano- and microlevel controller applications. TargeTing sTand-alone machine

applications with fewer than 48 I/O, the new Allen-Bradley Micro810 and Micro830 controllers, plus Connected Components Workbench software, are aiming to provide a cost-effective control solution for small applications. These component-class micro programmable controllers and IEC-61131based software are designed to be used with other Allen-Bradley component-

class products such as drives, motion control and operator interface products. The controllers are part of a solution bundle that offers easy selection, installation, and commissioning of low-cost, stand-alone machines. “Machine builders need economical, convenient control solutions they can customize to suit their customers’ specific application needs,” says Paul Gieschen, market development director for Rockwell Automation. “With this new line, Rockwell is delivering the functionality and flexibility of a micro programmable logic controller for the price of a smart relay.” Leveraging embedded USB and serial ports, machine builders can quickly program the controllers and link them to human-machine interfaces (HMI), and other serial devices. The controllers also offer a wide range of plug-in modules for analog/digital I/O, communications, and expanded memory.

w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

These plug-in modules enable machine builders to personalize the controllers to increase functionality without expanding the product footprint. The new family offers removable terminal blocks and simplified communication via point-to-point data exchange.

New Micro800 controllers from Rockwell Automation offer a low-cost, component-based solution for standalone machines, and easy-to-use IEC 61131-based software.

The new workbench software follows established IEC-61131 standards. It allows machine builders to program Micro800 controllers and configure other devices in the system, including PowerFlex drives and PanelView Component HMI products. Based on Rockwell and Microsoft Visual Studio technology, the new software provides controller programming, device configuration, and data sharing with the HMI editor for PanelView Component operator products. In addition, the software supports three standard IEC programming languages: ladder diagram, function block diagram, and structured text. The programming software features a run-time download, which enables live program adjustments. The Micro810 controller features embedded smart relay function blocks that can be configured from a 1.5-inch LCD and keypad. Available function blocks include delay off/on timer, time of day, time of week, and time of year for applications requiring a programmable timer and lighting control. The Micro830 controller provides flexible communications and up to six high-speed counter inputs. It also provides easy incorporation of as many as five plug-in modules on the 48pt models. These off-the-shelf, fully customizable controllers carry global certifications and support. The Micro810 and Micro830 controllers are available immediately. Additional plug-in capabilities for the controllers will be available later this year. — Al Presher, Contributing Writer

For More Information Allen-Bradley Micro810 and Micro830 controllers: http://dn.hotims.com/34938-514 Connected Components Workbench software: http://dn.hotims.com/34938-515

Source: Allen-Bradley

32 News

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34 News

2450Z Series BLDC Pump The innovative 2450Z BLDC pump is perfect for medical and other applications requiring a small lightweight pump with a high performance to weight ratio. • Efficient, variable speed brushless DC motor conserves power by matching output to requirement • Lightweight – 6.8 lbs. vs. 9.5 lbs with AC motor • Small footprint – 8.32" x 6.75" x 4.08" • Oil-less design • Maximum flow – 3.3 CFM @ 2200 RPM • Maximum pressure – 35 PSIG

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Improving lives through innovationTM

Materials & Assembly

Solar Panels Use Custom Plastic Part

New application for Spanish solar panels requires no lubrication and saves 70 percent compared to metal bearings. A custom-mAde plastic part supports the rotational motion of solar panels made by a Spanish company. The part was designed by engineers at Soltec Energias Renovables of Molina de Sugura, Spain, with engineers at igus, a compounder and molder of specialty self-lubricating plastic compounds used in bearings and other motion control products. The Soltec engineers say the plastic part is 70 percent cheaper to produce than the previously used metal bearings. The part eliminates the need for lubrication. Lubricated metal bearings had attracted dust that required maintenance in remote locations. Also, the light weight of the plastic part simplifies installation. The project was recognized as part of the manus 2011 awards program held by igus GmbH of Cologne, Germany. Igus developed the manus program to showcase innovative uses of plastic bearings. Igus develops tribologically optimized material compounds designed for low wear and long life. They are widely used as bearings and cable carriers. All of the igus technology is inhouse and very proprietary — even the identity of base polymers and particularly the compounds and compounding methods. It is known from company literature, however, that polymer families used include polyamide 6, 66 and PEEK (polyetheretherketone). Reinforcements include glass and carbon fiber, as well as a newly developed nanomaterial. The company manufactures its own tooling and operates several hundred molding machines at its home base in Cologne, Germany. D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

Source: igus

AN ILLUSTRATION IN INNOVATION

A custom-made part, shown in the middle of the photo, supports the movement of solar panels.

“The biggest battle we still have is convincing engineers that plastics can do a better job than steel as bearings,” bearings unit manager Tom Miller said in an interview with Design News at the company’s Rhode Island location. “One thing we run into is an engineer who says, ‘We tried plastics 10 years ago and it didn’t do the job.’” As in all technical applications — and particularly for bearings — it’s critical to make sure you have the right plastic formulation and that the parts are stress-free and made to the correct tolerances. Miller says a lot of molders are selling plastic bearings that aren’t up to snuff. DN — Doug Smock, Senior Technical Editor, Materials and Assembly

For More Information Watch a video from the manus 2011 awards program at http://dn.hotims. com/34938-516. igus: http://www.igus.com

“Innovation distinguishes between a leader and a follower.” - Steve Jobs

As the leading manufacturer of OEM pumps and compressors, our innovation in design and technology has helped our customers create new innovative products and become leaders in their marketplace. For more information on how Thomas innovation can help you lead your industry, go to

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36

Cover Story

Design for

Recyclability Component reduction through modular design is paving the way for faster disassembly. By Doug Smock, Senior Technical Editor, Materials and Assembly

M

ore engineers say they expect to design for disassembly in response to growing efforts to recover materials after products outlast their useful life. The trend, however, is advancing at a snail’s pace, so slow that some fastener suppliers say they haven’t even seen it yet. Driving disassembly discussions are new regulations, mostly in Europe, that require electronics and car parts to be recovered, and if possible, reused. Those plans got a lot of press in recent years, but are now partially mired in a bureaucratic bog.

D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

The pace of change driven by environmental pressures is slow because of strong pressure among manufacturers to avoid higher costs and the lack of a recycling infrastructure to reuse the waste. Looking at electronics alone, 1.9 to 2.2 million metric tons of electronics were thrown away in 2005, but only 345,000 to 379,000 tons were recycled. Let’s Do It Design engineers, however, are ready to go. According to a Design News survey, the two design for disassembly strategies engineers plan to use are component reduc-

37 tion through modular designs and fastener standardization. Major fastener suppliers said they can respond quickly when the designers are ready to move. They have already been providing products to ease disassembly to provide easier access for product maintenance. Nearly three in four respondents to the survey said they currently use design for disassembly concepts, primarily for ease of maintenance. Slightly more, 80 percent, said they expect to practice design for disassembly in the next five years. Cost savings and non-environmental reasons remain the most important considerations. However, the role of environmental pressures is rising, albeit slightly. Eighteen percent said customers are requiring design for disassembly for environmental reasons. Interestingly, 13 percent said the pressure to change is strictly internal. “In the past, it has been common practice to throw away products we no longer use and replace them

Source: Autodesk

Environmental factors are not front and center in design for disassembly decisions.

A prototype laptop can be disassembled in just two minutes without tools and in just 10 steps.

with newer versions. Only recently have we begun to realize the damage this does to the environment,” said Al Frattarola, director of global engineering and technology at Southco. “Recycling is vital to sustainability, and design for disassembly is vital to recycling.” Easier Maintenance Frattarola confirmed that other factors continue to play an important role, if not the most important, in design for disassembly. Machines designed for disassembly allow parts to be switched out when they fail or break, allowing the machine as a whole to remain intact and function properly for a longer period of time, he said. “It cuts down on the time and effort required for maintenance personnel to do repairs, as well as the time the machines are out of commission. Design for disassembly is gaining more momentum as resources and technology make it a more affordable and efficient process.” One example of a Southco product that fits the trend is a removable lift-off hinge that is now available in stainless steel. It allows cabinetry doors to be removed quickly without the use of tools. Another 17 percent of the respondents to the Design News survey said greater attention to disassembly is being dictated by new regulations, such as the WEEE (Waste Electrical and Electronic Equipment) Directive enacted by members of the European Union. The WEEE Directive sets collection, recycling, and recovery targets for all types of electrical and electronic goods, and places the responsibility for the disposal of electrical and electronic equipment waste on the manufacturers. Categories of products covered by the law are large and small household appliances, IT and telecommunications equip-

ment, consumer and lighting equipment, electrical and electronic tools (with the exception of large-scale stationary industrial tools), toys, leisure and sports equipment, medical devices (with the exception of implants), monitoring and control instruments, and automatic dispensers. Implementation of the law has been helter-skelter. According to an official EU report, only onethird of the covered products are in compliance. The European Parliament is now considering legislation to put teeth in the law and boost recovery rates. Missing Link One of the major problems with implementation of WEEE is that manufacturers are not required to make products easy to recycle. Problems include difficulty in disassembly, as well as the myriad of disparate materials used to make them. The European Parliament briefly considered an “eco design” requirement in the new, tougher regulations, but backed off in the face of complaints that the requirements would be too costly. A team of students last year demonstrated the feasibility of design for disassembly of a portable laptop computer. Students from Stanford and Finland’s Aalto University were given the task of designing a recyclable consumer electronics product that makes electronics recycling a simpler, more effective, and engaging process for consumers. The students used Autodesk Inventor and Autodesk Inventor Publisher software to create 3-D digital prototypes of the hardware components inside the laptop. The laptop’s modular design allowed easy separation of different materials including metals, plastics, and circuitry. Called “Bloom,” the prototype

w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

38 Materials & Assembly laptop can be disassembled in two minutes without tools and in just 10 steps. By comparison, a commercially available laptop takes about 45 minutes to disassemble, requires three separate tools, and involves as many as 120 steps. Beyond recyclability, Bloom delivers other benefits. The team used the easyto-disassemble modularity of Bloom to develop a keyboard and track pad that detach and allow for improved ergonomics. “We used Autodesk Inventor software often during the ideation phase to experiment with the design,” said Aaron EngelHall, a Stanford student and team member. “We created 3-D shapes to represent the hardware we had to design around, and the parametric design of Inventor software let me put in different parameters so that all the model dimensions would update immediately. I was also able to experiment with various thicknesses for the case enclosure, making it as thin as possible while maintaining structural integrity.” The ease of disassembly also makes it easier to repair and upgrade components over the lifetime of the product. “Consumer electronics waste is a significant and growing problem,” said Robert “Buzz” Kross, senior vice president, Manufacturing Industry Group at Au-

todesk. “It’s encouraging and exciting to see college students embrace Digital Prototyping to tackle the sustainability challenges of our times.” The project was part of Stanford University’s ME310 course. Consumer electronics giants such as Apple were corporate partners in the course. An investigation of recent design trends at Apple by Design News shows — if anything — a trend away from recycling consideration. Two materials being researched for portable electronics housings by Apple are carbon composite and bulk metallic glass — materials that would be very difficult to recycle. The new materials would replace aluminum in some cases, a highly recyclable metal. Apple had no comment when contacted by Design News.

Modularity and standardization are the two key strategies used in design for disassembly.

LCD Disassembly Similarly, there has been plenty of interest in the concept of LCD disassembly, but little action. The average TV screen size is now 32 inches, and LCDs are considered the fastest growing type of waste in North America and the European Union. A typical design has 20 different fastener types, more than 20

complex chemical compounds, several types of plastic film, and structural material, glass, and various adhesives. The UK funded a project called REFLATED, partially through the Technology Strategy Board (TSB), to investigate the recycling of LCDs and their constituent components right down to clean segregation of liquid crystal. One of the investigators was Dr.

