APRIL 19, 2012 MACHINE DESIGN.com 46 FASTENING & JOINING TECHNOLOGY GUIDE Bellows electrical contacts compensate for offsets and vibration electrical components.. thick-Mechanically form
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Trang 5CAD/CAM
Building blocks of systems engineering
Imagine this scenario: You are driving a brand new close it As the car accelerates, an annoying wind throb move You slow the car down, the throb stops, and sud- denly you can close the window At the dealership, they can’t find anything wrong with the car.
This happens to a number of consumers so the issue eventually makes it to the carmaker’s development de- termine the cause: a safety feature, a touchless sensor,
The potential for unintended consequences in today’s complex products makes
Siemens PLM software
Troy, Mich.
Edited by Leslie Gordon leslie.gordon@penton.com Twitter @LeslieGordon Key points;
• Systems engineering involves all stakeholders.
• The approach helps eliminate error in complex systems.
• The backbone of systems engineering
is PLM.
Resources:
Siemens PLM Software, www.siemens.
com/PLM
For another feature on “whole-system”
design, scan this code or go to: http://
machinedesign.
com/article/
efficiency-1117
engineering-for-These are the building blocks of a systems- engineering approach
PLM supports driven product development.
What is
SYSTEMSDRIVEN
DEVELOPMENT?
APRIL 19, 2012 MACHINE DESIGN.com 46
FASTENING & JOINING TECHNOLOGY GUIDE
Bellows electrical contacts compensate for offsets and vibration electrical components.
Metal bellows with low spring rates are highly sensitive and responsive Springs drawn from standard wire require more force to generate the same motion. Continued on page 59
Metal bellows are used for hermetic seals, volume compensators, pressure and bellows, one version of these products, are a viable alternative to metal springs durability while lowering costs Here’s a look at how they’re made and used.
Electrodeposition process Electrodeposited bellows are manufactured by first machining an aluminum mandrel to match the internal geometry of the desired bellows The mandrel
Precision bellows have extremely low spring rates, making them a better option than traditional coil springs in many mechanical and electrical devices.
Request free informat ion via our Reader Service Web site at
www.machine design.com/rsc
match the thin walls of deposited bellows As a result, they
do not have the same flexibility and responsiveness Electrodeposited-nickel bellows typically provide just one-fifth to one-tenth the spring rate of hydroformed brass bellows of the same size The force required to com- press them is especially low and stays consistent among bellows of the same size and type.
Bellows as spring replacements
In electrical devices, springs are commonly used as electrical interfaces for temporary connections Metal applications.
To increase conductivity, a layer of gold is plated over the bellows to ASTM B488 The actual shape of the bel- lows is a key factor in the design Because the signal travels with minimal self-inductance and insertion loss This makes bellows well suited for testing electrical cir- cuits The small size and many available shapes let bellows, handling during manual testing.
For example, a semiconductor-chip maker used a lows electrical contact to test miniature components as
bel-The tightly controlled deposition process produces walls define the end trim dimensions Next, caustic chemicals and testing complete the manufacturing process.
This proprietary electrodeposition process turns out helium-leaktight bellows that are highly sensitive, respon- sive, and reliable A bellow’s responsiveness and spring rate therefore, are capable of significant deflection with a mini- bility yields a bellows that is both sensitive and responsive
to changes in pressure.
By comparison, springs drawn from standard gauge wire require more force to generate the same mo- tion and, by their nature, are not helium leaktight Rubber compared to metal bellows.
thick-Mechanically formed (or hydroformed) metal bellows are limited in their minimum wall thickness; they cannot
Metal bellows REPLACE SPRINGS
Authored by:
Paul Hazlitt Director of Engineering
Servometer
Cedar Grove, N J.
Edited by Kenneth J Korane ken.korane@penton.com Key points:
• Metal bellows are extremely sensitive and responsive.
• They can be helium leaktight.
• Metals bellows can be made with infinite fatigue life.
Resources:
Servometer, www.servometer.com
RS# 621
APRIL 19, 2012 MACHINE DESIGN.com
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
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Engineering salaries: staying
ahead of the curve
See how you stack up against engineers
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A glimpse into the
engineering workplace
Our annual survey reveals what irks working
engineers and how they feel about their
companies and the economy
What is
systems-driven development?
