Machine design, tập 84, số 10, 2012

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July 19, 2012

A Penton Media PublicationTune in to EngineeringTV.com

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RS# 102

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of ±0.020 in or more Greens reveal the FDM-built part

In the realm of tive manufacturing, what exactly are the distinctions between accuracy, repeatability, and resolution? Accuracy describes how closely a man- conforms to a tolerance within a specified dimen- captures the equipment’s capability to produce consis- smallest measurement the machine can reproduce.

addi-These concepts are second nature to designers and man- conception about these mea- turing Over the years, some

as layer thickness or dots per hand term for accuracy.

Accuracy in

ADDITIVE MANUFACTURING

JULY 19, 2012 MACHINE DESIGN.com 56

MEDICAL INDUSTRY FOCUS

Parylene coatings are optically clear and do little

to change the look or dimensions of the underlying component or part, as demonstrated in this photo of two circuit boards The top one is coated with parylene, the bottom one isn’t.

plied to most vacuum-stable materials, including plastics, metals, ceramics, fabrics, paper, and even granular materials For example, parylene coatings could be applied to microspheres or moisture-absorbent powders.

Parylene can be selectively removed with plasma, lasers,

or strong abrasion, for instance, to repair devices Parylene

a “hard” coating, so excessive abrasion will remove it ever, most components coated with parylene do not abrade

How-or rub against other parts If an application candidate for parylene.

Parylene deposition

Parylene coatings are applied using por-deposition polymerization (VDP) in a deposition actually takes place on the mo- ing one molecule at a time This lets parylene

va-in areas where other coatva-ing methods such

as sprays and brushes cannot reach ing thickness is uniform, even on irregular process that uses no additional chemicals.

Coat-rounds the target and perfectly follows its coatings are ultrathin and pinhole-free.

The only raw material used in the ing process is known as dimer Technicians the coating machine The dimer is heated,

coat-or extraction issues.

Parylene coatings are also patible and stable in the presence of bodily fluids and tissues, critical factors in the medical-device industry.

com-Parylene provides film lubricity with coefficients of

dry-to 7,000 V at a mil (25 microns) of coating thickness No other material can be applied as thinly as parylene and provide the same levels of protection.

Par ylene withstands all common sterilization methods

— steam, ethylene oxide, electron and gamma radiation It can be ap-

This biocompatible conformal-coating material protects medical devices against fluids, chemicals, and stray electrical charges.

Many medical devices and their electronics need tion from moisture, chemical contamination, electrical charges, and body fluids Otherwise, patients and health- care providers may be put at risk One way biomedical

protec-or poprotec-or conductprotec-or of electricity, such as silicone, acrylic, purpose is parylene.

Parylene basics

Parylene is the generic name for a series of organic polymers — poly(para-xylylene) polymers — used as dielectric and barrier properties and are chemically inert

contain no fillers, stabilizers, solvents, catalysts, or cizers, so they are not subject to any leaching, outgassing,

plasti-Continued on page 22

Protecting MEDICAL ELECTRONICS with parylene

For more information on parylene coatings,

scan this code or go to: http://machinedesign.

adhesion-promoter- specialty-coating- systems-0609

com/article/coating-A short history of parylene

In 1947, Michael Szwarc was pursuing his academic career in

physi-cal chemistry at the Univ of Manchester, England His interest in the

aliphatic carbon-hydrogen bonds in which the carbon was directly plest compounds having both benzene and carbon — toluene and the xylenes — to high temperatures He monitored both the decomposi-

at-With p-xylene only, a tan-colored deposit formed in the cooler

reaches of his glassware The material has been described as a thin,

ﬂ imsy, tube-shaped mass, “the skin of a small snake.”

Szwarc correctly deduced that this ﬁ lm had been formed by

polymer-izing reaction products of the p-xylene, called p-xylylene He also noticed

the new polymer’s physical properties and chemical inertness This xylyene) Today its purer colorless form is called parylene N.

seren-A few years later, William Franklin Gorham at Union Carbide Corp

continued the research on parylene By 1967, this work led to the cess for applying them In fact, Union Carbide developed over 20 types

avail-of parylene, but only three were deemed commercially viable.

Parylene has been successfully used on implantable electronics such as cardiac-assist devices, pacemakers It’s also been used to coat nonelectronic medical devices as well, including coronary and cerebral stents, and catheters.

sublimating it directly to a vapor, and then heated again kept at a medium vacuum (0.1 torr) where it spontane- ously polymerizes onto all surfaces, forming an ultrathin, uniform film No curing or additional steps are required The size of the coating chamber may be an issue if

JULY 19, 2012 MACHINE DESIGN.com

20 JULY 19, 2012 MACHINE DESIGN.com 21

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

Protecting medical electronics with parylene

Parylene coatings give medical devices the dielectric strength to resist stray voltages as well as fluids and gases.20

A common mistake is to confuse high resolution with accuracy

Exploring rotary

ball splines

Rotary ball splines can produce

submillimeter accuracy However, the choice

of angular-contact or crossed-roller bearings

plays a critical role

Options for designing

the best hinge

Hinges with spring pins instead of solid pins

can lower costs and extend life

When SPC leads

engineers astray

The quest for minimizing process variations

can lead to parts that are needlessly

expensive

Polycarbonates go with the flow

A new class of high-flow polycarbonate

copolymers meets or exceeds the physical

and mechanical properties of traditional

materials, and provides better molding

characteristics

Advanced assembly techniques

for high-performance plastics

Engineers switching from metal to plastic

need to revisit how they assemble the parts

2

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SCANNING FOR IDEAS

Modular guarding system protects workers and equipment

One serious screwdriver

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CAD models

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6

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RS# 106

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A better way to find stand-out engineers