Which issues will most affect future decisions you make when it comes to design for disassembly? 0 5 10 15 20 25 30 35 40 45 Cost Savings Strictly internal requirements for reasons other than environmental Pressure from customers for reasons other than environmental Additional costs Pressure from customers for environmental reasons Pressure from government regulation, such as end-of life legislation (WEEE) in the European Union

What are the methods and products you are most likely to consider using as you begin a design for disassembly project? 0 10 20 30 40 50 60 70 Use of modular designs that minimize number of components Minimize fastener types Specialty design engineering software, such as those involving the concept of design for manufacturing and assembly Minimize fastener materials Minimize the number of material types used in assemblies, e.g., use of polypropylene family 3-D printing for prototypes New types of adhesives Avoid use of laminates, plating, or painting

Strictly internal requirements for environmental reasons

Use of advanced fastener technology, such as "destructive" fasteners that break down under certain conditions PLM or PDM software

Other

Advanced manufacturing technologies, such as innovative powder forming processes other

D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

39

Design for Disassembly: Tips to Get Started

T

he international drive toward eco-design and design for disassembly has slowed since the recession of 2008. But design engineers who want to think ahead can take some steps toward the goal of making products easier to recycle. Here are a few ideas: 1. Include recyclers in your early discussions of a design concept. It’s great to make a product that’s easy to take apart, but there needs to be an end market for the components. The trash guys can tell you what sells and what doesn’t. If there’s no potential end market, go slow. 2. Consider simple, modular designs that integrate components. Processes such as powder metallurgy and injection molding offer great opportunity to combine functionalities in a single part. 3. Reduce types of fasteners and use products such as self-clinching screws that promote disassembly. Keep an eye on new assembly technologies, including adhesives. 4. Focus on one material or a compatible chemistry for assemblies. For example, automotive engineers are using more plastics made with olefin chemistry (e.g., polypropylene, TPO) in car interiors, and backing off materials such as PVC that are harder to recycle. 5. When you’re pitching the idea in early team meetings, emphasize the cost savings and benefits to your customers. Those are easier selling points than “green.”

Joseph Chiodo, who has invented a group of active disassembly technology applications for LCD automated disassembly and clean segregation access. Chiodo’s company, Active Disassembly Research, is currently working on a new design for disassembly manual for LCDs. Other recommendations from the REFLATED project include use of fewer screws, screw standardization, development of removable adhesives, and use of designs that allow easier removal of lamps. And, of course, markets need to be developed for the recovered products. That’s been the missing link for the recycling concept for many years. Active participants in the REFLATED project were Active Recycling Ltd., Active Disassembly Research Ltd., Critical Processes Ltd., C-Tech Innovation Ltd., Engelhard Sales Ltd., Glass Technology Services Ltd., NIS Ltd., Sims Group UK Ltd., and the University of York. Modular Designs In the Design News survey on design for disassembly, engineers said they would use modular design — the strategy used

by the Stanford students to develop the Bloom laptop. Seventy-eight percent of the respondents said they would make use of modular designs that minimize the number of components. Next in line as a strategy is reduction in fastener types. Sixty-three percent of the respondents chose that step. One fastening option already in wide use is the self-clinching, one-piece captive panel screw in place of a mishmash of loose hardware. “Since the beginning, when the first self-clinching fastener was introduced, I believe the benefits of design for disassembly were evident,” said Leon Attarian, director of marketing at PennEngineering, a major supplier of self-clinching fasteners. “Before their introduction there were only two other basic alternatives: loose hardware (nuts, bolts, washers, etc.) and weld nuts (fasteners).” If you used loose hardware, you could disassemble a unit by removing all of the fasteners, Attarian said. In the case of a screw and nut combination, you would most likely also have to hold the mating (nut) from turning while

loosening the screw. This can be very cumbersome and, in many cases, access to the reverse side may be difficult. Then, once the loose hardware is removed, in order to reassemble, you must gather all of the loose pieces, mate them, and reverse the process, according to Attarian. With a weld nut, loose hardware is not an issue, but there are other problems. The screw can be removed without the need to keep the nut from spinning, Attarian said. The weld nut will remain attached to the opposite side of the assembly even after the screw is removed so that loose pieces are not an issue. The equipment for installing weld nuts can be expensive and the process can create environmental concerns. Also, weld “burnouts” and “spatter” can also create quality problems in the final assembly, according to Attarian. A screw or bolt can be removed from a self-clinching nut without having to hold the nut from spinning, expediting disassembly. Self-clinching, one-piece captive panel screws are already used extensively on access panels for ease of serviceability. When the access panel is removed, the captive screw stays attached to the panel to make reattachment easier. “I don’t think there is any greater trend for design for disassembly today than in the past,” said Attarian. “There are however more and more challenging applications for which fasteners for disassembly are required.” These include smaller packages, closer tolerances, different sheet materials, and better performance. Almost one in five of the respondents in the Design News survey said they anticipate the use of special design engineering software to better design for disassembly. One example is DFMA, Design for Manufacturing and Assembly, developed by Geoffrey Boothroyd and Peter Dewhurst of the University of Rhode Island. An extensive design for disassembly module was part of DFMA in 1996, but was dropped because the market demand did not exist. “As a result of the increased need for w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

companies to demonstrate compliance with various environmental directives, a form of environmental assessment has been included in the recent release of DFA 9,” said Winston Knight of Boothroyd Dewhurst, Inc. “This enables users to assess the materials preference and recyclability of new products.” Another mechanical solution to disassembly is a snap fit, using either metal fasteners or a plastic design. Gregory Breads, product manager for Dirak, said, “We are seeing a high demand in latching and fastening products that are snap-in for assembly and are also easily removable for disassembly, as they completely eliminate the need for mounting hardware, such as bolts, nuts, and washers, leaving minimal components to dispose of. One cannot successfully consider design for disassembly without considering design for assembly, they go hand-in hand.” Leading adhesive suppliers also have

skin in the disassembly game. Henkel Corp. offers an easy-to-remove anaerobic gasketing material. Loctite 5203 seals close-fitting flanges against the same temperatures, pressures, and chemicals as traditional liquid gaskets, yet removes easily without machining or chemicals, according to the company. Traditional anaerobic gasketing materials can be removed only with solvents or manual abrasion techniques. Henkel has also introduced Loctite 5590, a two-component elastomeric structural adhesive designed to provide a flexible, high-strength joint, yet can be easily cut away when repair is required. Based on Henkel’s proprietary FlexTec technology, this one-component adhesive bonds a wide variety of dissimilar substrates including metals, glass, and plastics. Most elastomeric adhesives require damaging heat or chemicals for removal. Loctite 5590 can be cut easily with a sharp tool or knife and releases from

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Source: Southco

40 Materials & Assembly

Removable lift-off hinges allow cabinet doors to be removed quickly without the use of tools.

the bonded substrate when a thin wire is pried between the adhesive and the substrate. Another approach is “active disassembly” technology promoted by Joseph Chiodo. In this concept, fasteners would disengage when subjected to a stimulus such as microwave energy, electromagnetic induction, infrared radiation, vibration, or flash heating that would not be encountered in its service life. Materials that could be used for “self-disassembly” include shape memory alloys for actuator devices and shape memory polymers for releasable fastener devices. One potential technique is placement of a thin wire in a hot melt adhesive joint. An electric jolt heats the wire and releases the adhesive. Chiodo’s efforts received a lot of media attention a few years ago when companies like Nokia investigated use of the technology. That was then, now it’s different. Chiodo tells Design News, “With the economy being rather sluggish since 2008, things have started to get slow this year despite the international drive for eco-design.” DN

For More Information: View full survey results at: http://dn.hotims.com/34938-509

D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

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42

Design Hardware & Software

Putting a New Face on CAD Interoperability While working with multiple CAD systems still raises its share of interoperability challenges, vendors have made strides leveraging new technologies and creating new workflows to facilitate cross-platform design. By Beth Stackpole, Contributing Editor, Design Hardware & Software

D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

Source: Lotus Renault

F

or more than a decade, it’s been one of CAD users’ more vehement complaints: 3-D models created in one CAD system can’t readily be used by another. While the CAD interoperability problem has by no means been sidelined, the industry has gained significant ground in addressing the issue via new technologies and through modifications to the design workflow that facilitate cross-platform collaboration. New visualization and collaboration tools that foster the exchange of lightweight models (meaning 3-D geometry without all the design intelligence) have been instrumental in helping companies better exchange multi-CAD data without the hangover of traditional platforms. In addition, new technologies advancing the concept of direct modeling, along with reorienting design workflows so that only critical parts of a design, not full assemblies, are translated between parametric-based offerings, are other tactics easing the interoperability burden. The solutions couldn’t come at a better time. In today’s global economy, and with the rise of outsourcing, engineers are just as likely sharing design information with

Elysium’s CAD interoperability and repair tools help Lotus Renault ensure data moving from design groups to analysis and simulation groups is high fidelity, so standards are upheld both in-house and when working with suppliers.

peers within their own company as they are with suppliers, partners and customers located across the globe. Needless to say, with few exceptions — large automotive OEMs, perhaps — it’s the rare instance when all of the parties within this extended and dispersed product development ecosystem can mandate the use of the same CAD tool, hence enjoy a fairly

seamless exchange of CAD data. To make matters even more vexing, companies across all industries are consolidating, and this age of mergers and acquisition (M&A) activity can leave companies in the lurch when they try to meld product development organizations. Not only do they have to integrate people and processes, but trying to standardize on a

single CAD tool or perfect a way to exchange CAD models created by different tools can be quite a challenge, to say the least. Finally, all of the R&D effort that vendors have poured into evolving CAD tools over the last few years has not gone unnoticed. Now, more so than in the past, companies are willing to consider swapping their legacy CAD system for a fresh offering. When they do that, the new system is typically used for new designs, but there is still a requirement to keep a connection to the legacy CAD data. “CAD interoperability is not just an ongoing issue — it’s a growing issue,” says Paul Brown, senior marketing executive for NX for Siemens PLM Software.“It’s not something that’s gone away. It’s become even more of an imperative for companies to figure out how to work in this area.” Multi-CAD on the Rise Recent research from Aberdeen Group highlights just how prevalent the use of multi-CAD has become and how critical the need for on-going solutions to the interoperability problem. According to a December 2010 survey of 269 companies, 82 percent of respondents reported using three or more CAD formats in their design process, with 42 percent using five packages or more. By having to juggle different CAD systems, companies face several issues — the worse being an inability to leverage the different models or alternatively, having to deal with data translation hiccups and the inefficiencies of not being able to effectively manage disparate CAD files. It’s not difficult to see the business impact of such bottlenecks — that is, wasted time and poor product quality. “So much information is now embedded into a CAD file that losing that data becomes painful,” explains Michelle Boucher, senior research analyst at Aberdeen and author of the report, “Working with Multi-CAD? Overcoming the Engineering Collaboration Bottleneck.” “Engineers are under such huge pressures to meet development schedules, they don’t have time to be remodeling, rebuilding, and recreating work that is

Source: Lotus Renault

43

A race car’s front wing assembly is being translated in Elysium CADdoctor.

