Machine design, tập 84, số 16, 2012

This article is meant to help size springs for prototyping, prior to seek-Mechanical equipment and related hardware routinely mating parts so that the design can use a stock spring.. f

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page 34 SIMULATION HELPS CALCULATE TRAJECTORIES,

page 40 PROTOTYPING WITH SPRINGS, page 44 CLOUDBASED HELP FOR MOTION SYSTEM

DESIGNERS, page 50

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[ MOTOR TRUTH #7 ]

Can I save energy by using

a VFD (inverter)?

The truth is that it depends on your application If you have a high-cycling application, a VFD can reduce the starting current on each cycle.

If you have a hoisting application, a VFD can provide energy regeneration.

If you have an oversized motor on a small load, a VFD with ﬂux control can maximize the motor efﬁciency.

Otherwise, a VFD is a load and actually consumes energy - especially

if you use a high carrier frequency.

Visit sewmotortruth.com/truth7 to get the whole story on VFDs and energy-efﬁcient drivetrains.

YES NO

MAYBE

sewmotortruth.com/truth7

864-439-7537

RS# 101

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We love a good challenge.

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Our extensive family of precision fluid control products offers unsurpassed

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• Integrated Fluidic Manifolds

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We’re not just talking about off-the-shelf solutions, either A Leeengineer will be happy to discuss your application, and develop

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Go ahead, push us to your limits.

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MECHANICAL

proven components Springs operating within their design sands of different sizes and versions Most common are materials, with or without a finish.

Stock springs are often used for applications requiring less than 500 springs per year Generally, however, it is not

• Stock springs are generally intended for can compromise designs.

• Experts recommend discussing specific design requirements with a spring manufacturer.

Resources:

Spring Manufacturers Institute, www.

smihq.org The SMI is a good source

for information on spring design and capabilities, as well as for locating spring manufacturers.

Working with

STOCK SPRINGS

only better but more cost effective to the manufacturer may recommend spring for little or no cost premium.

One cannot emphasize enough the importance of discussing design requirements with a spring

in production often compromises other aspects of a design.

This article is meant to help size

springs for prototyping, prior to

seek-Mechanical equipment and related hardware routinely mating parts so that the design can use a stock spring

However, that is usually not the case, and springs are quently an afterthought.

fre-Often this is because springs are well-engineered and

Stock springs are useful for prototyping, but altering mating parts to accommodate a stock spring can compromise other aspects of the final design.

Here are some tips when using springs for prototyping and design.

OCTOBER 18, 2012 MACHINE DESIGN.com 44

As CAE software becomes increasingly sophisticated,

in the product-development cycle The use of CAE ware is critical in the space industry, where it’s difficult

soft-to create test settings that simulate real-world tions Vacuum chambers and wind tunnels help, but they

condi-why spacecraft producer Thales Alenia Space Italia

(TAS-I) in Italy used CAE software in the design, testing,

European Space Agency.

Head of aeromechanics and propulsion at TAS-I, Cosimo Chiarelli helped design and test the vehicles He explains that the physics of atmospheric reentry are com- Variables include aspects of the spacecraft structure such as geometry (length and shape), as well as the di-

CAE software tests hypersonic-reentry- vehicle designs

Authored by:

Kyle Indermuehle Aerospace Lead

Simulia

Providence, R I

Edited by Leslie Gordon

leslie.gordon@penton.com Key points:

• Process-automation software can link design and simulation models to automate the execution of hundreds or even thousands of simulations.

• The software can help designers improve designs by improving them in terms of performance or cost variables through statistical methods.

Resources:

Simulia, www.simulia.com

For more on simulation software, scan this

code or go to: http://machinedesign.com/

of-thousands-of-simulations-0609

article/software-automates-the-execution-Building a

BETTER SPACECRAFT

ferent codes, and aide in the standing of results from all of the tasks “The software helped us create flexible simulation workflows and automate the exploration of solutions for the large design matrix,”

under-says Chiarelli.”

To conduct a feasibility study of their new MDO approach, engineers chose a theoretical hypersonic reentry vehicle and applied simpli- lining the process, they decided to each individual variable To mini- mize costs, engineers applied the process-automation software’s adap- tive simulated annealing algorithm, Isight performed 200 iteration cycles in only a day, assembling several

mensions and material attributes trajectory (comprising the vehicle’s the thermal conditions for the vehicle’s windward, leeward, and nose zones, and the thermal loads the vehicle encounters The final design accounts for all variables, with a focus on the 150 sec that make up the most-critical portion of reentry.

To improve designs, engineers conducted separate simulations for used a collection of software packages and divided the analysis into own input and output file types En- dence, R. I., to organize the tasks, manage the execution of TAS-I’s dif-

The MDO workflow for the reentry vehicle

in Isight comprised several analysis tasks such as grid generation and trajectory computations It used

a variety of commercial and proprietary codes and input and output file types Engineers tie together separate simulations and automate the analysis.

The European Space Agency launch of Thales Alenia Space’s Intermediate eXperimental Vehicle aboard the Vega small launch vehicle is planned for 2013.