There are K pegs Each peg can hold discs in decreasing order of radius when looked from bottom to top of the peg There are N discs, which have radius 1

to N Given the initial configuration of the pegs and the final configuration

of the pegs, output the moves required to transform from the initial to final configuration

What you see above is part of a sample problem found on Facebook’s Web

site Programmers looking for work at Facebook often start out by submitting

code to solve puzzlers like this one Code that impresses the Facebook crowd earns you a job interview over the phone If that goes well, you’ll find yourself

in Facebook’s Menlo Park, Calif., facilities for an in-person evaluation Facebook

says it has uncovered some of its most-able software engineers just by using its Web site to ask for solutions to programming brain-teasers

Whatever your opinion of Facebook social media, you have to give that pany credit for coming up with an inexpensive way of finding good engineers Its methods stand in direct contrast to the practice of asking riddlelike questions that have nothing to do with the job at hand, an interviewing technique popu-larized by Google and adopted by several other high-tech companies

com-Employers, though, increasingly seem to be coming around to the idea that responses to off-the-wall questions may say something about an applicant’s quick-wittedness, but don’t really reveal much about how that person will get

a job done So some organizations are now trying to find the real qualities that predict good work performance And many of them have concluded these qualities have little to do with academic credentials or job resumes

Engineering employers that still depend on brain-teasers to find

techni-cal talent might learn a few things from George Anders, a former Wall Street

Journal writer and book author A lot of traditional talent-scouting systems

don’t work, he claims Anders studied several professions to see how the best employers found new hires who would likely turn into first-rate employees He

summarized his findings in a book called The Rare Find Two of the groups he

examined had an interesting insight: The Teach for America project and the

U. S Army Special Forces both looked for evidence of one trait in particular — resilience

Teach for America sends teachers into low-income communities It figures educators who find success there must persist in the face of problems that might crush less-committed individuals So among other things, TFA is on the look-out for applicants who struggled in their first year of college but persevered and eventually earned higher grades year after year

Similarly, Army Special Forces drill sergeants these days aren’t particularly impressed by candidates who do the most pushups or crank out fast times for two-mile runs They are more interested in who performs well with little sleep during team problems where it’s important to think like a soldier Guys who ex-cel at pull-ups are still eliminated from the program if they get moody or hostile when things don’t go their way

I’d argue that resilience is just as important for many engineering tasks as

it is for teaching disadvantaged kids or gaining trust in a remote village But it doesn’t come up in many job interviews because hiring managers find it easier

to pull out a few head-scratcher problems than to spend time making a frank assessment about what a job really entails

— Leland Teschler, Editor

RS# 107

JULY 19, 2012

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Brass base (no plating needed)

Toggle-operated manual by-pass valve in base

Integrated needle

valve for precise

flow control

1/2” max Mounting

holes

Stainless Steel coil housing

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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

MACHINE DESIGN.com

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Medical equipment requires high performance motors Moog Silencer™ series brushless DC

www.moog.com/components

RS# 111

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of employment is difficult or the potential loss of benefits is too gre a t M a n a g e m e n t c a n t a k e advantage of this situation by withholding salar y increases

Membership in a union could be advantageous in this situation, and a union could also provide assistance against dismissal be-fore eligibility to retire

In my own career, I benefitted from a union I did not even be-long to The factory employees were represented by the United

A u t o Wo r k e r s U n i o n , w h i c h

n e g o t i a te d e a r l y re t i re m e n t , health-care benefits, and vaca-tion and holiday times The same benefits were then granted by management to salaried employ-ees Thus, there was no union of salaried employees who had no protection against age discrimi-nation or arbitrary dismissal

R Bruce Hopkins

No form and too much function

As an industrial designer, I ciated your recent commentary (“Form Should Follow Function, and More,” April 19) I suggest that anyone involved in the de-sign of any product that people use read two books from the 70s

appre-One is How Things Don’t Work,

Almost united on unions

I read with amusement the letters

sent to you concerning the

ques-tion of engineers joining a union

(“ Time for Engineers to Think

About Unionizing? Jan 19)

I was in an engineering union

several decades ago It was for a

large railroad-car manufacturer

in the Rust Belt, which is no

lon-ger in business (No, the union

didn’t bring it down.) As a de

-signer and engineer-in-training,

I was required to join the union

based on my job description It

was a good learning experience

on why engineers and unions

don’t mix I won’t go into details

of the office culture or issues

with having hourly and salar y

workers combined

The issue that I had at the

time and still do today is that

the union had many constricting

work rules on how you get

pro-moted and how people advance

within the organization

Profes-sionals or not, you were treated

differently if you were in the

union I found the whole process

to be nonproductive and

ineffi-cient for getting work done I was

denied advancement, not based

on experience or productivity,

but on years of ser vice Union

people didn’t go to lunch with

nonunion The entire culture was

counter to the teamwork

envi-ronment required in the

engi-neering profession

During the summers, while

attending college, I worked in

a manufacturing plant that was

also unionized I can honestly say

that the hourly union plant job

had more job satisfaction than

did engineers in the unionized

office My opinion is that there is

no place for a union in the office

environment, let alone the

engi-neering profession

Joseph C Dominick

There can be a period in an

en-gineer’s career in which the

in-dividual is too young to retire

but old enough that a change

and the other is Design for the

Real World Both books deal with

the same issues we need to deal with today

By the way, we have a 2005 German car purchased two years ago We are still trying to figure out all of the technology/gad-gets in the car My son has the same type of German car, but his

is a 2010 He will be trading it in this year for a new one He is a top engineering manager work-ing for one of the top computer manufacturers, and he still hasn’t figured out all the gimmicks and features of this German driving machine But he paid for all of them

There is no evidence of a man-factors approach in these two cars, just lots of interesting things to look at and play with, but hardly functional or germane

hu-to driving And who has the time

to figure out all of this?