done by someone else,” she says. They may not have the time, but the reality is that it’s a responsibility they can’t avoid. According to the 2010 “Collaboration & Interoperability Report” by Longview Advisors, 41 percent of professionals in product design, development, and engineering play some sort of role in CAD interoperability or data exchange activities. That’s a lot of highly paid talent spending valuable time doing relative grunt work compared to investing their time and effort in product innovation, according to David Prawel, president of Longview Advisors. Forgiving and Flexible CAD Despite those findings, Prawel and others aren’t ignoring the progress that’s been made. CAD vendors have made strides around solving the traditional problems around interoperability by coming up with new direct modeling and other technologies that are more forgiving around the interpretation of geometry. “There are much smarter ways of looking at models out there today where you don’t need all that precision,” Prawel explains, citing products from companies like Kubotek and SpaceClaim. “But it’s dangerous to say we’re solving a technical issue of two CAD models that don’t interoperate. It’s better to say the systems have become more forgiving.” In addition to being more forgiv-

ing, modern CAD tools are becoming more flexible, offering users the option of doing fairly sophisticated modeling without reliance on a parametric or feature-based history tree. Siemens PLM Software’s Synchronous Technology, for example, allows users to manipulate geometry directly to make changes, which makes it easier to work with data from other CAD systems, Brown says. Siemens PLM Software’s JT data format, a lightweight and open 3-D visualization technology, has gained widespread acceptance among vendors and industry standards organizations, thus facilitating new levels of data exchange between CAD and PLM applications. For its part, PTC is also talking up flexibility with its “Any Data Adoption” philosophy around the newly released Creo platform. With the new technology, users can download a lightweight version of CAD data, including models from thirdparty CAD tools, for basic viewing and design review purposes. They can also convert it to a CAD-agnostic format to do modeling or analysis in any of the Apps that are part of the new Creo platform; or they can create a fully editable version of the data for applying new features or modifying geometry via a direct modeling approach. With Any Data Adoption, PTC is challenging the thinking around w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

44 Design Hardware & Software

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Source: PTC

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the classic interoperability problem, moving away from a full geometric translation of the entire parametric model to a process of selectively choosing what parameters to bring over. “What we’re doing is forcing companies to think about which features in their design fall into the category of critical math equations that are driving their geometry and the physics of their design,” says Justin Teague, division vice president, Creo, at PTC. “In the old world, you’d have to translate a 100 percent of the geometry and rebuild 100 percent of the recipe. What we’re saying is maybe only 30 percent is critical to the design.” In addition to the new approaches underway by the CAD vendors, tried-and-true methods, including the STEP and IGES industry CAD data exchange standards, as well as best-ofbreed data translation platforms, have come a long way in helping companies successfully address the CAD interoperability challenge. At Lotus Renault Grand Prix, which manufactures race cars for a Formula One team, the need to share data with a range of suppliers using different CAD systems, coupled with a requirement to pass models back and forth for CAE analysis, drove a 10-year partnership with Elysium to implement its automated migration and data translation CAD tools. WithD e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

in the company’s stress department alone, there are six or seven CAE tools in play to analyze all different types of problems. And while the company uses Dassault’s CATIA V5, not all of its suppliers do. “We needed a universal tool that could deal with anything without planning ahead,” says Ian Goddard, senior CAE engineer for Lotus Renault Grand Prix. “Having a closed-loop, bidirectional FEA-todesign process with data translation is a big issue for us.” Without products like Elysium’s CADdoctor, which automatically does the work of healing native geometries between incompatible CAD platforms, Goddard isn’t convinced the latest vendor advances would solve the problem on their own. “The mega CAD solutions can’t offer everything in one package so there is always going to be a specialized engineering tool that comes from a third party that raises the (interoperability problem),” he says. “Only specialized software like Elysium makes the problem go away completely.” DN For More Information Aberdeen Group: http://www.aberdeen.com/ Longview Advisors, Inc.: http://www.longviewadvisors.com/ Lotus Renault Grand Prix: http://www.lotusrenaultgp.com/

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Electronics & Test

Boom Time for Lithium Batteries Higher capacities are enabling cylindrical, prismatic, and flat lithium batteries to move into medical instruments, power tools, and computing applications. By Charles J. Murray, Senior Technical Editor, Electronics & Test

A

new breed of flexible, high-energy lithium batteries is changing the shape of next-generation products. Portable electronic devices, ranging from notebook computers to handheld medical instruments to power tools, are benefitting from steady advancements in energy density, as well as from the rise of thin-format laminate cells. For design engineers, the bottom line is that compact products with longer charge times are more doable than ever. “The battery industry is really booming right now,” says Robin Tichy, marketing manager for Micro Power Electronics, a technology integrator that specializes in the creation of custom battery packs. “There’s a ton of research going on. If you have thin electronic applications, then lithium polymer is getting more interesting. But right now, there are a million different directions you could go in.” Indeed, makers of consumer products are doing just that. Apple Computer, Inc. has notably used laminate-style lithium polymer batteries to great advantage in the iPod and iPad, as well as in the paperthin MacBook Air computer. General Motors and Nissan are employing similar laminate-style technologies in the Volt and Leaf, while Tesla Motors is using 6,800 cylindrical lithium-ion batteries in its highly publicized Roadster. At the same time, lithium is finding a big niche

D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

During this march of progress, battery capacities rose to 2.6 and then 2.9 A-hr. In June, Panasonic rolled out the NCR18650A, a lithium-ion cell that again stretches battery capacity, this time to 3.1 A-hr. Later this year, a few battery makers plan to move to 3.4 A-hr. And 4.0 A-hr batteries in the well-known 18650 form factor (cylindrical batteries slightly larger than AA) could be out as soon as 2013, they say. “We’ve tripled the energy in the same size can from 1996 to today,” says Dennis Malec, senior applications engineer for Panasonic. “And the next-generation 4.0 A-hr battery isn’t very far off.” Source: BAK Battery

46

A flat lithium polymer battery allows handheld devices to be thinner than they could with prismatic or cylindrical batteries.

in the medical industry, where cart-based instruments are giving way to handheld monitors. One of the keys to the recent rise of lithium-ion cells is the ongoing increase in capacity. Not long ago, 2.2 A-hr cobalt-based lithium batteries were all the rage, but in the past five years, they were replaced by lithium cells that used nickelmanganese and then nickel-aluminum.

Cylindrical Cells Push the Envelope Engineers say the higher-energy breed of batteries is opening new applications in countless industries, but particularly in medical. There, customers are incorporating them in portable ultrasound, portable oxygen concentrators, and portable workstations for monitoring patients. At the same time, a more traditional set of customers is still using lithium-ion as a replacement for nickelmetal hydride batteries in notebook computers, cell phones, digital cameras, and even power tools. “It doesn’t so much open up new applications as it allows the old applications to run longer,” Malec says. “Take notebook

47

• Flexibility, which allows engineers to easily change a design to fit a prescribed space; • Aspect ratio, making it simpler to create a large, flat cell and; • Higher C-rate, which makes it possible to deliver more current in less time. “For most designers, the decision to use

N

ot every battery application offers easy access to recharging. In those situations, engineers are increasingly reaching for a chemistry known as lithium thionyl chloride. Lithium thionyl chloride batteries, which offer some of the highest energy density figures now available, are being employed in military, aerospace, RFID (radio frequency identification), and Vemco’s underwater telemetry system uses GPS tracking applications. lithium thionyl chloride batteries from A case in point: Vemco, a manufac- Tadiran that enable it to operate for nine turer of underwater acoustic telemetry years at depths of 500 ft. systems, uses lithium thionyl chloride for long-term underwater deployments where batteries can’t be recharged. Vemco employs a battery pack from Tadiran Batteries that combines 24 D-sized primary cells and 12 Hybrid Layer Capacitors in an acoustic receiver. The receiver is used for remote monitoring of aquatic species tagged with transmitters. During operation, the system’s acoustic modem wakes up the telemetry system, transfers data, then returns to a standby mode to minimize power consumption. It enables users to track the migratory patterns of aquatic animals, and develop early warning systems when sharks and other predatory fish approach beaches. The battery packs, known as Pulses Plus, enable the system to operate for more than nine years at depths of up to 500 ft.

Source: Panasonic

Laminate Batteries Make a Comeback Even within the lithium-ion category, however, a sub-category is gaining momentum. Lithium polymer, a branch of lithium-ion that employs a flat laminate structure, is reaching a growing range of applications. “There’s definitely a trend toward lithium polymer in portable devices because there’s a race to make them all thinner,” Barsukov says. “All of the newest, coolest gadgets out there, starting with Apple and Android devices, are using polymer because of the thin cells and the high energy density.” Indeed, Apple’s MacBook air measures 0.67 inches thick, thanks in part to its use of lithium polymer batteries. Lithium polymer offers other advantages. Among them:

When There’s No Access to Recharge Power

Source: Vemco, Tadiran

computers: It allows the manufacturers to offer a broad range of options. For the low-end customer who mainly uses the notebook on a docking station, there’s a cost-effective 2.2 A-hr cell. Or they can switch to a 3.1 A-hr battery, and push the computing time into the six-to-eighthour window.” For those reasons, lithium-ion has virtually taken over the mobile computing space. Since 1996, when nickel-metal hydride and lithium-ion were virtually neck and neck, a gap has slowly formed. Today, lithium-ion’s energy density far surpasses that of nickel metal hydride. “In cell phones and notebooks, lithium-ion batteries are almost the only ones being used now,” says Yevgen Barsukov, IP development manager for battery management systems at Texas Instruments. “Pretty much everything else has been eliminated at this point.”

Panasonic’s NCR18650A lithium-ion batteries over a capacity of 3.1 A-hr.

or not to use lithium polymer depends on the available space,” says Brian Way, senior research and development manager of BAK Battery in Canada. “If you have a large volume, then it’s usually cheaper to install a cylindrical battery. But if you have

a small, flat space, and you need a custom size to fill it, then polymer is probably the easiest way to go.” Lithium polymer offers those possibilities because it uses a laminate structure with an electrolyte that can range from w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

Source: Apple Computer, Inc.

03CY 04CY 05CY 06CY 07CY 08CY 09CY 10CY 11CY 12CY 13CY 14CY 15CY 16CY 17CY 18CY

liquid to gel to solid. Unlike conMarket Demand for Li Polymer Cells ventional lithium-ion cells, which Million cells/CY are contained in a metal can, lithium 4500 polymer cells reside in an alumi4000 3500 nized foil bag, similar to a potato chip Cy LIB 3000 bag. The multi-layered bag keeps Pr LIB 2500 Lami LIB water from getting into the battery Auto LIB 2000 and prevents electrolyte from leakNIMH 1500 ing out. It also provides an advantage: Auto NiMH 1000 NiCd It’s far lighter and thinner than the 500 cylindrical metal casing of an 18650. 0 That, in turn, makes it possible to create a battery that’s similar in form to a loose-leaf notebook. Lithium-ion applications are soaring, and lithium “They can be really thin and they polymer has surpassed nickel metal hydride in can be stamped out in a bunch of recent years. different sizes,” says Tichy of Micro Power Electronics. “You can make small “In some ways, lithium polymer makes batteries, like the ones used in ear buds. Or products much more functional,” Tichy you can make really big batteries for elec- says. “We’re seeing the possibility of it betric vehicles or fork lifts.” ing applied to wearable vests for the miliWhat’s more, lithium polymer cells of- tary. In medical, we’re seeing it being used fer higher rates of discharge. The C-rate in digital X-ray equipment, which has to — a parameter that describes how long be very thin.” it takes to fully discharge a battery — is much higher in polymer batteries than in Next Up: Greater Capacity cylindrical or prismatic lithium-ion bat- Engineers say the laminate-type techteries. Whereas traditional lithium-ion nology, which virtually disappeared after batteries top out at C-rates of roughly two, a high-profile emergence in the 1990s, lithium polymer batteries can have C- is enjoying a renaissance of sorts. Projecrates approaching 15 or more. The ability tions for lithium polymer demand by the to discharge current at faster rates trans- Institute of Information Technology, Ltd. lates to greater power for the applications. in Japan show it falling short of cylindrical

Source: Institute of Information Technology, Ltd.