OCTOBER 18, 2012 MACHINE DESIGN.com

40 OCTOBER 18, 2012 MACHINE DESIGN.com 41

Access our Reader Service Web site to quickly find and request information on the products and services found

in the pages of M ACHINE D ESIGN

www.machinedesign.com/rsc

VOLUME 84ISSUE 16OCTOBER 18, 2012

44

A robot for the rest of us

A relatively low-cost factory-floor robot

that can be trained or programmed by

a factory-floor worker

Taking aim with MEMS gyros

Superaccurate MEMS gyroscopes

simplify the motion-sensing tasks

of industrial robotics

Building a better spacecraft

CAE software tests

hypersonic-reentry-vehicle designs

Working with stock springs

Here are some tips when using springs

for prototyping and design

Motion design gets

help from the cloud

Free and simple cloud-based analytic

tools help designers quickly analyze

motion-system performance in both

the time and frequency domains

2

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Pneumatic Solenoid Valves and Manifolds Air Preparation

Fittings and

Air Couplings

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Manual control valves are designed for non-electrical

operator control applications These basic valves are

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See everything at:

Quick-disconnect Air Couplings

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connection styles

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Solenoid Valve Cables & Air Valve Connectors

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Manual Control Valves

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five-port spool valves, in 1/8” and 1/4” NPT port sizes

1/4” NPT ports, momentary or latching models

RS# 103

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For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at reprints@pentonreprints.com or visit

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SCANNING FOR IDEAS

Going big with ultrasmall ball screw

Rotary motion with speed and precision

4

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Imagine the conditions in the North Sea They take their toll on all types of equipment Bearings are no exception

At one of the major production platforms, failing motor bearings used to cause gas compressors to break down

as often as every third month Each time, that meant 25% lost production for several days

Jim Marnoch and his team provided SKF ProActive Reliability Maintenance services After thorough analysis

of the vibration signatures and the damaged bearings, they found a long term solution SKF NoWear bearings along with a new sealing arrangement made all the difference, allowing the compressors to run 6 times longer than before

At today’s high oil prices, for every breakdown that can be avoided, the platform operator saves tens of million dollars On top of that, these improvements also reduce health, safety and environmental risks It’s another great example of knowledge engineering

at work Find out more at www.skf.com/poke

The Power of Knowledge Engineering

Gas Export Compressor SKF ProActive Reliability Jim Marnoch, SKF

Maintenance

Secure your operations

with proactive maintenance

RS# 104

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What’s new online machinedesign.com

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Simulation Hall of Fame

Do you consider your simulations

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Elastomers and thermoplastics for vehicles

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Environmentally safe cryogenic machining

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RS# 105

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IT’S MOTION

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MOTHER NATURE

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WHEN IT COMES TO HIGH PERFORMANCE MOTION CONTROL, MOOG EXPERTS ARE THERE

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RS# 106

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Standard and Custom Clutch, Brake

& Power Transmission Solutions

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Phone: 860-643-1531

Reliability

in a Clutch

a clutch, brake or power

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products consistently prove

reliable and dependable in

every application Underwater,

on the ground and in the air,

There has been a lot of soul searching in the U. S about a perceived lack

of innovation among domestic manufacturers One sign U. S turers have trouble innovating comes from the management consulting firm Booze & Co.’s annual report on the 1,000 companies that spend the most on research and development Last year, only one company among the top 10 R&D spenders (Microsoft) made the list of the top-10 most innovative companies In a nutshell, Booze points out that a lot of companies spend piles of money on R&D that don’t result in innovative products

manufac-In the quest for things to blame for this poor performance, Six Sigma programs seem to be one of the latest scapegoats The case for Six Sigma

as a cause of mediocre research is made by Navi Radjou, Jaideep Prabhu,

and Simone Ahuja in a book called Jugaad Innovation, which outlines

ideas for innovating more frugally

What convinced these three business consultants that Six Sigma kills the innovative spark was 3M’s experience applying Six Sigma processes

to its R&D labs in the early 2000s By 2005, 3M’s share of revenues from new products had dropped from the 30% it had seen for decades to 21% The reason: 3M engineers became risk averse and played it safe, the consultants say The situation turned around when 3M rolled back the program and reinstituted an old practice of giving employees 15% of the their paid work time to pursue pet projects without worrying about whether such efforts could be immediately commercialized

But Six Sigma is just a symptom of what ails R&D in most nies, the consultants insist It is a manifestation of an approach to R&D structured so that it lacks flexibility and is insular Companies that run R&D under rigidly structured schemes like Six Sigma seem to think that innovations can be scheduled, say the consultants

compa-Another problem: Western companies often measure innovation the wrong way, by the number of patents they file Big mistake, the consul-tants claim The patenting process costs a lot, is time consuming, and often mires the patent holder in lawsuits Better to not bother with pat-enting at all Instead, focus on commercializing developments fast rather than trying to erect barriers around them