PLM is the best tool to create a
systems-engineering approach for complex products
Adhesives for making
electrical connections
Electrically conductive adhesives provide
durable bonds with conductive paths to suit
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VOLUME 84ISSUE 6APRIL 19, 2012
2
Trang 6The SR44 series is fully digital, and uses thyristors in all three motor
phases for controlled reduced voltage motor starting and stopping.
SR44s have an Automatic Application Setup that fully configures the
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RS# 103
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SCANNING FOR IDEAS
Roller-screw actuators use almost any motor
Sealed bearing cartridges are green and can handle the load
Predictive modeling can help manufacturers
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Trang 8www.rexnord.com
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RS# 104
Trang 9What’s new online machinedesign.com
Hot products from Design West
Engineering TV highlights the hottest new products from
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Instruments, the FSLBOT robot from Freescale, and the
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Motor sizing tool
Oriental Motor has a new online tool for sizing motors Users
supply parameters such as the basic type of application,
loads, friction coefficients, ball/leadscrew size, factors related
to transmission belts and pulleys, and device orientation The
program then calculates torque, speed, stopping accuracy,
and system inertia Find it at www.orientalmotor.com.
Plastics awards
The Society of Plastics Engineers is taking nominations
for its annual Automotive Innovation Awards It recognizes
technical achievements by vehicle engineers, as well as
innovative parts that provide benefits such as reducing
weight and cost or increasing safety Learn more at http://
speautomotive.com/inno.
FEA and motor efficiency
Cobham Technical Services has a new Web site (www.
motor-design-software.com) that helps engineers understand
how FEA can improve motor performance and efficiency
It explains the basics of electromagnetic FEA software and
covers topics such as magnetic gearing and linear motion.
Machine-safety book
The updated Fluid Power Safety for Machine Guarding book
is available from Ross Controls The book reflects the latest
safety standards such as ANSI B11.0-2010, ANSI/PMMI
B155.1-2010, and ANSI B11.19-2010, and also covers a wide
range of important safety issues, such as risk assessment,
control integrity, and press counterbalance Download or
order a free hard copy at www.rosscontrols.com.
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This detailed presentation will cover hybrid resins and glass reinforcements used for molding compounds that are
specifically designed for high-performance industrial applications IDI Composites International presents information
on resin formulations and thermoset compound manufacturing; Owens Corning discusses fiberglass-reinforcement
technology Learn more and register at http://machinedesign.com/training.
Medical-applications site
Mouser Electronics has launched its new Medical
Applications training site to help design engineers keep up to date on medical electronics, regulatory considerations, and medical-design trends It highlights devices ranging from telehealth monitors and digital stethoscopes to infusion pumps and pulse oximeters It also includes videos and design guides
Learn more at www.mouser.com/medical.
at next year’s bauma trade fair for construction and
mining equipment Learn more at
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Energy-savings calculator
Colfax Fluid Handling has a new online Energy
Savings Calculator for oil and gas-industry pump
applications The calculator, found at www.colfaxcorp.
com/oil-gas, permits head-to-head comparisons
between centrifugal and rotary displacement pumps in both single and multipump applications Users supply flow, pressure, viscosity, electricity costs, and pump type and efficiency, and the program projects annualized energy cost savings
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Trang 10` Increased precision and quality through
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RS# 105
Trang 11More hiring, less anxiety
Newswire headlines scream that hiring is back in a big way on college puses So for our annual salary-survey issue, it seems appropriate to check out this thesis for new engineering grads The schools we talked to report that prospects for engineers joining the workforce are indeed brighter than they have been in recent years, though some engineering disciplines are in hotter demand than others
cam-“We have seen a 20% increase in on-campus job interviews from last year,” says Georgia Tech Career Services Director Ralph Mobley “In 2011, 64.2% of our engineering graduates said they had a job lined up by our May commence-ment It is a little early to tell how that will go this year, but I think we will beat that figure based on interview activity.”