48 Electronics & Test

Apple’s MacBook Air uses lithium polymer batteries to achieve its 0.67-inch thickness. D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

49

Dealing with Heat

T

Source: Texas Instruments

hermal runaway is a pheSingle cell battery gauge: bq27520-G1 nomenon that’s never far 2.6 from the minds of design engineers who use lithium-ion bat2 teries, especially after news surfaced of laptop fires more than a decade ago. 0.625 Electronics suppliers are helping engineers prevent such prob0.5 lems, however, with the introducDimensions in mm tion of new battery management TI’s bq275xx family of battery gauges is targeted ICs that monitor voltage, temperaat cell phones and notebook computers. ture, and current conditions at the battery. “The main condition is over-voltage,” says Yevgen Barsukov, IP development manager for battery management systems at Texas Instruments. “Normal voltage for a lithium-ion battery is 4.2V. If the battery is charged to 4.3V or 4.4V, it can take you to a condition where you have thermal runaway.” TI’s bq275xx family of battery management ICs provides protection for battery packages. The ICs, which measure just a couple of millimeters on a side, include a microcontroller, Flash memory, random access memory, and an analog-to-digital converter. The devices serve as gauges for handheld devices, such as cell phones, laptops, and tablet computers. Both TI and Analog Devices make management units for electric vehicle batteries, too. In June, TI unveiled bq76PL536, a battery management unit targeted at rechargeable lithium-ion packs for EVs, hybrid vehicles, and power tools. Similarly, Analog Devices last year rolled out the AD8280, which works with a series of high-voltage comparators to “look” for undesirable voltage or temperature conditions in vehicle battery packs. “The idea is to monitor for voltage, temperature, and over-current conditions,” Barsukov says. “If any of the conditions are exceeded, the battery management system will turn off the appropriate components.”

and prismatic lithium-ion batteries, but gradually surpassing such technologies as nickel metal hydride and nickel cadmium. “Polymer has gone from a complete rarity to fairly common in only a couple years,” Tichy says. Experts expect lithium-ion batteries of all types to keep gaining market share over the next few years. The evolution of new lithium-based batteries will continue, they say, as the technology moves toward silicon alloy anodes over the next few years. “Silicon-based anodes are on everyone’s roadmap for this year or next,” says Way of BAK Battery. “They’ll take the cylindrical 18650 cell from a max of

about 3 A-hr to a max of about 3.5 or 4.” Within five years, some engineers believe battery capacities will even rise beyond that level. “The question is, will it go as high as 4.2 or 4.4 A-hr?” says Malec of Panasonic.“We don’t know yet.We can only hope so.” DN

For More Information: Panasonic’s NCR18650A: http://dn.hotims.com/34938-510 TI’s bq275xx and bq76PL536: http://dn.hotims.com/34938-511 and http://dn.hotims.com/34938-512 ADI’s AD8280: http://dn.hotims.com/34938-513 w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

Automation & Control

Miniature Motion in Medical Devices Solutions offering more compact, mobile, low power, and lightweight motion control help spur advances in medical device design and development. By Al Presher, Contributing Writer

A

s medical devices become smaller and more mobile, motion control solutions have been keeping pace by delivering new innovations, smaller footprint packages, and reduced power needs. But the key to these new solutions for miniature motion control is a much higher level of integration of the motion subsystem into the medical device itself. Use of integrated motor drivers and modular style controllers provide design tools that reduce the hardware required to implement control systems. New humanscale fluid power devices are combining ultra-low-power consumption valves, and force and position sensors, with control electronics to create new solutions such as an untethered ankle-foot orthosis. Along with a continuing focus on performance, the design challenge is to achieve the ultimate in reliability while making motion components more compact and intelligent. Design Trend to Integrated Solutions “For each segment within the medical devices space, motion control applications face different concerns, but the common theme across them all would be reliability, controllability, and more

D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

Source: Maxon Motors

50

Modular style controllers such as Maxon Motors’ EPOS2 modules offer design flexibility and reduce time-to-market by integrating the motion control more tightly into the device rather than using a black box mounted in a panel.

advanced control using feedback and closed-loop systems,” says Ryan Kehr, applications manager, Motor Products for Texas Instruments. “Especially with the certifications required in the medical space, it is important that these things are proven out.” He says there are three basic motor types used in medical devices: brushed dc, stepper, and three-phase brushless motors. Brushed dc motors operate in an on/off mode suitable for simpler applications that require lower precision. Stepper motors provide higher precision where there is a requirement to count

the exact number of milligrams that need to be dispensed. Complex three-phase brushless solutions provide the highest level of reliability, but involve more complicated controls for applications like ventilators or cooling fans in medical instrumentation devices. “A specific area we’re seeing as a design trend is integrated motor drivers,” says Chris Griffith, medical business development manager for Texas Instruments. “In the past, many of these applications have used discrete solutions where there are separate gate drivers and MOSFETs, and it is often difficult to provide the type of

51 protection that an integrated solution can offer. Robustness for medical devices is a key advantage that we can provide by integrating the solution.” By integrating components into a single package with on-chip over-current, over-temperature, and shoot-through protection, there is an ability to make sure the high and low side FET are not turned on at the same time, which can cause device failure. The approach also addresses cost from a PCB area standpoint, and shrinking board sizes tend to reduce the overall size of the end product. The reduction in board space can be up to 50 percent by using an integrated versus a discrete solution. “Many of the products in our portfolio can be used for both stepper and dc brushed control,” says Kehr. “Some have an onboard microstepping capability which minimizes the amount of external controls needed for step and direction applications, for example. For a urine analyzer moving between different vials, a stepper can provide a good positioning solution. For a fan motor in a ventilator spinning at a high rpm, a brushless dc device fits well and provides performance gains, which can provide increased efficiency in a smaller form factor. The long-term reliability of brushless is also a plus for applications such as ventilators.” Kehr says ongoing work with brushless dc systems is focusing on sensorless control algorithms. These systems can provide a cost advantage and eliminate another area where you can have a failure mechanism using external sensors like Hall Effect sensors required for sensored brushless dc control. In sensorless applications, feedback is provided by measuring back EMF voltages and phase currents. This requires a high slew rate, especially for applications such as fan motors, which are spinning at a higher speed; precise feedback on the currents and back EMF voltages; and often implementation of signal conditioning using op amps. The technical challenge is to make sure the current is calibrated from the standpoint of offsets to prevent introducing commutation errors.

vide assistive power and propulsion.” Enabling technologies for the system are the advent of ultra-low-power consumption valves, force and position sensors, and control electronics. McDonnell says the key is the ability to take a traditional rotary actuator and lighten it up to offer minimal weight for the wearer, making it compact while providing a substantial amount of shock and vibration protection. Use of pneumatics offers a lightweight solution that also delivers the desired motion profile. A core challenge with the non-tethered Source: Portescap, Inc. AFO is the need it creates for a compact To closely follow the breathing pattern of a patient, motors used in ventilators typically power source, which requires a pneumatic accelerate from 10,000 to 15,000 rpm up to reservoir and becomes another compo50,000 to 60,000 rpm in a very brief amount nent the patient will carry. The reservoir of time (usually 100-200 milliseconds). needs to be compact but also provide high enough pressure to sustain several thouHuman-Scale Fluid sand steps of use for the patient. Power Devices Other challenges include combining The development of a light, compact, the compactness and efficiency of the efficient, ultra-low-powered, untethered actuators with the effective transmisAnkle-Foot Orthosis (AFO) system has sion of pneumatic power to provide the the potential to yield significant advances desired torque from the actuator. Comin orthotic control mechanisms and ponent integration for reduced size and treatment strategies. weight is a key design constraint, along Active control of the joint, versus an with smart control schemes that accomorthosis which functions as a brace, is plish functional tasks during gait and achieved by offering a truly mechatronic effectively manage the human machine style set of components. The new ortho- interface (HMI). sis provides the necessary propulsion and “In the U.S. alone, there are more than an ability to adjust foot position during 6.2 million individuals who would benthe gait for patients suffering from medi- efit from a portable, powered, daily wear cal conditions and injuries. In collabora- AFO. For individuals with impaired antion with a leading research institution, kle function, current solutions are passive Parker Hannifin is developing a motion braces that provide only motion concontrol solution for this new category of trol and joint stability,” says McDonnell. human-scale fluid power devices. “These designs often fail to restore nor“The core piece of the innovation is mal ankle function because they lack the the optimization and development of ability to actively modulate motion cona dual vane rotary actuator that is high trol during gait, and cannot produce protorque and miniature in size,” says Rich- pulsion torque and power.” ard McDonnell, product sales manager for Parker Hannifin Corp.’s Automation Ventilators Use Slotless Group. “A rotary actuator at the apex of Brushless Motors the ankle bone allows the motion using “For the ventilator business, the trends in compressed air, and a piezo valve controls motion control are driven by manufacthe bidirectional movement of the actua- turer requirements to increase the pressure tor. Individual sensors at the toe and heel and flow levels to cure a broader spectrum provide feedback on the position of the of pulmonary diseases,” says Loic Lachefoot, and are used by the actuator to pro- nal, global medical segment manager for w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

52 Automation & Control age the temperature inside the motor is with a new slotless brushless motor design. As in typical slotless motors, this design has no iron in the air gap between the magnet and the copper wire of the stator, which helps to provide smooth operation. It also has no detent torque, and very low vibration levels, which is important for high-speed applications. Portescap’s newest slotless design with optimized magnet and winding maximizes torque output without increasing power consumption. “As a benefit OEMs can use the same amount of current that they use with existing motors, and get more out of the new motor. Or if they want to lower temperature inside their device, they can reduce the amount of current and still maintain the same performance level,” says Lachenal. Modular Style Controllers “The basic trend we see in medical devices is the miniaturization of designs, and new modular style controllers we have developed to help with those requirements,” says Biren Patel, applications engineer with Maxon Motors.