If I buy something, no matter what, I want to use it, not have to

go back to college for two years and take another 60 credits, just

to repeat the exercise the next time I buy a car

As my teachers used to say:

M a k e i t s i m p l e e n o u g h fo r a 10-year old to figure out

fe r s a m o re - o p t i m i s t i c

v i e w B u t r e a d e r s a r e speaking with one voice

to criticize modern design and the fact that form no longer follows function

They also seem to agree that sustainability stan-dards will do more harm than good We’ll see

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All the Tools you Need for Embedded

Measurements and Control,

in one rugged box.

The NI CompactRIO hardware platform can handle your embedded measurement and control applications, and do it in a way that outperforms other off-the-shelf systems so you don’t have to spend time developing a custom solution The range

of high-quality measurements, coupled with an extremely rugged design and the ability to modify the hardware using NI LabVIEW system design software, gives you all the beneﬁts of customization with the convenience of an off-the-shelf platform.

RS# 112

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Make the Switch

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afford the extra cost and the drag

of more bureaucracy will have closed up shop

Remember when efficienc y

m e a n t d o i n g m o re w i t h l e s s, when economical meant cost-ing less? Some day that com-mon sense will again prevail In the meantime, keep up the good work

Wayne A Strand

I do a lot of presentations about Reduce, Rec ycle, and Reclaim and I paraphrase another engi-neer (her name escapes me) She wrote: “I cannot design anything green Everything will consume resources I can make my designs greener, so they consume less resources both when built and when they run.”

to those politically correct produc tive meddling by non-producers They firmly believe

non-we all, but especially everybody

e ls e, w ill ju st h ave to b uck le down and throw more money

at another nonproblem (until it dies from suffocation under its own weight) By then, of course, two new great sounding ideas will have covered it up, and all the money that can be squeezed from the last idea will be taken

The small companies that can’t

I just read your commentary and

now I think we are wired similarly

I agree with all your comments

At my firm, we are always talking

about form following function

and to design for use, not looks

Cars today get too cluttered

because so many automakers are

competing to have the most

“op-tions” for mass marketing I told

my spouse the other day that if I

could, I would get our next

com-pany vehicle with a hand-crank

starter Less to go wrong, no

bat-teries, and those cheap

magne-tos used to work pretty well

All kidding aside, I enjoy

con-trolling the functions of driving

It’s not that difficult to clutch and

shift and hand crank the

win-dows up and down, especially

when there’s little physical work

to do while sitting there anyway

Larry Kooiker

RS# 113 JULY 19, 2012

MACHINE DESIGN.com

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HUCK 360

Once vibration begins,

clamp load quickly

decays with nuts and

bolts, while it holds

constant with the Huck 360

®

No gap exists Threads are locked preventing any movement.

Gap between the threads allows for transverse movement.

RS# 114

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Edited by Stephen J Mraz

Request free information vi

a our Reader Service Web site atwww.machinedesign.com/

rsc

Factory owners don’t want workers interfering with

equipment Nor do they want them injured To keep

workers safely away from moving machinery and

inventory that shouldn’t be disturbed, engineers

at Wireway Husky Corp., Denver, N. C (www.

wirewayhusky.com), have developed the modular

Matrix Guard line of products

The OSHA-approved doors, walls, posts,

connectors, latches, and other accessories are

designed to work together and assemble quickly

and easily A new chalice bolt, a nonremovable-type

fastener used on the panels, also meets European

and Canadian safety standards

And enclosures or walls can be easily

expanded or changed to meet new

Modular guarding system

protects workers and equipment

conditions and situations For example, standard tall walls can be expanded to tower 30-ft high, and roofs can be added if needed to keep out trespassers

Cable-tray guide for use with Unistrut or Cablofil cable- management systems

2.5-in 2

oversized foot plate

Standard slide-bolt lock, but other standard and custom locks are available, including interlock mounting brackets.

Swinging door

Half-sized mesh panel

Mesh guard

panel

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Machine builders and other

manufacturers can now acquire

a ready-to-go, preprogrammed,

modular screw-driving machine,

the Viper MBC from Visumatic

Industrial Products, Lexington,

Ky (www.visumatic.com) And

though it’s said to be the fastest

screw-driving module available,

installing up to six screws in 5 sec,

it can also install nuts, bolts, pins,

clips, brass rings, and barbed

darts

Viper uses a Visumatic 94

feeder to deliver screws and

other fasteners directly to the

tooling tip Other

screw-install-ing robots fall in the

pick-and-place category This means the

robotic arm spends time getting

the fastener and then returning

to the work area Viper eliminates

this wasted time

Viper uses a SCARA robot to

handle motion because, as its full

name suggests (Selective Compliant

Assembly Robot Arm), it is

selec-tively compliant So it is stiff in the

vertical direction, which helps when

installing screws and pushing parts

together, but a bit compliant in the

horizontal plane, which lets it

com-pensate for less-than-perfect

align-ments between the tooling tip and

the hole for the screw

The Viper also features zero-offset

mounting for the screw-driving

por-tion This is a change from

conven-tional designs where mounting points

are located beyond the extreme end of

the robot, which creates an exaggerated

cantilever effect This means

screw-tighten-ing torque transfers directly to the robot’s

extended joints, and the tooling payload is

magnified by the moment arm and applied to

the joints as well With the Viper, joints three

and four do not see any tightening forces,

and they carry only one-third the weight of

the tooling This leads to faster motions,

The Viper has a working envelope of at least 7,000 in.3, and an NST traceable axis

RS# 402

Screwdriver with torque- angle control

Quick disconnect for maintenance

Zero-offset quill mount

Tooling tip holds screw

Independent

“Z” stroke and

bit stroke

SCARA robot Gearbox

18

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When you need it!

Where you need it!