But more hiring hasn’t yet translated into bigger paychecks “My overall sense is that salaries aren’t going up,” says Mobley “The median salary in 2011 was $63,000 Though, if we have another year like this one, that figure is likely
a 90% rate They just didn’t have as many offers,” says U of T at Austin Career Center Director Michael Powell “Last year recruiting went up about 20% across the board and students got more opportunities for full-time employment and internships This year is similar, though the increase in recruiting visits isn’t as large.”
Powell says more than 94% of U of T at Austin engineering grads who wanted employment had found jobs six months after graduation last year, and
he expects that percentage to rise a bit for the school’s 1,400 newly graduated engineers this year
Finally, interesting statistics emerge from U of T at Austin’s tally of starting salaries for its 2010-11 graduates The top earner was someone with an MS in engineering management who walked away with a salary of $150,000 The low-est was $38,000 for a postdoc position that went to a biomedical Ph.D There was a tie for the highest BS-level salary: It was $105,000, earned by both an elec-trical engineer and a petroleum engineer
A confirmation that these sorts of salaries aren’t out of the ordinary comes from Cornell University College of Engineering Career Services Mark Savage
“Computer-science majors can walk away with multiple offers,” he says “A few have gotten six-figure salaries On average, those graduates probably earn
$15,000 more than those in other engineering areas.”
All in all, only 2% of Cornell’s 2011 graduating class of engineers (about 1,500) who wanted jobs were still looking six months after graduation Savage calls hiring in the mechanical-engineering area “stable.” But he thinks hiring
is “lagging” in civil engineering because many civil-engineering projects get funded by states, and many states have no money “I think it will come back eventually because of infrastructure needs,” he says But all things considered,
“We are not seeing a lot of hiring anxiety among students,” he says “It’s certainly nothing like what it was in 2009.”
— Leland Teschler, Editor
RS# 106
APRIL 19, 2012
Trang 12RS# 107
Trang 13For complete RFA4000 information, visit www.novotechnik.com/rfa
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EDITORIAL STAFF
EDITOR
Leland E Teschler leland.teschler@penton.com
MANAGING EDITOR
Kenneth J Korane ken.korane@penton.com
SENIOR EDITORS
Leslie Gordon leslie.gordon@penton.com Stephen J Mraz stephen.mraz@penton.com
1300 E 9th St Cleveland, OH 44114-1503
RS# 109 RS# 108
APRIL 19, 2012 MACHINE DESIGN.com
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Trang 14PELICAN PRODUCTS , INC
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RS# 110
Trang 15see how an employee performs, give them the rundown on a cur-rent problem you are facing and see how they approach it Make sure to emphasize that there are no right or wrong answers
Watch them and talk to them, periodically picking their brain, while they work out a solution
This will give you a glimpse into their capacity to think, their cre-ativity, aptitude in working with your company ’s produc t, and their temperament Plus, I always walk away from such interviews having learned something new
L.A Margagliano
M a ny ye a r s a g o, I w a s i n t e r viewed by a HR type who seemed
to me to be smug and pomp ous He asked if I was a plodder
-I told him that if -I were a plodder,
I would have gone into human resources I didn’t get the job
David Hunt
It seems the only purpose such questions fulfill is to take a mea-sure of just how many stupid, as-inine, and totally irrelevant-to-actual performance questions a candidate is willing to tolerate
This can be a useful skill as an engineer
Paul Richter
Thanks, but no to unions
The recent commentary (“ Time
for Engineers to Think About
Unionizing?” Jan 19) is right
about one thing; engineers do
have a reputation for
individual-ism and shy away from unions
But do unions offer better pay
and benefits? For the most part,
they do However, I look at unions
as placing a cap on my earnings
I can produce results and earn a
higher wage in a nonunion
com-pany Also, as a former union
em-ployee (U. S Steel Workers), I was
unable to perform even the
easi-est multitasking job I could only
do one thing at a time, which was
inefficient and boring to say the
least This was not an option for
someone who likes to create
In my position today within a
large organization of 25,000
em-ployee’s worldwide, I feel like an
entrepreneur as I can respond
to various situations without
fearing reprisal from colleagues
concerned only with job
preser-vation and working at a minimal
pace Besides, unions are
noto-rious for protecting
less-than-q u a l i f i e d o r d e re l i c t wo r k e r s
simply because they are union
members
I’ll take my chances in the
non-union masses any day and
pro-tect my hard-earned money from
being used by union manage
-ment to support their wealthy
lifestyle and political interests
that are not always in tune with
the average union worker
Unions are a racket, just like
a ny o t h e r o r g a n i z a t i o n w i t h
power They want to preserve the
power within their small group
of people They are not
necessar-ily looking out for the workers as
they should be
Mike Zupkofska
Odd job interview
If I caught one of my managers
asking those type of questions
(“How to Ace an Engineering Job
Interview,” Jan 19), I would escort
them to the door If you want to
No skilled U S workers and engineers?