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Airpot.com

Source: Texas Instruments

Portescap Inc. “New devices are also capable of supporting respiratory conditions for smaller people and children with higher breath per minute count, so the increase in therapy frequency is placing greater Motor drivers often integrate demands on the motor.” control circuitry such as current regulaOne challenge is to manage tion or digital state machines to operate the the heat rise inside the motor, motor, in addition to providing a high-voltwhich directly relates to the life age and high-current drive. These motion of the motor. Temperature affects the ball solutions provide a level of robustness plus bearings and directly impacts the life of compact size that can be ideal for medical the bearing. Since children have a faster device design. breathing pattern than adults, the extra number of breaths per minute influences 100 to 200 milliseconds). The shorter the pressure and flow in the system. the acceleration time, the more comfort“Reliability is utmost important for able it is for the patient because the time ventilation, and our motors are used for accelerating affects the air flow. Low to rotate an impeller in a blower which inertia motors help to create a very creates a flow generation function,” responsive device. says Lachenal. “We provide the air flow “The more frequently the system through an OEM’s impeller and blow- operates (50 to 60 times per minute er design, and either sell motors to the for children, compared to adults who OEM or integrate the blower and impel- breathe 35 to 40 times per minute), the ler, and ship a complete solution.” more demanding the performance beWith a goal of closely following the comes, and the more temperature the breathing pattern of a patient, the mo- motion control system is dissipating tor typically accelerates from 10,000 to because faster operation requires more 15,000 rpm up to 50,000 to 60,000 rpm current,” says Lachenal. 6/30/10 7:31 PM is Page 1 to maninAIR006_DashDemoAd_DN7x3.375ƒ:AIR006 a very brief amount of time (usually One way Portescap helping

53 “With our positioning controllers, for example, we now have an EPOS2 module which is only 1.5 inch by .5 inch with a PCI Express style connection layout, so the customer can design a motherboard and plug the module into it.” Modular controllers provide flexibility because the motherboard can trace out the connections, rather than using long cables connecting to a black box. The design approach helps reduce weight, and there are fewer cables to rout through the device. With a module, a key advantage is that the customer can design the motion control more tightly into the device rather than using a black box mounted in a panel. Basically the printed circuit board (PCB) module can be plugged in the motherboard to achieve greater design flexibility. In applications with limited available space, the motherboard can implement multiple axes in a small volume and can also be mounted either vertically or horizontally. The approach offers tight integration with existing electronics and there is no need to run extra communication cables, since power and communications is traced out on the PCB. Modules are available to provide position, velocity, or torque control for brush

type or brushless motors. Patel says motor selection is generally application dependent, but there is a move toward brushless solutions in medical applications where the motors often need to last longer. As the cost of brushless is coming down, more and more applications are moving in that direction. “A key advantage of modular style controllers is their ability to help companies reduce the time to market,” says Patel. “With the motion controllers becoming smaller, engineers don’t need to design their own drives and controllers. This approach offers a solution that fits more easily into their existing design rather than re-designing the control scheme.” By using a module, all the customer needs to develop is the logic to feed into the controller, which takes care of the trajectory generation; moving the motor; and checking the encoder feedback to verify motor positioning. Options for standard modules include motor types, different feedback types (encoder or absolute encoder), plus the ability to provide dual-loop operation. For positioning a linear screw, where there is a need to know the position of the screw versus motor position because of backlash issues, separate encoders can be

mounted on both the lead screw and the back of the motor. The encoder on the lead screw is used for positioning to compensate for backlash within the gearbox. Custom firmware can also be used to create a simple routine of point-to-point moves, for example, and the customer can use digital I/O to initiate moves rather than writing a program and communicating over the serial or CANopen bus. As far as software is concerned, the approach Maxon has taken is to use industry standards (IEC 61131-3), which are intended for industrial robotics rather than creating their own protocol. “As more engineers are moving between medical, robotics, and automation, they often don’t need to re-learn the software but use what they already know and reduce the learning curve,” says Patel. DN

For More Information Texas Instruments www.ti.com/motors Parker Hannifin Corp. www.parker.com Maxon Motors www.maxonmotor.com Portescap www.portescap.com/BrushlessSlotlessDC

w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

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Why Isn’t Embedded More Innovative? By ALEXANDER WOLFE, Content Director

EmbEddEd systEms is the most bifurcated of design engineering categories. On the one hand, there are the tried-and-true — but decidedly aged — 8-bit microcontrollers. They’re still going strong in everything from servo control to portable medical devices. At the same time, embedded yearns to own the cutting edge; for example, with multicore MCUs in robotics applications. What’s it going to take to continue that upward momentum? That’s the question we posed to our Systems & Product Design Engineering group on LinkedIn (http://bit.ly/designnewsLI). Specifically, we asked: What needs to change with embedded systems for real innovation to occur? William Ketel, an engineer in the Detroit area, set the parameters of our debate by warning: “Innovation that does not add actual value is a waste of the designer’s time.” He alluded to the case of MCUs being replaced by more powerful microprocessors. “There are a whole lot of instances where adding a processor adds features that at best nobody asked,” Ketel says. But if MCUs are the sweet spot for embedded systems, manufacturers often make them needlessly diff icult to use. This, in turn, forestalls innovation. That was the take of our own contributing editor Jon Titus. “Many engineers, programmers, and product designers struggle with poorly written, incomplete, and cryptic manuals and data sheets,” he says. D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

The upshot is that hard-to-use tools can raise an insurmountable roadblock to innovation. “If someone has an idea for a product that could use an embedded microcontroller or OEM PC, they face a steep learning curve, which frustrates innovators who might not want to become experts in compilers, CPU architectures, and communication protocols,” Titus says. “The diff iculty of understanding how to do what they want with embedded components deters many innovative people from pursuing an idea. Yes, good hardware, software, and documentation exist, but in my experience, not always all from a given vendor. Make the wrong choice and your innovative idea dies.” I concur with Titus. I’d point out that there’s certainly innovation in embedded — witness the emergence of 64-bit and of multicore MCUs. However, we’re talking about innovations which apply embedded. In that regard, I’d point out the embedded users are among the smartest engineers and designers around. They have to be, not only for the reasons Titus mentions, but because they’re stuck with the tightest constraints around in terms of power budget, cost, and required application performance. Yet, because embedded tends to be an insular niche, innovation within the space isn’t apparent to the broader cohort of engineers. As a result, embedded doesn’t benef it from the interdisciplinary cross-pollination that’s at play most everywhere else. DN

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Design

Decisions

Fiber-Optic or Flexible Coiled Fiber Fiber-optic cable has speed on its side, but is also fragile; coiled fiber, however, can resist breakage when extending or bundling. By Kyle Miller, JEM Cable & Fiber

As increAsing Amounts of cable are used to connect

components in industrial systems design, including everything from robotics to telecommunications, the end results are all about speed and reliability. With these two ends in mind, design engineers face numerous decision-making paths when it comes to choosing between copper and glass fiber-optic conductors. Fiber-optic cable is constructed of optically pure glass as thin as a human hair and is often used in telecommunications, cable TV, and the Internet. The down side to this high-tech innovation is the optically pure glass core is fragile and cannot be stretched or bent because the glass core can easily break. Coiled fiber can be extended and recoiled without fiberglass breakage, extending the life of the fiber cable. Coiled fiber can be stretched without breaking the fiberglass so less fiber cables have to be replaced, saving the time and money associated with replacing damaged cables. JEM’s coiled fiber cables, for example, are rated Curl OD: Ø20

1st Connector Type

for up to 80,000 stretches. The adaptable length extension of coiled fiber can reduce the number of fiber cables needed in the field to meet various length requirements. For example, one cable can be used in various applications that require different lengths and can be used in applications that have limited space. The coiled design neatly bundles any excess fiber cable and is useful for constantly moving parts that require fiber cables. Coiled fiber also helps with organization, and reduces safety hazards by cutting down wire clutter and keeping excess cables off the ground. The fiber is tightly coiled so the excess fiber does not hang loosely. This design also utilizes less space for applications that are short on space when storing the cable. JEM’s coiled fiber can be used for constantly moving parts and for applications in military and defense, datacenters/IT/IS, medical, and robotics. DN

Curl Length

Total Length

2nd Connector Type

Kyle Miller is an operations assistant for JEM Cable & Fiber. For more information, go to http://bit.ly/mzVj8Z. D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

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Design Engineering

Products Best of the Engineering Marketplace Compiled by Lauren Muskett, Assistant Editor

Electronics & Test High Optical Power for 3D Camera Provides light for the new 3D camera from Swedish manufacturer FOTONIC.

The FOTONIC C70 camera is based on a CMOS sensor and employs the principle of time-of-flight measurement. When integrated into the camera, the laser diode transmits a light pulse that is reflected back from the target. Each of the 120 x 160 pixels of the camera chip records the distance to the object by measuring a respective phase shift compared to the emitted light pulse. The precision of this distance

voltage outputs, which vary with acceleration, and features a four-wire connection, supporting both single-ended and differential modes. The sensitive axis is perpendicular to the bottom of the package, with positive acceleration defined as a force pushing on the bottom of the package.

Silicon Designs, Inc. www.silicondesigns.com

Miniature Illuminated Snap-In Rocker Switches Useful for compact or crowded designs requiring illuminated switches.

measurement and the range of the sensor increase with the modulating frequency of the light source. Due to their fast switching times of only a few nanoseconds, laser diodes are well-suited for this application.

NKK Switches’ CWS Series of full-face illuminated miniature rocker switches are available with red, green or amber illumination and have snap-in mount capability. They are configurable with either LED (CWSC) or neon (CWSB) lighting.

OSRAM Opto Semiconductors www.osram-os.com

Compact Low-Frequency MEMS Capacitive Accelerometer Modules Compact size supports the measurement of smaller components.

Silicon Designs, Inc. has expanded the availability of its 2260 series modules to include new low-frequency ranges to 0 Hz within a footprint that is 37 percent smaller than typical single-axis models. The accelerometer produces two analog D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

The compact rockers are rated 9A @ 125V ac for resistive loads. The LED illuminated CWSC has an additional rating of 6A @ 250V ac. The neon-

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We’re not just talking about off-the-shelf solutions, either. A Lee engineer will be happy to discuss your application, and develop a custom design if needed. From managing nanoliter droplets to creating fully integrated fluidic systems, we’re unsurpassed in breadth and experience to deliver the precise, reliable performance you require. Whatever problem you face, make the solution easy. Contact The Lee Company today.

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60 Design Engineering Products

Long Range Inductive Sensor for Difficult Applications

illuminated CWSB versions also offer a built-in resistor for direct connection to the ac power source.

Compact in size, senses at long ranges, and detects various metals.

NKK Switches www.nkkswitches.com

Automation & Control Basic Sensor Line AutomationDirect’s offering of industrial sensors now includes two series of low-cost, high-performance sensors.

The FB series M18 plastic dc photoelectric sensors are 18 mm sensors in diffuse, polarized reflective, and through-beam models with sensing distances ranging from 70 mm to 8m. All models feature M12 quick-disconnects and are available in NPN and PNP output logic configurations. FB series inductive proximity sensors are priced at $21.50. Also added are the PB series inductive dc proximity sensors. Twelve models

are available in 12, 18 and 30 mm sizes, with shielded and unshielded housings and sensing ranges of 2 to 15 mm. Fitted with M12 quick-disconnects, the nickel-plated brass sensors are IP67rated and feature either NPN or PNP logic outputs. PB series sensors prices start at $13.50.

Balluff developed the Q40 inductive proximity block sensor with Factor 1 technology to solve difficult application problems. The Q40 delivers sensing ranges up to 40 mm in a small housing, with weld field immunity, and the ability to sense aluminum and steel at the same distance. Each Q40 sensor head can be mounted in five positions and has highly visible cor-

AutomationDirect www.automationdirect.com/sensors

Last Brake Standing.

ner LEDs. The connector outlet is also adjustable within a 270-degree range. Balluff www.balluff.com/inductive

Materials & Assembly UV-Curable Adhesive/Sealant Meets NASA’s outgassing requirements.

Nexen brakes and clutches outperform and outlast. Our rugged brakes and clutches deliver high torques and cycle rates, withstanding heat, corrosion and are washdown available. Select yours at nexengroup.com or call 1.800.843.7445 and ask about our Twice the Life program for clutch-brake applications.

Quality you can depend on. Delivery you can rely on. D e s i g n N e w s J u l y 2 0 1 1 w w w. d e s i g n n e w s . c o m

Master Bond, Inc.’s one-component, UV-curable, modified epoxy system, UV10TKLO-2, offers optical clarity, high physical strength properties, and is chemical resistant. It is not oxygen inhibited and cures rapidly at room temperature when exposed to UV light. Maximum UV absorption takes place in the 320-365 nm range. Master Bond UV10TKLO-2 is easy to apply and has a high viscosity. It has passed tests to meet low outgassing specifications as per NASA ASTM E-595. It can be used in a wide array of optical, electro-optical

61

disc is available in acetal plastic for high torsional stiffness and zerobacklash, or nylon for shock absorption and noise reduction. Ruland offers numerous standard bore combinations from 1/8 (3 mm) to 1 inch

(30 mm) with hubs also available in stainless steel.