Price & Availability Check

FAQ and Assistance

Price List

CAD Drawings, and more!

Trang 22

Parylene coatings are optically clear and do little

to change the look or dimensions of the underlying component or part, as demonstrated in this photo of two circuit boards The top one is coated with parylene, the bottom one isn’t.

This biocompatible

conformal-coating material

protects medical devices

against fluids, chemicals, and

stray electrical charges.

Many medical devices and their electronics need tion from moisture, chemical contamination, electrical charges, and body fluids Otherwise, patients and health-care providers may be put at risk One way biomedical engineers provide this protection is by encapsulating devices in a conformal coating, one made of a dielectric,

protec-or poprotec-or conductprotec-or of electricity, such as silicone, acrylic, urethane, or epoxy But one of the best materials for this purpose is parylene

Parylene basicsParylene is the generic name for a series of organic polymers — poly(para-xylylene) polymers — used as coatings They are polycrystalline and linear in nature, optically clear, and colorless Parylene coatings have useful dielectric and barrier properties and are chemically inert Three different types give engineers a range of dielectric and other properties from which to choose The coatings contain no fillers, stabilizers, solvents, catalysts, or plasti-cizers, so they are not subject to any leaching, outgassing, Protecting

Senior Medical Market Specialist

Specialty Coating Systems Inc.

For more information on parylene coatings,

scan this code or go to: http://machinedesign.

adhesion-promoter- specialty-coating- systems-0609

com/article/coating-JULY 19, 2012 MACHINE DESIGN.com

20

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plied to most vacuum-stable materials, including

plastics, metals, ceramics, fabrics, paper, and even

granular materials For example, parylene coatings

could be applied to microspheres or moisture-absorbent

powders

Parylene can be selectively removed with plasma, lasers,

or strong abrasion, for instance, to repair devices Parylene

is not soluble in harsh detergents and chemicals; in fact, it

protects components from such chemicals Parylene is not

a “hard” coating, so excessive abrasion will remove it

How-ever, most components coated with parylene do not abrade

or rub against other parts If an application

does include abrasive contact, it is not a good

candidate for parylene

Parylene deposition

Parylene coatings are applied using

va-por-deposition polymerization (VDP) in a

vacuum chamber at room temperature Film

deposition actually takes place on the

mo-lecular level, with the coating literally

grow-ing one molecule at a time This lets parylene

penetrate and coat small cracks, crevices, and

openings, and protect even hidden surfaces

in areas where other coating methods such

as sprays and brushes cannot reach

Coat-ing thickness is uniform, even on irregular

surfaces And VDP is a clean, self-contained

process that uses no additional chemicals

Parylene is deposited as a vapor, so it

sur-rounds the target and perfectly follows its

contours, literally encapsulating it Parylene

coatings are ultrathin and pinhole-free

The only raw material used in the

coat-ing process is known as dimer Technicians

place the powdered double-molecule dimer

into the vaporizing chamber at one end of

the coating machine The dimer is heated,

or extraction issues

Parylene coatings are also

com-patible and stable in the presence of

bodily fluids and tissues, critical

factors in the medical-device

industry

Parylene provides

dry-film lubricity with coefficients of

friction similar to that of PTFE

(Teflon), and dielectric strengths up

to 7,000 V at a mil (25 microns) of

coating thickness No other material

can be applied as thinly as parylene

and provide the same levels of

protection

Par ylene withstands all

common sterilization methods

— steam, ethylene oxide, electron

beam, hydrogen peroxide plasma,

and gamma radiation It can be

ap-Continued on page 22

A short history of parylene

In 1947, Michael Szwarc was pursuing his academic career in

physi-cal chemistry at the Univ of Manchester, England His interest in the

strength of individual chemical bonds led him to investigate a class of aliphatic carbon-hydrogen bonds in which the carbon was directly attached to a benzene ring While doing so, he heated gases of the simplest compounds having both benzene and carbon — toluene and the xylenes — to high temperatures He monitored both the decomposition products and rates of decomposition as a function of temperature.

With p-xylene only, a tan-colored deposit formed in the cooler

reaches of his glassware The material has been described as a thin,

fl imsy, tube-shaped mass, “the skin of a small snake.”

Szwarc correctly deduced that this fi lm had been formed by

polymer-izing reaction products of the p-xylene, called p-xylylene He also noticed

the new polymer’s physical properties and chemical inertness This dipitous polymerization was the world’s fi rst vapor deposited poly(para- xylyene) Today its purer colorless form is called parylene N.

seren-A few years later, William Franklin Gorham at Union Carbide Corp

continued the research on parylene By 1967, this work led to the ability of a new polymeric coating “Parylenes” was the term used to de- scribe both a new family of polymers and the vacuum-deposition process for applying them In fact, Union Carbide developed over 20 types

avail-of parylene, but only three were deemed commercially viable.

Parylene has been successfully used on implantable electronics such as cardiac-assist devices, neurostimulators, cochlear implants, and pacemakers It’s also been used to coat nonelectronic medical devices as well, including coronary and cerebral stents,

and catheters.

sublimating it directly to a vapor, and then heated again until the dimer cracks into a monomeric vapor This vapor flows into an ambient-temperature deposition chamber kept at a medium vacuum (0.1 torr) where it spontane-ously polymerizes onto all surfaces, forming an ultrathin, uniform film No curing or additional steps are required.The size of the coating chamber may be an issue if

JULY 19, 2012 MACHINE DESIGN.com 21

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Vaporization section

Pyrolysis section VDP section

This modular machine turns gas feedstocks into parylene monomers then coats parts with them using VDP.