The lack of qualified engineers and designers has nothing to do with academics (“Why does the U. S lack skilled workers?” Blog entry)
U. S manufacturer ’s don’t pay and education costs are rival-ing the housing bubble Hence, the cream of the crop use their engineering degrees to work on Wall Street where they can make
a living wage Want proof, you say? At my company, there are newly minted MIT graduate en-gineers who are forced to share a two-bedroom apartment among three renters
Lawrence Margagliano
I used to t h i n k t h e d u m b i n g down of public-school systems was a result of misguided but good intentions But things are becoming so bad you have to wonder if it isn’t intentional The biggest threat to a king’s power
-is not posed by other kings, but rather his subjects becoming fit
to rule themselves Perhaps this
is all a ploy to mitigate the threat that an educated and capable (i.e., independent and critical-thinking) pubic pose to those who want to rule them I doubt
it is really intended to dumb
ev-Unions, interviews, and worker shortages
R e a d e r s d o n’t l i k e unions, don’t care for off-target questions during job interviews, and don’t fully believe there’s a shortage of engineers or skilled workers in the U. S
Those readers who
do agree that the U. S
lacks skilled workers, point the ger at companies that refuse to do any employee training or pay com-mensurate wages and an education system that tries to get everyone into college
fin-APRIL 19, 2012 MACHINE DESIGN.com
12
Trang 16Touch It! We’ll Send You a Sample
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Trang 17Dedicated to the Science of Motion
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LETTERS
600 qualified applicants every time we have an entry-level ap-prenticeship opening, absolutely unheard of ever before And the part-time worker at Home De -pot that sells me conduit fittings
is a mechanical engineer with
18 years experience (His ous company shut down its U. S operations.) Unemployment is at record highs
prThere appears to be little dence indicating a lack of skilled
U. S workers, but plenty of dence pointing to a cover story trying to justify giving U. S jobs
evi-to other countries Perhaps, as one previous letter writer said, the problem developed when
p u re gre e d a n d a m b i t i o n re placed skill, responsibility and plain old common sense as job requirements for managers and corporate bigwigs
-Barb Daniels
The problem with our current system is that the schools try to prepare ever yone for college
The fact is that on average only
10 to 20% of high-school grads continue on to college, and only 10% of those make it through college In other words, our cur-rent system works for 1 to 2% of the students You would think someone, especially educators, would realize this and change it
Another contributing lem is that most current high schools don’t teach basic per-sonal-finance skills Guess what the number one reason is for quitting college? Finances
eryone down, but it does make
you wonder if there isn’t a grain
of truth in there somewhere
Mark Willis
As a former teacher, it seems to me
that what we in the U. S need to
learn is that it’s a waste of time
and energy to try to turn all
high-s c h o o l high-s t u d e n t high-s i n to co l l e g e
students Instead, we need to
take a more European approach
in which high schoolers are put
into tracks based on their
capa-bilities, aptitudes, and desires
That way, some go to college and
others pursue vocational
train-ing Each student gets what they
need to be successful and will
be ready to enter the workforce
And don’t forget those in jobs
us-ing vo-tech skills can earn just as
much or more than those with
jobs requiring college degrees
Just look at teachers compared
to plumbers or electricians
RS# 112 APRIL 19, 2012
MACHINE DESIGN.com
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RS# 113
Trang 19SCANNING FOR IDEAS
Edited by Stephen J Mraz Roller-screw actuators
use
almost any motor
Request free information via our Reader Service Web site at
www.machinedesign.com/
rsc
The new K Series actuators from Exlar, Chanhassen, Minn
(www.exlar.com), mount to most types of motor and are
available in several configurations and price points They