Ruland Mfg. Co. Inc. http://www.ruland.com/ps_couplings_ oldham.asp

and vacuum applications that until now have been off limits for UVcurable compounds. To optimize low outgassing properties, UV10TKLO-2 should be preheated to 50C for 15 minutes prior to use, and then allowed to cool to room temperature. Master Bond, Inc. www.masterbond.com

Oldham Couplings for Zero-Backlash Performance Can be used in motion control applications and as an alternative to straight jaw couplings.

Oldham couplings from Ruland Mfg. Co., Inc. have been increasingly used as an alternative to straight jaw couplings on general industrial equipment such as pumps, valves, gearboxes, and conveyor systems. The oldham coupling is a threepiece assembly comprised of two anodized aluminum hubs and a torque transmitting center disk. This design results in a customizable shaft coupling which can easily interchange inch to metric, different bore dimensions, and keyed shafts. The center w w w. d e s i g n n e w s . c o m J u l y 2 0 1 1 D e s i g n N e w s

Advertisers

62 Advertiser

Page

Advertiser

A&A Mfg.

30

EXAIR Corp.

Ace Controls

44

IMS Schneider Electric Motion

Airpot Corp.

52, 53

3 48, 49

Advertiser

Page 7

Rockwell Automation Rotor Clip Co. Inc.

58 41

40

Siemens AG

63

Siemens PLM Software

4

10,28

Smalley Steel Ring Co.

32

Solidworks Corp.

15

Tadiran

45

61

Lin Engineering

Allied Electronics

C3

Master Bond Inc.

2

Page

Kepner Products Co.

All Sensors Corp.

Asco Valve Inc.

in this issue

6

Mouser Electronics

AutomationDirect

23

National Instruments

Avnet

11

Nexen Group

60

TDK-Lambda Americas Inc.

31

Northwire Inc.

62

TE Connectivity Ltd.

55

The Dow Chemical Co.

33

The Lee Co.

59

14, 16

CIT Relay & Switch

19

Clippard Instrument Lab.

C1, C2

Digi-Key Corp.

1

Omega Engineering

12

Phillips

EBM Pabst

21

Proto Labs Inc.

Element 14

17

Pyramid Inc.

25, 27, 29, 54

8 10

Thomas Division Yaskawa America Inc.

34, 35 C4

Publisher does not assume any liability for errors or omissions in this index.

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July 2011

automation: networking trends / a supplement to design news

networking trends in automation

PLUS Optimization of Energy Use ■ Strategies for Energy Monitoring ■ Hardened, Robust Switches and Routers ■ Hot New Products ■

w w w. d e s i g n n e w s . c o m

More choices give you freedom to design the system you need Use the technology built into the Productivity3000 programmable automation controller to make your job easier. Over 35 I/O modules (up to 64-point discrete and 16-point analog) capture and control a wide range of field signals. I/O modules can be placed in any slot, in any base - no need to remember special restrictions or calculate power budgets. And for critical systems, the hot-swap feature can save you from downtime or worse. Build systems with local (USB) and remote (Ethernet) racks and get over 115,000 I/O. The convenient USB port on each remote slave module lets you program and monitor from any remote location. Drive-intensive applications are a snap - connect up to 64 GS/DuraPulse AC drives to the Ethernet remote I/O network and configure through the free Productivity Suite programming software.

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Emerald Technology Automation: networking trends A Supplement to Design Ne ws J u ly 2 0 11

Emerald Automation Controller A new standard in motion control for the industrial automation marketplace using the SERCOS III servomotor drive network.

CONTENTS Feature

Feature

S4 Optimization of Energy Usage

S15 Hardened, Robust Switches and Routers



T  he ODVA energy initiative pushes toward extending the coverage of Common Industrial Protocol to encompass energy applications. By Al Presher, Contributing Writer



Industrial networks can use upgraded technology to address concerns about temperature, redundancy, data creep, security, and software standards.

By Jim Krachenfels, Garrettcom, Inc.

Feature

Products

S12 Strategies for Energy Monitoring

S17 In the Marketplace

Standard Ethernet networking and PAC technology, new software tools, and DemandResponse programs team up to identify energy savings and reduce consumption. By Al Presher, Contributing Writer [w w w. de s ig n n e w s . c o m ] 



A look at some of the most innovative and useful new product technologies and solutions.

• • • • • • • • • • • •

32 axis of synchronous control 250 micro-sec position updates 512 points of I/O control Hi-speed input interrupts Multiple connectivity options Fieldbus network SERCOS III or II network interface Motor/drive systems up to 55K watts Electronic cam and ratio functions Easy programming Free servo system sizing support Call us for a quote today!

Industrial Indexing Systems, Inc. +1 (585) 924-9181 Web: http://www.iis-servo.com Email: [email protected]

Automation: Networking Trends

Optimization of Energy usage The ODVA energy initiative pushes toward extending the coverage of Common Industrial Protocol to encompass energy applications. By Al PreSher, ContriButing Writer

T

he industrial sector consumes approximately 40 percent of the world’s total delivered energy, making it the largest energy-consuming sector. Within the industrial sector, the production domain consumes 80 percent of the energy, making it fertile ground for energy optimization efforts. With that in mind, ODVA has launched a new initiative to transform the industrial energy resource allocation model. The goal is a comprehensive approach and standards for the optimization of energy usage (OEU) that is scalable, open, and inclusive of users and suppliers. Adding new objects and services to the Common Industrial Protocol (CIP), the strategy is to use the power of industrial networking and the market dominance of EtherNet/IP to initially drive awareness and data sharing around energy usage. Ultimately, industrial energy management will be taken to new levels of granularity, and potentially offer important information to the smart grid as those standards continue to evolve. And while the energy issue sits at the core of ODVA’s adopter community, there are also powerful drivers within industry to create more sustainable business models, and improve sustainability reporting. “Energy has emerged as part of the next generation of productivity enhancements for industrial automation,” says Katherine Voss, executive director at ODVA. “We spent the early years at ODVA working on getting networks to make products better, faster, and cheaper. Energy optimization is a new frontier that will not only help companies meet their sustainability objectives, but will result in energy becoming a managed resource in production processes and actually being a line item on production bills of material.” To enable a holistic approach to energy, ODVA has set out to develop a common understanding of energy with the key metric being an awareness of energy information. Energy data will be shared throughout the production domain from assets to systems to processes, between industrial and enterprise systems, and also with the grid. The initial goal for the ODVA Energy Initiative is to develop energy awareness of objects and services in CIP, making possible the rollout of energy-aware products from ODVA vendors

in 2012. Voss believes it may be possible, in some cases, to implement simple awareness functionality in software with limited or no impact to existing product designs, provided adequate memory is available. To achieve more advanced aggregation or metering functions, there may be additional changes required by device suppliers. A special interest group (SIG) has been working to develop the specification enhancements for energy applications utilizing the CIP, and the project seems on track to include the initial energy awareness objects and attributes in the next edition of its specifications scheduled for the fourth quarter of 2011, according to ODVA. “Our goal has been to develop a common interface and set of data types, engineering units, and structures for representing energy and power within the overall framework of the (CIP) specification,” says Rich Morgan, co-chairman of ODVA’s SIG for Energy Applications and engineer for power and energy products at Rockwell Automation, an ODVA principal member. “This reduces complexity by enabling devices to share energy data using the objects and services regardless of

S4 Autom At i o n: net w o r k i n g t r e n d s / A s u p p l e m e n t to de s ign ne ws Ju ly 2011

[www.designnews .com]

Automation: Networking Trends Model of Industrial Energy Domains

it takes to make a product. The facility can be consuming a lot of energy but it can be very efficient based on the energy consumption per widget. Granularity is essential to understanding the details of the issue. “One of our goals with this project is to make it simple for simple devices to be simply energy aware,” says Voss. “While ODVA didn’t want to reinvent the wheel, (it) actually found a void of standards and pre-existing work pertaining to energy awareness standards for the production domain.” Standardization is an important element of ODVA’s work, along with making sure an adequate model for energy awareness is developed. At the same time, ODVA is seeking to provide structures for energy awareness within CIP that is efficient for data transmission and straightforward to impleODVA’s vision for industrial energy optimization encompasses the three domains of the industrial ment. ecosystem: production, enterprise, and power grid. While recognizing the value of the smart use “Of our two main chalof energy for production processes, the model enlarges the possibility to view and use energy lenges, the first is to agree on as a shared resource and common currency across the three domains critical to the industrial terminology and a language. consumer. Energy isn’t rocket science, but the vendor. The CIP architecture and tools reduce the cost and it is specialized and has its own language. Kilowatt hours mean time to implement by reducing the engineering hours it takes one thing, and kilowatts mean something different, and they to determine what register to use, and how to translate the data are not interchangeable terms,” says Morgan. type into useful information.” “The second part of the challenge is to come up with a Morgan says the awareness piece is the foundation everything standardized way to express energy on a network. It can be that else is built on. Industrial users have been interested in energy a device is actually measuring energy, calculating usage through usage for a long time, but have not typically been challenged to analysis and a formula based on its outputting conditions, or do anything about energy because it is difficult and expensive uses a fixed number. So when the device is on, it is using so to get a view of usage down into the organization. many kilowatts. The standard framework needs to permit that The monthly electric bill makes it easy at the utility level, level of variation to make it simple to implement.” giving the user visibility into their energy and demand charges. An example is an overload relay which is energy aware and But it is much more difficult to tie energy usage to decisions reports energy usage. Today, vendor A will have a relay that on the plant floor — even something as simple as determining reports energy using Modbus registers; vendor B may report department usage, and how much they should be back charged energy in a couple general-purpose DeviceNet parameters; and to provide accountability. vendor C has yet another method for expressing usage data. The goal with the new energy objects is to drive that energy Within the energy additions to CIP, energy usage value will be awareness into the control and information architecture of the standard attributes within an energy object, so the format of production domain. This approach will allow very granular energy usage data is the same from vendor to vendor. information at the device, motor, drive, and overload relay level What goes into those parameters, in the case of an overload to be aggregated together to create meaningful information. relay, may be a measured energy component, but also a fixed That information can then be exposed to create energy visibility offset that can be set by the vendor, a system engineer working for the managers and operators of the plant, and also be used on a specific system, or a user that accounts for part of the load by smart algorithms for automated control of energy. that is not measured. The motor consumes part of the load but The information can also help solve another problem in there is also a fraction of the load from a motor controller not the production domain, which is tracking how much energy being measured by the overload relay. This provides an ability S6 Autom At i o n: net w o r k i n g t r e n d s / A s u p p l e m e n t to de s ign ne ws Ju ly 2011

[www.designnews .com]

Automation: Networking Trends to derive actual energy usage for that branch Key Areas for Industrial Energy Optimization of the circuit by adding the offset to the measured power and energy. The overarching goal is to monitor an entire operation from an energy perspective, while also being able to drill down to a very granular level and specific details. The challenge in the past has been to get access to the detailed energy information because it costs the same to put a power monitor at the primary mains, as it does to put a power monitor at a substation bus, as it does to put a power monitor in a motor controller. Every time you go down a level, the Technical innovations and energy optimization in five key areas offer the potential for significant savings for the industrial sector. Many of these mechanisms will amount of energy being used is smaller, and fall within the next generation of productivity enhancements for manufacturing the amount of possible payback by controlprocesses where energy becomes a measured cost and budgeted resource in the ling that energy also decreases. One of the production bills of materials. main financial goals with the energy object is to minimize the cost of getting that energy information at the very granular level. mented using a controller/translator device with the smarts “It is necessary to gain that visibility of information to proprequired to do energy calculations. If there is a machine with 20 erly manage the 80 percent of energy usage in the production energy-aware devices all feeding into this controller, the aggredomain,” says Voss. “You wouldn’t know where to start without gator function of the energy object provides a view of the whole that level of information available because the overall number machine. Instead of paying for a power monitor to capture that doesn’t provide enough data.” data, this function can interface these simple, low-cost devices Another key software function is aggregation, possibly imple- over the network. It provides a standardized way for aggregating AH0510F_CSG_Advanced_Controls_7x4_625:AGR_halfpage.qxd 6/6/2011 1:08 PM Page 1