Maybe so, but having heard these arguments, I am convinced the real obstacle to innovation in many companies lies elsewhere: In the ranks

of top management Even when an innovative product gets developed, bottom-line oriented managers are likely to axe it before consumers can venture their opinion That’s because ivory-tower managers often don’t know their own customers, so the only thing that can convince them an idea is good is a spreadsheet full of data But there won’t be any such data for something that is a real innovation (After all, the market for MP3 players was microscopic prior to Apple’s invention of the iPod.) And by the time there’s enough evidence to justify an innovative project, it may

be too late to commercialize it

Radjou, Prabhu, and Ahuja seem to agree They say top management’s overreliance on formal data shows why 90% of all consumer-product R&D goes into tweaking existing offerings, and why big R&D spenders leave the door open to competitors with truly innovative ideas

— Leland Teschler, Editor

RS# 107

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of production cycles Cylinders that provide outstanding performance and payback.

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onfigurator mak

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GRAPHITE METALLIZINGCORPORATIONYonkers, NY 10703 U.S.A.

MANAGING EDITOR

Kenneth J Korane ken.korane@penton.com

SENIOR EDITORS

Leslie Gordon leslie.gordon@penton.com Stephen J Mraz stephen.mraz@penton.com

ASSOCIATE EDITORS

Lindsey Frick lindsey.frick@penton.com Robert J Repas, Jr.

robert.repas@penton.com

INDUSTRY COVERAGE: AUTOMOTIVE, PACKAGING,

EDITORIAL PRODUCTION

Denise Greco Editorial Production Manager Randall L Rubenking Art Director

RS# 110 RS# 109

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RS# 111

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Over the last 25 years I have gone from a technical illustrator to an

a u t o m a t i o n d e s i g n e n g i n e e r without an engineering degree

However, it is important to note that at some companies I would not be considered an engineer without an engineering degree

Prior to the meltdown of 2008,

I was a special projects engineer

at a company that was growing and letting HR control titles As

a result, HR personnel would not consider anyone without an en-gineering degree for any engi-neering positions and were forc-ing people with 10 to 15+ years

of experience but no degree out

of engineering positions

At another company, I was given the title mechanical de -signer because I do not have an engineering degree Those with engineering degrees were called mechanical engineers

My experience indicates that the term “designer” has two ba-sic definitions The one used in the editorial refers to the person responsible for the look, touch, and feel of the product The sec-ond is the person who does the same functions of an engineer without an engineering degree

The second definition is the one most of your readers are most familiar with Another way to look at it is that the first defini-tion refers to industrial design, while the second refers to me-

An engineer is

an engineer

Having run an engineering and

design business for over 40 years,

I have followed with amusement

t h e “C A D J o c k e y ” d i s c u s s i o n

(“The Attack of the CAD Jockey?”

Aug 23) We design and build

commercial products and

pro-duction machiner y, and I find

that a person’s title or degree

doesn’t matter It is what comes

out at the end of a project that’s

i m p o r t a n t We l e t p e o p l e d o

whatever they can and benefit

from their experience

Harold Parks

A good engineer must be both

a good engineer and a good

de-signer A good designer is not an

engineer (and is not expected, or

required, to be one)

Dayle D Winnie

Anybody can learn CAD and

cre-ate geometry But not all people

can design Designers have

cre-ativity and some sense of what

will make a product work I’ve

been on all sides of this designer/

engineer debate for many years

and have met many design

en-gineers who could not design

something as simple as a pin On

the other hand, I’ve worked with

designers who understood

ba-sic principles and could engineer

and design products

In companies, there is a mix of

people There are those who can

analyze things once they are

de-signed, those who can take

some-thing from concept all the way

through manufacturing, and those

who create geometry from

con-cepts sketched out on napkins

It is not incorrect to state that

design is simply creating

geom-etry I realize that in some places,

CAD jockeys are called

design-ers, but nothing could be further

from the truth It takes someone

with engineering-design

knowl-edge to create designs

Jaime Robledo

chanical design

As a side note, I found the initions for “designer” frustrating during a job search A thorough and specific list of job duties and responsibilities is much clearer than just a title with generic qualifications

def-By the way, I have continued

my education by earning ates degrees in technical illus-tration and math, a BA in Family Studies, an MBA, and a graduate degree in accounting It would

Associ-be nice if engineering classes were offered in the evenings like

so many other programs

John E Melton

CAD jockeys are computer-age draftsmen a n d d r a f t s wo m e n They are not designers unless they have additional training in, knowledge of, and aptitude for one or more of the numerous fields of design Even sketching

or drawing free hand requires talent not necessar y for good CAD jockeys Indeed, I am a CAD jockey and I can’t draw a pretty picture to save my life

Bob Vanstone

Farewell ethics

O u r s o c i e t y h a s g o n e f ro m a Christian-based one in the ide-alistic past to the “if it feels good

do it” attitude in the 60s, to our current and cynical “get it while

Job-title controversy

Readers are still hashing out the meaning of the terms “designer”

and “engineer.” And although they have

no problem defining ethical behavior, they also think ethical behavior is disappearing

12

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RS# 112

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LETTERS TO THE EDITOR

Please include your name, address, and daytime phone number Letters may

be edited for brevity and to focus on essential points.