Also, medical-device ers typically do not want to become experts in a coating process they may use on only one or two prod-uct lines Some device manufac-turers do, however, purchase VDP equipment and bring the process in-house

manufactur-Parylene variantsThe parylene family includes sev-eral members Parylene N, for ex-ample, is nonchlorinated poly(para-xylylene) that has a low dissipation factor, high dielectric strength, and a dielectric constant that doesn’t vary with the frequency of the electrical current Parylene N also performs well when it comes to penetrating and coating into a device’s small crevices and spaces

Parylene C is produced from the same dimer used to make Parylene

N, but it is modified by a chlorine atom attached to the molecule’s benzene ring It has a useful com-bination of electrical and physical properties, plus a low permeability

to moisture, fluids, and corrosive gases Its ability to provide pinhole-free conformal barriers makes it the coating of choice for many critical medical electronic assemblies.Parylene HT is the newest com-mercially available parylene It car-ries fluorine atoms on the benzene ring instead of hydrogen atoms It

products are too large to fit inside

For example, medical wire on a reel that needs to be coated as one con-tinuous piece may not be suitable for parylene However, if wires are precut to various lengths, hundreds

of pieces might fit into one chamber

Because there is never a liquid phase in VDP, there is no meniscus

or pooling There is also no ing or blocking of small openings, which can happen when applying a liquid coating

bridg-The thickness of a parylene ing can range from 500 Å to 75 mi-crons, so it does not significantly change the coated device’s dimen-sions or mass In many medical de-vices, such as intraocular and co-chlear implants, maintaining mini-mal dimension and mass are critical

coat-to the device’s performance

An added benefit of parylene is its ability to strengthen delicate wire bonds by an estimated factor of 10

The preparation and coating cesses vary from device to device

pro-Typical turn times are five to 10 ness days, but that can be negotiated

busi-Times may be extended if parts quire extra inspection, pretreatment,

re-or masking and demasking

Many medical-device turers send parts to coating-service providers due to the art and com-plexity of parylene coating process

manufac-Continued from page 21

RS# 117

JULY 19, 2012

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Coating costsThe cost of coating a product with parylene depends on several factors, including:

▶ Complexity of the item being coated Do one or more areas need to be masked so that parylene does not coat them?

▶ How thick a coating is needed?

This depends on the coating’s intended function Will it be used to protect electronics, add lubricity, be a tie-layer for other coatings, or be an elution-control layer for drugs?

▶ What type of parylene is required? N, C, or parylene HT?

▶ How many parts are to be coated

at one time? It is obviously less expensive to coat hundreds of parts in a large chamber than 10

or 20 parts in a smaller chamber

While some elastomeric O-rings can be coated for less than a penny each, a single, large, complex, mili-tary circuit board can cost hun-dreds of dollars to coat In general, parylene is competitive with other coatings given the right production volumes, complexity, and other vari-ables And although it may be more costly than some other coatings, pa-

has the lowest dielectric constant

and dissipation factor of all the

pa-rylenes, as well as the highest

contin-uous service temperature (350°C) It

also maintains its properties despite

exposure to UV light The other two

parylenes are susceptible to damage

by UV light

All three parylene formulations

are biocompatible and biostable, as

confirmed by ISO-10993 and USP

Class VI biological evaluations

Parylene applications

As noted, parylene coatings

pro-tect devices from moisture,

bioflu-ids, and biogases that can cause

as-semblies to fail prematurely This

protection extends product life,

pre-vents costly repairs and, most

im-portantly, reduces the risk of failure

Parylene has also been helpful in

tackling challenges raised by new

regulations Metallic whiskers, for

example, are one of the unintended

by-products of removing lead from

solder as part of RoHS regulations

These whiskers can lead to

reliabil-ity problems for electronic

assem-blies Parylene coatings suppress the

formation of metallic whiskers

Another benefit is parylene’s

dry-film lubricity, which makes it

an ideal release agent for molds

Be-ing solid and inert, parylene leaves

no residue to contaminate molded

products And parylene’s

lubric-The molecular structure

of the various parylene monomers used for coatings shows how they are similar and are all based on benzene rings.

JULY 19, 2012

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POWER DISTRIBUTION

Thousands of enclosures

Hundreds of options

Designed and delivered in 10 days

technologies, let parylene coating perform on medical-device compo-nents, circuits, and equipment, re-gardless of their size, configuration,

or material MD

implants, parylene provides term biocompatibility and device protection The available parylene formulations, coupled with newly developed adhesion-enhancement

long-rylene may be the only option for the

protection needed by a given device

For the sophisticated

microde-vices being developed for medical

Continued from page 23

Comparing coatings

PARYLENE HT

PARYLENE C

PARYLENE N

SILICONE (SR)

POLYURETHANE (UR) Dielectric strength (V/mil) 5,400 5,600 7,000 2,000 3,500

This table compares the three available parylene conformal coatings to silicone and polyurethane, two other

material used to impart dielectric properties to devices and components.

Trang 27

SOFTWARE & SERVICES

silicon-Dr Tony Kenyon, a leader of the UCL Electronic and Electrical Engineering team and Fellow of the Institute of Physics, states,

“Our ReRAM memory chips need just a thousandth of the energy and are around a hundred times faster than standard Flash memory chips The fact that they can oper-ate in ambient conditions and have a continuously variable re-sistance opens up a huge range of potential applications.”