Increase Throughput with Advanced Controls • Decrease Settle Time • Increase In-Position Stability • Increase Rate Stability Command Shaping

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S8 Autom At i o n: net w o r k i n g t r e n d s / A s u p p l e m e n t to de s ign ne ws Ju ly 2011

Aerotech Worldwide United States • Germany • United Kingdom • Japan • China • Taiwan AH0510F_CSG

[www.designnews .com]

Automation: Networking Trends Creating Basic Energy Awareness

The ODVA model is that energy-aware devices contain the objects and services needed for basic energy awareness. Because the object-oriented approach of CIP allows for scalability in implementation, each device may support other more advanced functions for control of energy, aggregation, and reporting of energy information or dynamic Demand-Response.

for many standards organizations. Part of the problem is defining the models but there is also a need for determining how a collection of dissimilar devices

can be modeled effectively. The goal is for control decisions and modeling to be simplified so that they are both useful, and not too complicated and expensive to implement. “One thing about energy optimization is that it doesn’t exist in a vacuum. It is one part of an enterprise along with efficient utilization of labor and raw materials. It is a complex ecosystem that we are working within, so modeling needs to make components mutually aware of each other to make the right decision for a given situation,” says Morgan. “We can reduce energy without impacting the business needs of an industrial facility, but if there are trade-offs to be made, the optimization model needs to help management identify those trade-offs to make informed decisions based on a situation.” From a technical perspective, the new objects and services in CIP will enable companies to provide energy optimization tools and algorithms. The challenge is to make sure the available tools within CIP are both robust and elegant to implement into the devices. The objective is not to develop a modeling predictive control system, but rather a framework so vendors can provide added value using the infrastructure and architecture provided by ODVA networks and devices. For More Information: ODVA: www.odva.org

S10 Au to m At i o n: net wo r k i n g t r e n d s / A s u p p l e m e n t t o de s ign ne ws Ju ly 2011

[www.designnews .com]

charts and graphs courtesy of odVa

energy and power usage, and reporting back up to a management system. “In the next phase when we get into energy optimization and control of conservation states, the aggregator may be equipped with modeling and control capabilities to do simple functions. If the operator goes on a break, for example, the aggregator may have the smarts to move the system to a reduced energy state for a period of time,” says Morgan. “A big part of the standardization effort is determining how to model devices by their behavior or using state models. A device can be turned off, turned on and idling, turned on at partial output, or turned on going at full speed — each of which has a different energy signature. There are many different devices, some that operate on/off and some that are continuously variable. Energy savings may be linear based on how fast the device is operating, or may vary nonlinearly with speed of operation.” Trying to find a model that works for all of the possible devices is a challenge

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CC-Link IE Field is a deterministic, gigabit speed, Industrial Ethernet network that allows devices from numerous manufacturers to communicate for effective automation control. Want to learn more? Visit www.CCLinkIE.org or scan the QR code with your smartphone.

Automation: Networking Trends

Strategies for Energy Monitoring Standard Ethernet networking and PAC technology, new software tools, and Demand-Response programs team up to identify energy savings and reduce consumption. By Al PreSher, ContriButing Writer

A

s industry gets serious about reducing consumption of electrical power, the first step is to begin monitoring energy usage to learn more about where power is being used, and to develop more efficient strategies for managing peak demand. New energy-monitoring hardware and software solutions are emerging to make that process easier. Standard solutions are making it easier for companies to take specific actions

both internally from a control perspective and through participation in new Demand-Response programs. The longterm goal will be to use monitoring as part of a real-time solution that interacts with the power grid. “The promise of the smart grid is largely coming from the supply side: generation, distribution, and transmission which form the supply side of the electrical system,” says Benson Hougland, vice president of marketing for Opto 22. “There

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are major investments going into those areas but ultimately what the smart grid is built upon from a technology perspective is communications, sensors, and data. That includes the free flowing of data to whoever might benefit from it.” Hougland says the future potential of the smart grid will be based on communications, moving data very quickly, and using it to create more of a real-time operation from an energy perspective. The problem with the smart grid at the moment is that the supply side is only one side of the coin. Technological development and investment from this single perspective isn’t enough. What’s needed are more end customers on the demand side implementing intelligent meters, sensors, communications hardware, and other components of the smart grid to create more of a real-time system. “Rather than waiting for the smart grid to just slowly develop, what we’re advocating is for companies to be more proactive. With an approach based on communications, data, and sensors, users can get started within their own facility so they’re prepared when the smart grid does come,” says Hougland. “Companies can have the communication interfaces in place, and standard methods for capturing energy data and distributing that data wherever it needs to go. They can have a way to participate at more of a real-time level, so decisions can be made based on fresh, accurate information.” With new energy-monitoring appliances such as the OptoEMU sensor introduced by Opto 22, the idea is to take standard, off-the-shelf automation hardware and provide a convenient, cost-effective package for energy monitoring. From a hardware perspective, Opto 22 started from the base of its programmable automation controller (PAC) products but packaged the sensor to provide fixed I/O functionality adapted specifically for energy monitoring while also making it as simple as possible to get the system up and running. A utility that runs on a PC allows the user to configure the unit and establish system parameters. A few mouse clicks determine where the user wants the data to go, whether it’s cloud-based energy-monitoring applications like Google PowerMeter, Pulse Energy, or popular databases like Microsoft SQL Server and Access. Two important development goals were to make the unit more like an appliance from a hardware perspective, along with making it as simple as possible to configure and start viewing data from a configuration and software perspective. Ethernet networking is an enabling technology to make the overall system work. Not only is Ethernet a ubiquitous standard, it also enables many communication protocols or methods that make it easier to fit into an existing system, onto an existing network, and to communicate to other devices that may speak a specific protocol. With its most recent release, the OptoEMU Sensor can now communicate using Modbus TCP, EtherNet/IP, standard TCP/IP communications, and OPC connectivity. The system also uses Ethernet networking to move data over the Web to Web-hosted applications such as Google PowerMeter or Pulse Energy. For simple applications such as viewing energy usage data [w w w. d es ig n n e w s . c o m ]

over time, Google PowerMeter can provide that functionality for free. To take a deeper dive and understand energy usage in a building or to see how that data correlates to external temperatures or past usage, the Pulse Energy tool is a better fit because it is a more comprehensive and granular energymonitoring tool. Hougland says the initial focus with the OptoEMU product family has been to focus on monitoring and use it as an input-only device. The idea is that nobody should be talking about control until they’ve identified the problems and begun to isolate and pinpoint where those opportunities exist. Instead of relying on industry assumptions about using VFDs or LED lighting, first identify what is going on within the building and then move into what controls might be required. “What we’ve also seen emerge in the last few months is a trend to Demand-Response,” says Hougland. “DemandResponse (DR) is interesting because it is relatively straightforward for us to do, and we’ve been engaged in DR projects with partner companies and Curtailment Service Providers. CSPs sit between an energy consumer (facility, building, or campus) and the utility company, regional transmission operator (RTO) or independent system operator (ISO) responsible for managing the grid, generation, and distribution of power.”

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J uly 2011 A uto mAtio n: ne two r king tr e nds / A s up p le me nt to de s ign n e ws S13

Automation: Networking Trends To be effective, CSPs need tools that provide real-time data on demand side consumption. Using the sensor, signals can be sent to a building management system, and there is a range of different things the user can do to create a curtailment event or to lower electrical demand based on the Demand-Response trigger. Since many companies are charged for electricity based on their peak demand within 15-minute windows, one approach to saving energy is to understand what is occurring within the building and recognizing how it is contributing to potentially high demand charges. The Demand-Response component can also be a revenue opportunity. To participate in this program with a utility, and through a CSP, the customer receives a check for enrolling in the program and being on-call to reduce demand based on the trigger. When an event occurs, there is also a payment based on how much load is shed. Within the automation field, users are looking for methods to extract data from

the hardware into other applications, such as a SQL database or standard SCADA/ HMI packages like Wonderware. Opto 22 recently introduced a simple API that makes it easy to get data from the OptoEMU Sensor. If a user has a building management system that communicates using Modbus TCP, which is common, there is now an ability to use the OptoEMU Sensor on a piece of equipment or a load panel and even at the service entrance to a building to start sending data over the Web. It can also simultaneously provide that data to the local building management system on site. For more information, go to http://www.opto22.com/lp/energy. aspx.

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Source: opto 22

Opto 22 used its PAC automation technology and repackaged it to create the energy-monitoring appliance. The configuration is fixed with multiple inputs, no outputs, and can be mounted on a wall or panel.

Automation: Networking Trends

Hardened, Robust Switches and Routers Industrial networks can use upgraded technology to address concerns about temperature, redundancy, data creep, security, and software standards. By Jim KrachenfelS, Garrettcom, inc.

[w w w. d es ig n n e w s . c o m ]

downtime and no swap-outs. One of the most obvious differentiators in industrial networking products is temperature rating. Enterprise products are installed where people are at work, with a typical product temperature rating of 0 to 40C. Additional hardening is required for the factory floor where typical product temperature ratings might be -25 to 60C. At yet another level, premium-rated models for applications such as power utility substations and traffic control equipment are specified to withstand outdoor temperature extremes of -40 to 85C. The power utility industry is a good example of the niche design issues facing industrial equipment suppliers. The power industry has faced numerous challenges in the past two decades, addressing extended intelligence, remote data collection, and massive data manage-

the motherboard of a Garrettcom magnum 6K Series managed switch with conformal coating and special heat sinks is designed to support convection cooling. Both features are important when installing switches in dusty, corrosive or damp environments.

ment requirements. These include Smart Grid, North American Electric Reliability Corp. (NERC) requirements for physical and cyber security, and developing a reliable, forward-looking strategy for integrating ubiquitous serial equipment, with IP-network-enabled products necessary to manage many of the growth and security issues. Power utility substation concerns include EMI shielding, temperature-uncontrolled environments, dirt, moisture,

J uly 2011 A uto mAtio n: ne two r king tr e nds / A s up p le me nt to de s ign n e ws S15

SouRce: GaRRettcom

T

here is great diversity in the requirements for industrial networking applications. Industrial switches and routers have to operate reliably, and for a long lifetime in harsh environments. And since industrial networks can cost hundreds of thousands of dollars, the products must be specified to the appropriate criteria for the job. In oil and gas applications, for example, where there is concern with flammables and corrosion, power substations must shield against strong electromagnetic interference, and deal with high-particulate and uncontrolled temperature conditions. Water treatment plants and food processing plants have to worry about humidity, and transportation often needs to worry about vibration. A wide variety of applications from outdoor monitoring and management systems to mines, unmanned remote locations, and some processing plants have to worry about temperature variations. The truth is, industrial and commercial switches and routers are not interchangeable. A copper mine in Utah tried to use commercial-grade switches in a control room, but the sulfur dioxide in the atmosphere corroded the internal electronics and they failed in six months. When the mine installed industrial-grade switches with conformal coating, they were still running two years later with no

Automation: Networking Trends ment Protocol). The sheer volume of data passing through industrial networks makes it necessary to automate much of the managing, analyzing and visualizing of all that data. As data traffic increases, appropriately hardened switches and routers need to support greater numbers of ports (mostly 100Mb and Gigabit fiber) to provide the bandwidth to accommodate increased video security. A secondary benefit of increased port density is that it also increases network reliability by providing fewer points of failure. Video and access security appli-

consumer side where fiber cabling would be cost prohibitive. Wireless has also made it possible to bring remote substations, particularly in rugged terrain, cost effectively into Smart Grid management systems. As wireless deployments increase, wireless functionality continues to be reviewed and refined by industrial equipment vendors and their targeted industries to address both security and regulatory concerns.