Mail: Letters, M ACHINE D ESIGN ,

1300 E 9th St., Cleveland, OH

44114-1503, Fax: 216-621-8469 E-mail, Editorial:

Dennis McKee

Good catch The correct figures for the Super D raco should be 15,000 lb of thrust or 67,000 N — Stephen J Mraz

and get involved Thanks for your words of wisdom, I was feeling like a loner in this new world

Felix Ronmint

Curing the U S blues

More engineers, greater agement of the entrepreneur-ial spirit, and most importantly, fewer MBA’s (“Made in America?”

encour-June 14) This is what we need for manufacturing to thrive in this country

Bill White

you can” mood today (“ Where

Did Ethics Go?” Sept 6)

There is a tendency to push

morals to the side when it comes

to personal responsibility in

so-ciety Why are we surprised to

find out it carries over into

pro-fessional careers? Or, if we take

the Darwinistic approach of

sur-vival of the fittest, instead of

tak-ing care of the least among us,

did Madoff actually do anything

wrong other than get caught?

Mike Bartle

Ethics went to the same place

morals and principles went Our

nation has been in a state of

de-cline for many years now as we

stand idle watching

entertain-ment, and political and other

institutions raise our kids to be

what we see today This will not

stop until we get off the sidelines

RS# 113 OCTOBER 18, 2012

MACHINE DESIGN.com

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RS# 114

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SCANNING FOR IDEAS

Edited by Stephen J Mraz

ultrasmall ball screw

For more information on rolled and ground

ball screws, scan this

code or go to: http://

machinedesign.com/

ground-ball-screws- stack-up-0708

article/how-rolled-and-Request free information vi

a our Reader Service Web site at

www.machinedesign.com/

rsc

Engineers at Steinmeyer Inc., Burlington, Mass

(www.steinmeyer.com), recently added a new

device to its line of precision balls screws, the Ultraminiature, which the company claims is the

“world’s smallest commercially available ball screw.” Its diameter can be as small as 3 mm and have a pitch of 1 or 0.5 mm This makes the de-vice well suited for medical applications such as dispensing exact amounts of liquids

The ball screw can be ordered in several sizes ranging up to 16 mm in diameter with a 30-mm pitch The screws come with one of four types of ball nuts and with or without preload The actua-

tors are made of precision-ground, hardened tool steel Stainless steel is

an option The screws can meet ISO tolerances from P0 to P5

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N OW I T H I N K I N 3 D

AND MY DESIGNS JUST KEEP GET TING BET TER.

®

And that makes it easier to improve my design with each iteration Our Dimension

is right here in the ofﬁ ce, and that helps us get our

products to market faster And, with the Dimension Print

Pack TM we got everything we needed to start printing immediately.

The Dimension models we create are made in ABS, so they’re

also tough and durable Overall, Dimension gives me an amazing

sense of freedom—and creativity.

Find out more at www.dimensionprinting.com/macd4

With our Dimension 3D Printer, I know my model will represent my idea exactly

RS# 115

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The new 955 eBrik linear displacement transducer.

Price and performance

so well balanced,

it just might displace potentiometers.

At last, there’s a purely electronic solution to position sensors Our new

955 eBrik uses magnetostrictive technology so there’s no contact, no moving parts, nothing to wear out No erratic position signals Available

in 1" to 72" stroke lengths, it’s economical and versatile enough for many applications, field-programmable, and the perfect replacement for old-style potentiometers Learn more at our website.

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SCANNING FOR IDEAS

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18

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RS# 117

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REPORTER’S NOTEBOOK

An industrial robot can cost

hun-dreds of thousands of dollars just

for the hardware It can cost three

to five times more to add it to an

assembly line and get it working

That’s why industrial robots are

typically only used by large,

well-capitalized manufacturers That’s

also why Rodney Brooks, one-time

robotics professor at

Massachu-setts Institute of Technology and

Director of its Computer Science

and Artificial Intelligence

Labora-tory, founded Rethin k Robotics

in 2008 He wanted to develop a

relatively low-cost factory-floor

robot that could be trained or

programmed by a factory-floor

worker

That $22,000 robot, Baxter, is

now rolling off the U. S assembly

lines and is ready to go to work

Baxter’s basics

Baxter is equipped with two

arms on a turnable torso Each arm

measures 41 in from shoulder to

wrist and has seven degrees of

freedom (dof ) The arms move at

up to 3.3 fps empty and 2 fps when

loaded They come with two

inter-changeable hands or end effectors

that can pick up 5-lb payloads

Electrical parallel grippers

with interchangeable fingers of

different lengths, as well as

in-terchangeable fingertips, can be

customized to pick up and handle

specific objects The grippers add

1 dof and open or shut within

1 sec They include a force sensor,

which detects when an object is in

the robot’s grasp and how much

force it is exerting on that object

Vacuum-cup grippers work

on smooth, hard-to-grab objects

such as mirrors, plastic sheets,

and larger packages The cups

come in a variety of sizes and an

air-pressure sensor detects when

they have “grabbed” an object The

cups reduce the risk of marring an

object’s finish, but they do require that users hook the robot to an air-pressure supply