Researchers at University College

London (UCL) have developed

the first purely

silicon-oxide-based resistive RAM chip that

can operate under ambient

conditions The new design

opens the possibility of

creating superfast memory

that doesn’t lose stored data

when power is turned off

The most-often-used materials

for resistive RAM (ReRAM) chips

are metal oxides whose electrical

resistance changes when a

volt-age is applied But unlike other

electrical properties that vanish

when power is turned off, the

resistance change of these

materi-als remains even after power is

removed ReRAM chips need much

less energy and space than current

Flash memory used in USB sticks,

so they could be used for

low-powered fast memory with greater

storage capacity

The novel structure developed

by the research team is made from

silicon oxide The silicon atoms

change to form less-resistive

fila-ments within the silicon-oxide

material The presence or absence

Speedy memory chip uses

low-power resistive RAM

The continuously variable tance depends on the last voltage applied This lets the device mimic how neurons in the brain function Devices that operate in this way are known as memristors

resis-Earlier memristors were based

on titanium dioxide The ment of a silicon-oxide memristor offers greater potential for incor-poration into silicon chips

develop-The new ReRAM technology was discovered by accident while engineers at UCL were testing silicon oxide in the production

of silicon-based LEDs ers noticed that the devices ap-peared to be unstable UCL Ph.D student Adnan Mehonic discov-ered that the material wasn’t unstable, but predictably flipped between various conducting and nonconducting states.MD

Research-Resources:

University College London,

http://www.ucl.ac.uk/news/ news-articles/May2012/120518- new-silicon-memory-chip.

This prototype ReRAM memory chip hints at nonvolatile memory devices that are

100 times faster than current

Flash memories yet require only a fraction of the power.

Photo: UCL/Adnan Mehonic

RS# 119

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Our New Standard in Geared AC Motors

• 2 Times More Torque

• High Strength, Long Life

and now they are

offered at the same

Stepping Motors • Servo Motors • AC Motors • Brushless Motors •

Linear & Rotary Actuators • Cooling Fans

The three mechanical engineers who make up the San Francisco-

based Ronin Metal Masters have

developed a method of cutting perforation lines in sheet metal using lasers or a punch press The sheet metal can then be folded

by hand into a variety of shapes, including prestressed, reinforcing tubes Folded sheets can then be riveted or glued together with automotive chassis epoxy and turned into bracket joints or furni-ture But the company has decided

to concentrate on sheet-metal terns that fold into bicycle frames

pat-“We can fold sheet metals into geometrically strong shapes, which is prohibitively expensive in small-to-medium runs using con-ventional methods, “ says Robert Hannum, CEO of Ronin Metal Mas-ters “There is no specialized tool-ing involved, which lets us come

out with new and exciting designs whenever we chose.”

Their current prototype of a bike is made of 0.024-in.-thick 6061-T6 aluminum It took about three weeks to cut the pattern and manually assemble it, and the resulting frame weighs under

3 lb Because the bike is made without welding, there is no risk of the fastening method weakening the metal, a problem with welds

It also means frames can be sembled without the heavy-duty industrial welding equipment used in most bike factories In-stead, patterns might be created

as-on sheet metal, then shipped to

JULY 19, 2012

Trang 29

Brushless Motor Advantages

• Compact, High Torque

• Wide Speed Range

• Continuous Duty

• No Maintenance

Brushless Motors offer all the design ﬂexibility needed for many different types

of applications

Learn more about the Brushless Motor Advantages from Oriental Motor.

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Technical Support Tel: 800-468-3982 7:30am- 7:00pm, CST (M-F)

Stepping Motors • Servo Motors • AC Motors • Brushless Motors • Linear & Rotary Actuators • Cooling Fans

local assembly shops This would

cut transportation costs but could

complicate overall logistics

The company plans on

offer-ing five material options for

buy-ers: low and high-end aluminum

and steel, and a single grade of

titanium Estimates on prices

range from $200 for a steel frame

to $1,000 for the titanium

ver-sion And the high-end aluminum

frame should be about $500

In an unusual scheme to get the production up to speed quickly, the company is accepting pledges

of $300, which will get a person

an unpainted frame, when and if the company gets enough orders

to pursue production A $1,000 pledge earns a completed and painted bike (again, if and when it goes into production). MD

Ronin Metal Masters plan on selling their folded, sheet-metal bike to the public for about $200

to $1,000, depending

on the metal used

to make it.

RS# 121

JULY 19, 2012

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Stepper motors keep seismometers

on the level in Davy Jones’ locker

Geophysicists like to

keep tabs on the

mo-tion of earth’s tectonic

plates and the

earth-quakes they generate

using a device known

as a seismometer But

that’s easier said than

done when the plates

are on the ocean floor

Most dynamic

mo-tion seismometers use

an inverted pendulum

design that requires

leveling prior to use On

dry land, leveling the

instrument is easy On

the ocean floor

thou-sands of feet below the

surface, the leveling

process gets a bit more

challenging

Researchers toss

the seismometers into

the ocean attached to

weighted sleds The

sleds can land on the

sea floor in just about

any position, often on

a muddy surface with

an unknown

topog-raphy As a result, the

mechanical leveling

system must be able to

right the sensing

ele-ments even when the

instrument comes to

rest upside-down The

seismometers made

by Nanometrics Inc.

in Canada use three

inertial masses aligned

on orthogonal axes to let the instruments measure in

three dimensions The three measurement axes within

each of the Trillium Compact OBS (seafloor) and

Com-pact All-Terrain (dry land) seismometers rigidly attach

to each other This lets the system level the platform as

a whole

Nanometrics mounts the seismometer in a

motor-ized gimbal The inner frame rotates the instrument

around its own axis The outer frame then rotates the

instrument with respect to the case Accelerometers

on the seismometer and case determine the degree of tilt and, thus, the amount of correction needed A microprocessor adjusts the motors’ position as re-quired, fully leveling the system in less than 20 min.The positioning mechanisms needed a high degree

of torque to level the instrument Normally, the easiest way to boost torque is to use a larger motor or add a speed-reduction ratio via a gearmotor However, the design was space constrained, so a larger motor or

Resources

MICROMO, www.

micromo.com

RS# 406 Nanometrics Inc.,

www.nanometrics com/

RS# 407 Seismometers,

en.wikipedia.org/ wiki/Seismometer

Users attach the Nanometrics seismometer (the black cylinder) to a metal sled that carries it down to the sea floor

At the end of the experiment,

a transponder signal triggers the release of ballast and the instrument floats to the surface.