Next-generation switches built for the power utility market are adding features such as hot-swappable power supplies and heavy-duty cooling fins.

cations in power utility substations and other industrial applications has been a main driver in the increasing popularity of Power over Ethernet (PoE). PoE provides both device power and network data using a single wire, extending the industrial network in ways that were previously physically impossible or too expensive due to the necessity to run separate ac power wiring. Many of these PoE products are located in outdoor cabinets or in dusty industrial settings. Therefore, it is not enough for networking products merely to integrate PoE — they must also be hardened. As the need for security in remote sites has increased, so has the need for sophisticated, industrially hardened routers that can be utilized as firewalls and repositories of other cyber-security technologies. IP-based WAN services reduce costs (compared to expensive leased lines), enhance security, and provide compatibility with corporate IT. Wireless extensions to Ethernet networks have been gaining in popularity, enabling the installation of Automatic Meter Reading (AMR) devices on the

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Software is as important as hardware in today’s industrial communications networks, with managed switches penetrating deeper into the networks. Application-specific functionality, such as the latest precision timing (IEEE 1588v2) and fault recovery/redundancy (RSTP-2004) protocols are important for the power industry. Security is also an issue; industrial and enterprise security initiatives are helping to ensure that critical industrial applications can withstand cyber attacks, and reliably manage and direct huge volumes of data. Standards have made industrial networking equipment easier to integrate, future proof, and scale. However, as industrial networking improves and matures, and as additional demands are made on the switches and routers, it is important to understand that innovation must continue and that “one size fits all” is not a concept of value to developers of industrial networks. Jim Krachenfels is marketing manager at GarrettCom, Inc. For more information, go to www.garrettcom.com. [www.designnews .com]

Source: Garrettcom

precision timing, and high availability and redundancy. The International Electrotechnical Commission (IEC) 61850 standard was developed to address needs for that community on a global basis. The IEC’s first project group met in 1995 when multiple protocols, many of them proprietary, were impacting the ability of substations to cost effectively take advantage of evolving technology. The IEC today oversees more flexible digital substation communications. IEC 61850 integrates standards such as Ethernet and TCP/IP, along with XML for system configuration and Manufacturing Message Specification (MMS) for real-time data exchange. It offers flexibility by supporting common device specifications with an option to extend as required for vendor-specific functionality, providing adopters access to future-safe substation automation strategies that can take advantage of technology advances. There is no single right way to implement a power utility communications network, just as there is no single right way to implement any industrial networking application, but there are common concerns. Redundancy is no longer a luxury. The growing demand for electricity from industrial, commercial, and consumer accounts means switches, routers, and other networking products that support the substation require redundant power supplies along with network-path redundancy to ensure data keeps flowing. In addition, there is the threat of sabotage. Today, even 1U rack-mount switches have entered the market with hot-swappable power supplies to reduce the chance of downtime. Networking software also comes with redundancy features. Another issue that must be addressed by all industrial markets is data creep. SBI Energy predicts the volume of Smart Grid data will grow from 10,780 terabytes in 2010 to more than 75,200 terabytes in 2015. IEC 61850 recognizes that IP technology is important for managing increased data flow because it is standards-based, flexible, and scalable. Other concerns in managing exploding data transmissions are greater throughput and intelligent, bandwidth-protective routing of information through protocols such as IGMP (Internet Group Manage-

Automation: Networking Trends

IN THE MARKETPLACE Splinerail linear actuator with an integral connector option For users who want to plug directly into a pre-existing wire harness. Haydon Kerk Motion Solutions’ motorized SplineRail Linear Actuator with an integrated connector is offered alone or with a harness assembly. The connector is RoHS compliant and features a positive latch for high-connection integrity. The integral connector is rated for up to 3A and the mating connector will handle a range of wire gauges from 28 to 22 gauge. This configuration is for users who want to plug directly into a pre-existing wire harness. The SplineRail combines mechanical drive, guidance, and a stepper motor actuator in a single, compact component. The system uses a Size 17 single stack or double stack stepper motor with either a 1.8- or 0.9-degree motor step angle. Screw leads are available from 0.05 to 1.2 inch per revolution, providing a wide range of performance profiles that include self-locking threads, which can support a load without external power or breaks. Haydon Kerk Motion Solutions, Inc. www.haydonkerk.com all-in-one controllerS Support high-Speed inputS and outputS Enables users to implement up to three independent PTO instruction sets at once. Incorporating the advantages of a fully functional PLC and integrated operator interface, the new PTO models now enable the user to implement up to three independent PTO instruction sets at one time, as well as create and save multiple speed profiles for precise step-motor control. The new high-speed I/Os offer particular benefits to the motion industry, or wherever speed control is required. Users no longer have to manually calculate the output for each instruction; the new models have the ability to pre-calculate the ratio between the length and the number of pulses within the unit itself. Another user advantage of the new PTO function is jerk control, or the intensity of the acceleration curve. It can go from a trapezoid to a smooth S curve in just 16 steps. Users can also control movement in absolute or relative positions, and control each axis independently. The new PTO control functions are open-loop functions that do not rely on positional feedback, increasing the speed and accuracy of the application. Unitronics www.unitronics.com [w w w. d es ig n n e w s . c o m ]

Automation: Networking Trends Speed drive for Batteryoperated BruShleSS dC MotorS

ler to complete its BLDC motor offering for battery-operated applications.

The motor/external drive combination boasts 500W of continuous power, and up to 1KW of peak power.

The BGE30100 is a single quadrant digital speed drive with an input supply voltage range of 8-30V dc, a continuous output current capacity of 60A, and a peak current output of 100A for up to

Dunkermotoren has introduced a highpower, low-voltage brushless dc control-

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two seconds. It is a match for Dunkermotoren’s new low-voltage BG75 brushless dc motors. The motor/external drive combination boasts 500W of continuous power, and up to 1KW of peak power. The BGE30100 start/stop, direction, and speed1/speed2 commands can be triggered by digital inputs or preselected by dip-switches. Speed control is given by an analog 0-10V, 0-20mA or a PWM signal, while status of the controller is reported on its digital outputs. Parameters and configuration can be changed via a USB interface. Dunkermotoren www.dunkermotoren.com Miniature preCiSion regulator Offers accurate air pressure control in a compact package. Pneumadyne’s new Miniature Precision Regulator offers accurate air pressure control in a compact package and is useful for limited-space applications. This precision-machined, high-quality regulator features an output pressure

The new state of the art bellows coupling At first glance, all steel bellows couplings look more or less the same. However, the differences are in the details. Our new primeflex® has all the characteristics you expect from a mayr ® bellows coupling, such as: Zero backlash Highly competitive price/value ratio Extremely compact with a high performance density Simple and easy installation via clamping hubs or shrink disk connection ● Excellent misalignment capability ● Modular construction for maximum design flexibility ● ● ● ●

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Plus, and most importantly: ● The primeflex® is ideal for applications requiring blind assembly ● It can be assembled safely without risk of damaging the bellows section. ● It can also be disassembled safely, even after long periods of operation, again without risk of damaging the bellows section. If leading, innovative and future minded technology is importand to you, please call 800-4NJ-MAYR (465-6297) for more information on our new primeflex® steel bellows coupling. Mayr Corporation 4 North Street, Waldwick, NJ 07463 Phone (800) 465-62 97, Fax (201) 4 45-80 19 www.mayrcorp.com

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range up to 100psi and high flow rate of 4.5scfm. With a maximum supply pressure of 250psi, the Precision Regulator is dependable and repeatedly returns to the set pressure when turned on and off. Tight design tolerances minimize vibration, allowing the regulator to remain stable under changing operating conditions. Pneumadyne, Inc. http://dn.hotims.com/34939-500 Curve tool MakeS poSition and forCe Control eaSier For complex motion control profiles. Delta Computer Systems’ RMCTools software package now includes the Curve Tool, which shortens the time it takes to program custom motion profiles including cams and splines for Delta’s [www.designnews.com]

RMC70 single- and dual-axis and RMC150 multi-axis motion controllers. The smooth motion that the curve tool creates can improve machine productivity and decrease machine maintenance costs. Using the Curve Tool’s graphical environment, it is easy to view and edit the curving motion profiles as they are being programmed. With options such as linear or cubic interpolation, velocity and acceleration limits, and endpoint behavior, the RMC curves satisfy a wide range of applications.

Emerald Automation Controller. Three feedback interface options are available: enhanced resolver (24,000ppr), 1- bit absolute encoder (131,765ppr), and multi-turn absolute resolver (24,000ppr). Four modes are available for tuning the servo motor to

the mechanical load using PC-based tools: real-time continuous tuning, semi-auto tuning mode, standard tuning mode, and manual input tuning mode. Industrial Indexing Systems www.iis-servo.com

Delta Computer Systems, Inc. http://deltamotion.com/ X-Series Servo Drives with the Sercos Automation Bus A full complement of heavy-duty servo motors are available ranging from

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30 to 55K Watts. IIS has a full range of servo drives employing the new Velconic high-speed digital hardware by Toshiba Machine Co. for control of position, velocity, and torque. Now with the sercos automation bus option available, the X-Series drive can be used in the high-performance, multi-axis automation systems using the new Emerald Automation Controller. With the sercos automation bus option installed, the following on-board I/O points on the X-Series drives are mapped into the sercos network: Digital inputs (8), one dedicated, seven general-purpose; Digital outputs (5), all general-purpose (24V 50ma); Analog inputs (2), 12 bit ±10V, all-purpose; Analog outputs (2), 12 bit ±10V, all-purpose; Auxiliary encoder interface (A-B channel) A separate control power input allows the X-Series drives to communicate on the sercos automation bus when main power is removed, thus keeping access to vital status information available to the [w w w. d e s i g n n e w s . c o m ] 

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Automation: Networking Trends ADVERTISERS IN THIS ISSUE Advertiser

Page

Advertiser

Aerotech Inc.

S8

Bosch Rexroth

Allied Electronics

S2

CC-Link Partner Assn.

AutomationDirect

SC2

Farrand Controls

Autonics USA

SC3

Haydon Kerk Motion Solutions

BEI Sensors

S10

Igus Inc.

Belt Technologies

S19

Industrial Indexing Systems

Bird Precision

S20

Mayr Corp.

Page S1

Advertiser

Page

National Aperture

S20

S11

Nippon Pulse America Inc.

S13

S14

Nook Industries

S7

Opto 22

S5

SC4, SC1

S17

S3

S18

S14

Raco International

S9

Wittenstein

Publisher does not assume any liability for errors or omissions in this index.

Miniature Micro-Positioning Stages Linear and Rotary

Products include linear and rotary stages (manual & motorized) and a full line of motion controllers. Our large rotary stage MM-4M-F will carry a top load of 4.5 kg and has an accuracy of ±2 arc minutes and repeatability of ±30 seconds. The smaller version MM-3M-R will carry a top load of 2 kg and has similar accuracy and repeatability as the MM-4M-R. NAI motorizes linear stages are available with travel from 5mm to 200mm and will handle direct top loads from .25 kg to 3 kg. Manual stages are available with travel from 3mm to 12.5mm and will support direct loads from .25 kg to .35kg. Visit or web site for complete information

National Aperture, Inc. Ph:800-360-4598 Fax:603-893-7857 [email protected] www.nationalaperture.com

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