The arms can be “trained” or programmed to work together, or they can each carry out tasks inde-pendently of what the other arm

is doing

The torso can be bolted to a table or other stable surface, but can also ride on a 141-lb pedestal from the company The pedestal has two adjustable heights and

is sized to fit through standard doorways It lets the 165-lb robot

be rolled from workstation to workstation on industrial-grade casters The casters come with legs that lock it into place and adjust to level and stabilize the robot

For safety and to carry out tasks, Baxter has 360° sonar and machine vision with one main “face” cam-era and access to four others The wrists, for instance, carry a camera

so Baxter can closely monitor what its end effectors are doing Each wrist also carries a range finder

Baxter operates in tures from 32 to 104°F and is rated

tempera-IP50, which means it is protected against dust but not water and other liquids It runs on 120 Vac and 10 A, and is rated for 6,500 hr

What makes Baxter different

Baxter is different from other industrial robots in that it uses be-havior-based intelligence, a con-cept Brooks developed through-out the 1980s and 1990s He used

Baxter can be set up and trained by factory workers to help them load and unload boxes one day, then rolled to another workstation to sort and align products the next.

A robot for the rest of us

20

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What Baxter can do

Rodney Brooks tells

of how his team regularly takes Baxter out of its packing crate at a customer’s facility and has it set up and working on a line they’ve never seen before within an hour But what kinds of tasks does Brooks believe Baxter will be widely used for, at least at first?

• Material handling: Moving

objects from one location to other, counting, and reorienting

an-• Loading and unloading lines:

Putting parts on or removing them from conveyor belts or fixed surfaces

• Inspecting, testing, and ing: Checking parts for weight

sort-or shape, evaluate them against

a criteria, and perform different actions depending on results

• Operating machines:

Watch-ing machinery and performWatch-ing sequences of actions based on input or alarms For example,

it could insert a part into a chine, push a button, then re-move the part

ma-• Packing and unpacking:

Pick-ing up an object, bag, box, or tray and arranging them in an array for packing It can also un-pack containers

• Light assembly: It can be

quickly trained to align and snap fit parts together and insert them into containers

• Finishing: Grinding, polishing,

and other finishing operations

then lifts the arm The robot now knows it is supposed to pick up one of these objects in this area.”

“And if you’re training the robot

to pick up an object and put it in

a box, you can first train it to put the object in the box, then where

to pick it up,” explains Brooks “You don’t have to do it in order Baxter

Later, Baxter will be able to visually identify the object, even if it’s in a different orientation and amidst other objects and clutter, and pick

it up

Another one of these basic stincts is self-preservation, “For ex-ample, the arms never collide with one another, thanks to the pre-programming,” says Brooks “Even

in-if you grab both arms and try to bring them together, you will feel

a force, one that gets stronger the closer the arms get to one another, resisting you This behavior keeps the robot safe from itself.”

“Another built-in behavior is that Baxter knows it can’t put something down if it doesn’t have something in its hand,” says Brooks “So if the robot picks up

an object to place in a box, and a worker grabs the object from its gripper, the robot doesn’t try to put that object in the box Instead, the robot goes to the designated area to pick up another object.”

“To get the robot to pick up an object, a worker simply takes its gripper and places it over the ob-ject,” says Brooks “Pushing a but-ton on Baxter’s sleeve closes the gripper on the object The worker

the concept for all the robots

de-veloped and built at his previous

company, iRobot (makers of the

Roomba) “You program in a

col-lection of parallel behaviors, each

running independently, that look

at the environment and input

con-ditions, then decide if they have an

action to perform.”

Conventional robots come with

little or no programming, so users

have to define and program all error

conditions Baxter comes

prepro-grammed with certain “instincts”

right out of the box that always run

in the background when Baxter is working This lets users program tasks rather than a string of repetitive motions

For example,

if you show Baxter an object and position its gripper so that

it can pick the object up, the robot builds a visual model of the object and stores this data

Baxter’s computerized “eyes” do more than try to humanize the robot The robot will

first “look” in the direction it will be reaching with its arms, and workers quickly pick

up on those cues The eyes never looks angry, but can look puzzled if you don’t fully

explain what you want the robot to do And the eyes will close when the robot is off

the job or “sleeping.”

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Political aﬃliation

Democrat 14.5%

Republican 42.1%

Independent 33.7%

Other 9.4%

Which political party best represents the interests of engineers?

Democrat 10.2%

Republican 37.8%

Neither 48.1%

Other 3.9%

Political outlook

Liberal 11.9%

Moderate 40.7%

Conservative 47.4%

The politics of engineers

Engineers tend to view themselves as much less liberal and slightly more conservative than the general public, according to a recent survey of over 1,200 readers of MACHINE DESIGN and Electronic Design magazines

The same survey also found that engineers say they are more likely to

be Republican (42.1%) or Independent (33.7%) voters, as opposed to Democrats (14.5%) And although over a

third of the engineers think Republicans represent the best interests of the engineering community better than Democrats, a majority of engineers (48.1%) believe neither party is really

on the side of engineers. MD

Compared to the general public, engineers seem to be twice as likely

to be Independents and only a third

as likely to be Democrats A recent Gallup poll found that the public divides into 43% Democrat, 40% Republican, and 15% Independent.