Continued on page 30

28

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RS# 122

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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.

ametekapt.com

seismometers

The use of stepper

motors makes the

in-strument dependable

and simple to control

The motors are merely

commanded to rotate

the instrument to a

specific position The

design transfers motion

from the motor to the

gimbaled seismometer

What’s a seismometer?

In its simplest form, a seismometer consists of a frame that moves with the underlying rock, a pendulum that essentially acts as an inertial mass, and electronics that track the displacement between the two The frequencies of interest extend from 100 to below 0.001 Hz Classic pendulums consist of a weight hanging on a string The weight always centers itself thanks to gravity But this type of arrangement is not suited for measuring ground motion Broadband seismometers typically use the form of an inverted pendulum in which

a spring, rather than gravity, provides the restoring force If not leveled prior to use, gravity pulls the weight to one side producing a false motion reading.

The Nanometrics leveling mechanism integrates a high- torque-density stepper motor and

a gearbox to adjust the position of the instrument.

gear reducer were not workable

options Increasing the diameter

by only a couple of centimeters

would force the use of a larger

sled This could make the

differ-ence between deploying 10 or 15

instruments on a given cruise,

pos-sibly boosting costs by hundreds

of thousands of dollars

Nanometrics worked with

MICROMO in Clearwater, Fla., a

member of the Faulhaber Group,

to develop efficient motors that

were compact, had high torque,

and the reliability necessary for

the seismometers The design uses

two stepper motors controlled

by a microprocessor The leveling

algorithm reads the

accelerom-eters to calculate how to make the

platform nearly level Final leveling

is then checked using the

Continued on page 32

RS# 123 JULY 19, 2012

MACHINE DESIGN.com

30

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RS# 124

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WINGSDETAILEDTECHNICALSPECS FOR#!$DRAW

temperature variations deep underwater are fairly minimal Such is definitely not the case on dry land, where a seismometer deployed at the South Pole faced operating temperatures that varied from 0 to 50°C below zero

The MICROMO motors were designed to operate

at temperatures as low as –58°C (–72°F) The system temperature of the South Pole unit stabilized around –50°C (–58°F), with the leveling motors performing exactly as planned MD

whole, the motors adjust each pendulum individually

Using bubble levels, the installer manually levels

the seismometer to within a few tenths of a degree

The additional leveling accuracy provided by the

mo-tors means the electronics aren’t working as hard to

center the masses This lets the instrument measure

signals at extremely low frequencies, such as the

natu-ral resonance of the whole earth

Seismometer installations on dry land are not

without their own punishing conditions For example,

using a worm gear, which promotes a

compact and sturdy design The gear

also offers stability, even under exposure

to shock and vibration For example,

worm gears are not easily back driven,

which protects the gearbox load

Next, the design team needed to

integrate the worm gear with the

gear-head The obvious method was to tie

the two together with a setscrew

cou-pling, but the motor-shaft diameter is

just 2 mm In addition, setscrews could

loosen over time, potentially

prevent-ing the motor from levelprevent-ing the

instru-ment MICROMO developed a way to

weld the drive gear directly onto the

gearbox output shaft The prewelded

gear greatly speeds and simplifies the

assembly process

Though designed for underwater

deployment, the motorized levelers

also perform their duties on dry land,

but with a slightly different twist Rather

than positioning the platform as a

Ocean-floor seismometers, like this Nanometrics Trillium OBS, must

be both rugged and reliable.

RS# 125 JULY 19, 2012

MACHINE DESIGN.com

32

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[ MOTOR TRUTH #4 ]

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stop losing energy through belts,

pulleys, chains, and sprockets

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improve efﬁciency A shaft-mounted

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RS# 126

Trang 36

How do you

correctly

implement the ideal

reliable network performance? askTURCK.com

A special casting reel lets a person with severe

paraly-sis cast a rod and reel, work the lure, and reel in fish

The reel, called Ken’s Power Caster, comes from

en-gineers at Adaptive Creations in Waltersburg, Pa The

firm develops equipment that lets people with severe

disabilities take part in fun and challenging hobbies

and sports such as kite flying and playing billiards

The reel is relatively simple: a motorized rod and

reel mounted on a swivel Using three pushbuttons,

a person can aim the rod, pull it back for a cast, then

release it, letting it cast up to 100 ft

Manipulating all three buttons lets

the fisherman pump the lure, set a

hook, and then play-out and land a

large fish

Adaptive Creations wanted

the fishing system to be usable by

those with little to no use of their

hands To do so, they

converted the three

pushbuttons to

sip-and-puff technology, long

used by people with

dis-abilities For the

conver-sion, Adaptive worked

with World Magnetics

Co., Traverse City, Mich.,

which has made reliable

switches for sip-and-puff

applications

In the end, Adaptive

used Magnetics PSF100A pressure

switches, which are rugged and

rela-tively immune to false activations,

even in harsh environments The switches can detect pressure changes down to 0.5 in of water and can be programmed to work on pressure, vacuum, or differ-ential pressure

The switches mount in a chest plate, which makes them readily accessible to the fish-

erman For people with more bility, the three switches can be ac-tivated by the chin, feet, or hands, and mounted accordingly. MD

mo-Sip-n-puff rod and reel lets the disabled go fishing

Resources

Adaptive Creations,

www.kenspowercaster.com

RS# 408 World Magnetics Co.,

www.worldmagnetics.com

RS# 409

Three sip-and-puff controls based on PSF100A pressure switches from World Magnetics Co., let people with disabilities use Adaptive Creation’s fishing system.

Ken Dvorchak, founder of Adaptive Creations, uses his companies fishing system, this one equipped with chin buttons rather than sip-and-puff switches on the chin plate.