Engineers skew more toward the moderate and conservative end

of the spectrum than the public

42% of the public considers itself conservative, 37% thinks of itself

as moderate, and 21% claim to be liberal, according to a Gallup poll.

Engineers exhibit some healthy skepticism in their answers to this question, with 48% saying that neither of the two major political parties represent the best interests of engineers.

RS# 118

OCTOBER 18, 2012

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How would you grade President Obama

D 20.3%

F 28%

Approve 2.5%

Yes 64.7%

Do you approve

of the way Congress is doing its job?

Disapprove 87.9%

Would term limits on members of Congress help get things done in Washington?

No 35.3%

Would a win by Romney improve the economy?

Yes 48.1%

No

51.9% A slim majority (51.9%) of engineers do not think Mitt

Romney would improve the economy if elected But almost the same number (48.1%) think

But the most popular grade was an F, awarded

by 28% of the engineers.

RS# 119 OCTOBER 18, 2012

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LOOKING BACK

10 YEARS AGO — 2002

Make way for 42 V: Say one thing for new 42-V automotive

electrical systems: Battery makers will cheer as more vehicles

start carrying dual batteries And consumers should get ready

for more-expensive, 36-V car batteries This according to a new

report titled, “Impact of 42-V Electrical Systems on North American

Automobiles,” from Frost & Sullivan, San Jose It examines how the

move to higher-voltage systems will affect alternators, starters, batteries,

and electronics

The report sees more demand for unusual electronic products that may open doors for new manu-facturing companies to enter the automotive market

According to analysts, ers have their work cut out convincing automakers of potential benefits of 42-V systems, which include better fuel economy and lower emissions, among other things

manufactur-30 YEARS AGO — 1982

Fluorescent bulb for an old socket:

When a new 15-W fluorescent bulb

from Interlectric Corp., Warren, Pa.,

is screwed into a standard base) incandescent-lamp socket, it is said to produce the light output of a 60-W incandescent bulb for an aver-age life of 10,000 hr Phosphors give the 8¼-in.-long bulb color similar to

(medium-incandescent lighting, and an efficient solid-state ballast is credited with eliminating hum and flicker The bulb can be operated in any position

100 miles away The telescope’s two mirrors are cast aluminum coated with nickel

phide

phos-A parable glass and metal in-strument would weigh sev-eral hundred pounds; this one weighs

com-50 lb With stable and vibration-free mounting, it could be carried in an air-plane above atmospheric turbulence, haze, and clouds to obtain clear views

of missiles and satellites MD

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tasks,” explains Brooks “ You don’t need an engineer, and you don’t need to set up the environment

or have accurate metric data for the workstation You just show the robot what to do and it adapts through vision and its other senses And if you move the robot

a bit, it keeps on working job cause it uses task coordinates, not robot coordinates.”

be-Baxter is said to be safe for mans to be working around it Its sonar and moving-target indicator alerts it to where people are and the robot avoids those areas If one of the robotic arms happens

hu-to strike a human, a wall, or cally anything of size, sensors in its joints immediately signal Baxter to

practi-go into zero-force mode This inates any forces on the arms The robot also compensates for gravity and the arms remain motionless (They can be gently pushed or nudged into any position and will maintain that position.) This protects nearby workers and the robot itself Another safety feature slowly lowers the arms if power is removed or lost

elim-And there’s no reason for ers to override or work around safety measures “There’s really nothing for workers to bypass,” says Brooks “If they throw a bag over the ultrasound sensor, for ex-ample, the robot just shuts down We’ve tried to make it as safe and foolproof as possible.”

work-“I have worked in industries where people were paid piece-work, and they did try to get around safety devices to work faster,” notes Brooks “But with Baxter, bypassing safety features doesn’t speed production or im-prove performance.”

Baxter’s future

Baxter is designed for sion and growth Its wrists, for instance, have end-effector plates that accept third-party grippers There’s also Ethernet and USB con-nections which will let users plug other devices and capabilities into

expan-moving or exactly where the belt

or it, the robot, is stationed You can even change the belt speed

Baxter can see the belt and object and adjust to pick up the object

“A line worker can quickly and simply program Baxter for new

figures out the proper sequence.”

Baxter is also adaptable If you

train the robot to pick up an object

from a moving conveyor belt and

place it in a box, you don’t have to

tell the robot how fast the belt is

Continued from page 21

RS# 121 OCTOBER 18, 2012 MACHINE DESIGN.com

26

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RS# 122

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a box and train it to pack items in a

3 × 4 array, it will do so even if you turn the box 30°.”

The company is targeting smaller companies as its first customers, and they’ve built a scalable distribution network around that plan “We have gotten interest from larger com-panies with national brands,” notes Brooks “But those companies don’t buy one or two robots, they buy doz-ens, even hundreds So it takes time

to make a sale as they want to try out the robots, evaluate them, and see how the robots might work in their plants.”

But there can be problems with small companies as well It can be a challenge convincing owners and managers that they won’t need expensive consultants

or nonstop maintenance to keep Baxter up and running

“At one small plastics factory, the manager watched as one of our engineers went up to one of our robots that was packing boxes and moved it by about half a foot,” recalls Brooks “The manager’s face fell and he said, ‘Well now you will have to teach that task

to the robot again.’ He was quite surprised when the robot kept on packing boxes Seeing that the ro-bot adapts to its environment and doesn’t need specialists really gets the message across.”

One of reasons Brooks is so mant about his new robot is that he believes it can bring manufacturing jobs back to the U. S This may seem counterintuitive as many people take it for granted that robots re-place human workers

ada-“But our robot is not made to replace people, just like the PC didn’t replace office workers,” says Brooks “This robot can change factory workers’ jobs, letting them offload simple, repetitive, dull tasks, and let them — cognitive beings with dextrous hands — do the higher-value-added work and thereby be more productive So it’s a tool ordinary workers can use, not a way for management to dis-place workers.” MD

later we will have an app-level kit that works with high-level software for new manufacturing features.”

“We also plan on bringing out software next year that lets Baxter understand how to pack boxes,”

says Brooks “If you show the robot

the robot And Rethink Robotics

plans on releasing new software

“Next year we will release

soft-ware that lets researchers use the

hardware platform to program

new capabilities using our

low-level software,” says Brooks “And

RS# 123

28

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RS# 124

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“Innovation distinguishes between

a leader and a follower.”

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RS# 125

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Improving Lives through Innovation TM

I read an article the other day that had some good news, some bad news, and

some disturbing implications It seems eBay is banning the sale of “spells,

curses, hexing, conjuring, magic, prayers, magic potions, and healing

ses-sions.” eBay says the policy is part of its effort to “build trust in the

market-place and support sellers.”

Kudos to eBay for putting an end to scammers selling worthless

“merchan-dise” to an all-too gullible public Those unscrupulous sellers were proving the

old saying popularly attributed to P.T Barnum, but which actually came from

his competitor, David Hannum: “There’s a sucker born every minute.”

The bad news is that eBay is interfering in the sale of legal and harmless items

between willing sellers and buyers If somebody wants to buy what another

of-fers, why should eBay stand in the way? (Not that there aren’t other sites on the

Web eager to sell you a spell or a South American charm vial Check out the

Lucky Mojo Curio Co. at www.luckymojo.com.) After all, the folks selling spells

and hexes on eBay garnered comments from satisfied buyers that included,

“Best spell-caster on eBay,” and “We bought four spells! Highly recommend!”

And the disturbing implication is that the people buying all this junk are

allowed to vote, drive a car, and have children The fact that they grew up to be

adults with their heads still filled with so much misinformation is a pretty strong

indictment against our schools in America

I also wonder if eBay will continue its efforts toward building trust in

the marketplace It doesn’t look like it A quick search through its inventory

revealed:

— 79 listings for dowsing rods One model, going for about $55, had

“special proportions based on the Pythagorean Theorem and sacred

geometry principles found in nature.”

— 51 listings for ear-candling paraphernalia, including a $57 book

titled the Practical Guide to Ear Candling: A New Twist on an Ancient

Practice After all, if ancient people used it, especially the Chinese, it

must work

— 401 Homeopathic “medicines.” One, a cure for dizziness, advertises

that it’s a 55× dilution, which is homeopathic jargon meaning there’s a

1:10-55 ratio between its inert and active ingredients That breaks down

to 1 × 10-55 gm/ml I’m pretty sure science can’t even detect the active

ingredient in this concoction, whatever it is

— 107 listings for ghost detectors These are mostly gauss meters and

handheld devices that detect microwaves and EMF repackaged to

appeal to modern-day ghostbusters and people paranoid about health

damage from cell phones and power lines

— 133 listings for relics of the True Cross Some of these have historic

value in that famous figures (aka suckers) have owned them My

favorite is a holy card with a piece of cloth that once touched a piece of

the Holy Cross (only $15)

It seems odd that the Internet, a marvel of science, engineering, and

ra-tional thought, is being used to peddle such nonsense But that’s life in a free