RS# 127

Trang 37

(952) 927-1400

www.mnrubber.com

Minnesota Rubber & Plastics

Engineered to improve performance Designed to reduce costs.

High tolerance components and assemblies are

what we work with everyday at Minnesota Rubber

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We Mold Ideas Into Reality.

RS# 128

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10 YEARS AGO — 2002

GPS tracks gorillas in the mist: African mountain

gorillas are catching diseases from tourists in the

Virunga Mountains and Vwindi Impenetrable

National Park, says Rich Minnis, a research scientist at Mississippi State Univ

To help protect them, researchers are using sophisticated GPS to generate

geo-graphic information that helps determine when and where the endangered

mountain gorillas make contact with humans and domestic animals

Though only about 10 tourists per day visit the gorillas, the animals have experienced an outbreak of mange The data from GPS will be incorporated into a geographic information system (GIS) to track where the gorillas travel and when they cross paths with hu-mans, other primates, and livestock Researchers expect to record about 1,200 gorilla observations in the next nine months

Promising new lead-frame material:

A new lead-frame material,

copper-clad stainless steel from Texas ments, Metallurgical Materials Div.,

Instru-offers six times the thermal ity of Alloy 42, the standard iron-nickel mate-

conductiv-rial This property

is said to significantly reduce junction-to-ambient tempera-ture differences In addition, the clad material provides better mechanical strength, ductility, and fracture resis-tance, all at much lower cost, and is fully compatible with existing stamp-ing and assembly operations

Ceramic insulates while conducting away heat: A new magnesium-oxide

ceramic stops a current while passing

heat Developed by Honeywell Regulator Co., the mate-

Minneapolis-rial doesn’t melt below 2,800°C, and

is an excellent electrical insulator

at temperatures above 1,200°C As

a thermal tor, its conductiv-ity is better than that of metallic lead Rated at 99.9% purity, the ceramic has a 25,000-psi transverse strength This, coupled with the material’s high density, gives it thermal shock resistance comparable

conduc-to alumina ceramics It is more than 98% nonporous and can be made in

a wide range of sizes and shapes with varying degrees of translucency MD

36

Trang 39

Works with any Cicoil ﬂ at

for high accuracy motion

Rugged and reliable:

rated for millions of

ﬂ exing cycles

Cicoil® FlexRail™

www.Cicoil.com/FlexRail

Cable Carriers

Need Not Apply

While Cable Carriers have served a purpose in the past, they come with a price: Noise, Size and Cost Wouldn’t it

be nice to reduce all three, with bonus

beneﬁ ts? Now you can with FlexRail™

Self-Supporting Flat Cables

Our new FlexRail™ makes any Cicoil ﬂ at

cable completely self-supporting, in a quiet, compact package The patent-

pending FlexRail™ design keeps the cable

parallel along its entire length, enabling a tighter bend radius and a more compact cable design than is possible with a cable carrier Its smooth rolling motion, compact

size, and quiet operation make FlexRail™

cables far superior to cable carriers in most linear motion applications

Visit our website or call today to learn

more about FlexRail™ - and say goodbye

to that clunky old cable carrier!

The Clear Choice

661.295.1295

Flex Support

Eliminate!

PATENT PENDING

Introducing FlexRail™

Self-Supporting Flat Cable

Any Wires, Cable, Fiber-Optics, or Tubing

RS# 129

Trang 40

11 Bowles Road, Agawam, MA 01001 • Tel: 413-786-9922 • Fax: 413-789-2786

800-732-2358

Complete Conveyor Systems

Teflon is a registered trademark of DuPont ISO 9001 Registered

Designed For Today’s Technology

STAINLESS STEEL BELTS

Coated Steel Belts

QUICK SELECT GUIDE

The 75+-page Quick Select Product

Guide 4.0 from Pepperl+Fuchs,

Twinsburg, Ohio, provides

technol-ogy overviews and product

sum-maries for the company’s family

of proximity, ultrasonic, and

pho-toelectric sensors; rotary ers; AS-Interface solutions; RFID, imagers and scanners; industrial vision sensors; PosiTrack Absolute Position Tracking System; machine safety sensors and controllers; and cordsets The guide is available at

encod-http://www.pepperl-fuchs.us/usa/ en/17733.htm Pepperl+Fuchs de-

signs and manufactures ity factory and process-automation products and services

high-qual-APPOINTMENT

IDI Composites International,

Noblesville, Ind., has appointed Larry Landis to head a develop-ment team for a new line of structural-thermoset compounds designed for high-reliability appli-cations in military, transportation, and industrial lDI Composites is

a formulator and manufacturer of SMC and BMC thermoset-molding compounds

TÜV Rheinland, Boxborough,

Mass., has named Gerhard Luebken as its new Chief Regional Officer, President, and

CEO of TÜV Rheinland North America Holding Inc and of TÜV Rheinland of North Amer- ica Inc TÜV Rheinland offers

independent testing, inspection, and certification services

TESTING 802.11 AC SIGNALS

The”Testing Very High Throughput 802.11 ac Signals” (5990-9987EN)

application note from Technologies, Santa Clara, Calif.,

Agilent-gives insight on how to quickly and accurately generate and ana-lyze wider bandwidth 802.11 ac signals To obtain a copy, or other

free application notes, go to www.

agilent.com/find/powerofx

Regis-tration is required

ENVIRONMENTAL TESTING

TÜV SÜD America, Auburn Hills,

Mich., has expanded its mental-testing capabilities, and reorganized its Auburn Hills facil-ity TÜV SÜD provides environ-mental testing in North America at several facilities in Michigan, and Ontario, Canada Additional envi-ronmental services include accel-erated life testing, fluid dynamics, thermal shock, metallurgical, and mechanical testing

environ-RS# 130 JULY 19, 2012 MACHINE DESIGN.com

38

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