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INDUSTRIAL DESIGN

For everything from coat

hangers to cars, industrial

designers use

tried-and-true tricks to make

eco-nomical products look

expensive For example,

how do designers create an

attractive coat hanger for

mass production that can

be sold for $15 each? To

start, they use an

inexpen-sive hardwood with a

high-gloss finish and use simple

pegs that require minimal

tooling to hold the parts

together They also design

hangers to be lightweight

to keep down shipping

Those tips alone helped

designers create a coat

hanger that’s been bought

by the hundreds of

thou-sands at big-box stores

Some companies such

as housewares supplier

InterDesign in Solon,

Ohio, demands this simple,

mod-ern approach That’s why the

housewares section at your local

Target features so many low-cost

items with trendsetting finishes

and textures, sleek styling,

user-friendly operation, and colors that

work well together

Target recently selected

InterDesign’s Buzzo rack for its Cool

Stuff Collection The rack is made

of stylish silver-plated, low-carbon

steel wire and wood balls The bars

are flattened and pierced for a

cost-effective, yet elegant mount

Designers extended the line simply

and inexpensively by adding a

two-hook rack with the same distinct

look as the larger four-hook rack

Also consider InterDesign’s

Seville Bath Hardware, a line of

matching towel bars, towel rings,

tissue holder, and multipurpose

hook, all made from braided steel

The clean, modern shape and Mercedes-silver powder-coat fin-ish make them look costly

It’s also a good idea to check out car interiors to see how dif-ferent materials enhance users’

experience For example, Kia Rio

designers created new colors from scratch, mixing and matching them with different textiles, fab-rics, and materials, all to please the driver’s eye

In trying to create the right ors, designers took into account the surroundings of would-be drivers as well as cultural color codes Designers wanted the colors to scream “luxury” while evoking a feather-soft sensation

col-They created Wendy Brown, a rich chocolate color, for instance, to target stylish and chic fashion-forward drivers Designers also searched long and hard for the

interior colors They came up with

“Armani Black,” which has hint of deep blue that is said to glisten

in a soft light, and a grayish beige that’s supposed to convey the feel-ing of urban luxury

Even areas in the car where drivers rest their hands came under close scrutiny The crush pad on the steering wheel sports in-mold graining to give a more luxurious feel to the touch and in-cludes Nano PU material that pre-vents damage from daily wear MD

Making “cheap” products

Optic Lingo Inc., www.opticlingo.com

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MOTION CONTROL

Examine smartphones and advanced video-game

con-soles and you’ll find MEMS gyroscopes giving feedback

for a variety of tasks involving orientation and position

Yet the MEMS devices in these consumer products fall

short for a number of industrial uses where the gyroscope

sees conditions much rougher than those characterizing

living rooms or the pocket of a cell-phone user

Full 3D motion-sensing applications require a

com-bination of accelerometers, gyroscopes, compasses and

pressure sensors Accelerometers measure linear

accelera-tion along the X, Y or Z axis, and can be used to measure

gravitational acceleration They have served for many

years in products such as automotive air bags and PC

note-book disk-drive fall-protection systems Compasses sense

the earth’s magnetic field to provide an absolute heading

Pressure sensors measure atmospheric pressure and can be

used to determine altitude Gyroscopes measure rotational

motion around the X, Y and Z axis and are used for

appli-cations such as stability-control systems in aircraft,

stabili-zation systems for satellite receivers, and to augment GPS

navigation systems

A wide range of industrial applications now need

MEMS gyroscopes These industrial-grade MEMS

sen-sors differ from consumer-grade devices in that they can

accurately perform in harsh conditions characterized by

extreme temperature ranges, despite shocks and constant

vibrations But industrial-grade gyroscopes also tend to be

costly and bulky The typical way of making an

industrial-grade multiaxis gyroscope has been to combine discrete

Solid-state gyroscopes aren’t just

for video games and smartphones

Industrial-grade devices can handle tasks

that demand superaccurate sensing.

signifi-Industrial applications for motion sensing include form stabilization, land, air, sea, and space navigation sys-tems, precision agriculture, precision robotics, unmanned aerial (UAV) and nautical vehicles, construction equip-ment, offshore drilling, borehole survey, and handheld inventory-control systems to name just a few

plat-Industrial applications have different needs than the consumer space Specifically, there are four basic areas where an industrial gyroscope must outperform a con-sumer-grade gyroscope: temperature range, bias instabil-ity, noise, and vibration performance while maintaining small form factor and low cost

In agriculture, for example, farmers must maximize crop yields One pass of a tractor through a field must align with the next to within a few centimeters The task requires use of a precision gyroscope able to accurately measure the tractor heading despite vibrations from mov-ing machinery, heat from its engine and the environment, and location noise from the uneven ground Marine-based satellite antenna stabilization is another good example, where a boat must constantly communicate with a satel-lite Industrial-grade gyroscopes counterbalance boat mo-tion caused by the oscillation of the waves Additionally,

Authored by:

Kapil Kamra Vishal Markandey

• Early industrial gyroscopes were discrete devices that often demanded precision alignment on a PCB to eliminate the possibility of cross-alignment errors.

Resources:

InvenSense, www.invensense.com

For more information on

microelectromechanical systems, scan this

code or go to: http://

machinedesign.com/ article/inclination-and-tilt- detectors-0719

34

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RS# 128

Going to Electronica?

The Design Engineering and Sourcing Group, featuring Electronic Design,

Microwaves and RF and Electronic Design Europe has some exciting things planned.

Make sure to come to Hall A5, Booth 279 at the show and

enter to win an ipad every hour.

YES–YOU HEARD RIGHT

We are giving away an ipad every hour

during the show!! Now that’s excitement

at Electronica.

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