also have dimensions and form factors consistent with
ISO metric pneumatic cylinders, so they make good
re-placements for air cylinders, as well as hydraulic ones
The actuators’ corrosion-resistant, anodized aluminum
housings are sealed to provide IP65 protection
The units operate in
maximum allowable force ranges from 675 to 1,800 lb-in
There are four levels in the K Series The KT Series is for
high loads and cycle rates The KX Series provides high
performance in a range of demanding applications The
KM Series, like KT and KX Series, use roller screws, but the
KM actuators are the most economical of the roller-screw
actuators The KA Series use an Acme screw and works well
in applications that position and hold a load
RS# 401
Provisions to mount any motor NPT ports
Sealed output rod
Several rod ends are available
Standard cylinder mounts and T-slots for adding mounting attachments on all sides
Limit switch can
be mounted on any side
Roller screw
Belt and pulley drive with built-in tensioner
or in-line mount available
APRIL 19, 2012 MACHINE DESIGN.com
16
Trang 20!
)! *+ ,
RS# 114
Trang 21SCANNING FOR IDEAS
Sealed bearing cartridges
are green
and
can handle the load
Sealed bearing cartridges such as those
from GGB Bearing Technology, Thorofare,
N. J (www.ggbearings.com), are
cost-effec-tive, environmentally friendly alternatives to conventional bronze, hardened-steel, and rolling-element bearings The key compo-nent in the cartridge is the filament-wound
bearing, which can be made of either GAR-MAX or HSG, and each provides different operating ranges Being self-lubricating, the cartridge needs no grease, making the unit maintenance-free Cartridges are available to handle loads up
to 90,000 lb/in.2and come in sizes ranging from 1-in
ID with a 1.75-in
OD to 4-in ID with a 4.875-in
OD They modate shafts
accom-or pins ranging from 1 to 4 in (25 to 100 mm)
in diameter For best perfor-mance, the manu-facturer recom-mends shafts and pins have hardnesses greater than 50 Rc and surface finishes of 8
to 16 μin after plating The manufacturers also mend potential users consult them for engineering support
recom-The cartridges are sealed, so contaminants are not
a problem And because they are not metal, there is
no galling of the shaft or pin, or corrosion The sionally stable cartridges absorb little water and do not swell The units also withstand shocks and edge loading
Industry-APRIL 19, 2012 MACHINE DESIGN.com
18
Trang 232012 2011 2010 2009 2008 2007
how-$83,770 in 2010 to $86,615 in 2011
But that number is simply the average of all responses, including those just starting out, those with 30 years of experience, and even a few retired engineers who are still in it for fun (We exclude unem-ployed respondents when we calculate the number) The more-inter-esting and insightful numbers come from drilling down to compare salaries by years of experience, industry, job titles, and geographical regions
This year, in addition to analyzing results from the current year, we decided to look at the last six years of salary data to see how salaries have trended over that time span What we found is good news for engineers generally: No matter which way you analyze the numbers,
article/salary-survey-Engineering
salaries
STAYING AHEAD OF THE CURVE
With a couple bumps along the way, average salaries of MACHINE DESIGN survey respondents have grown since 2007.
For design engineers, project engineers, and those involved in R&D, who make up the bulk of our annual surveys, average salaries have gone up 6.4% over the last six years How do you compare?
APRIL 19, 2012 MACHINE DESIGN.com
20
Trang 242010 2009
Fabricated-metal-product manufacturing Electrical equipment, appliance, and component manufacturing Computer and electronic-product manufacturing
salaries are trending up, for all job
titles and in all industries It’s the rate
of growth that differs, of course, in
sometimes surprising ways
2012 results
In light of engineering salaries
creeping upward, it probably should
come as no surprise that only 28% of
respondents reported their salaries
were the same as last year Fifty-nine
percent reported a 1 to 5% increase
and 6% reported a 6 to 10% bump A
total of 4% say their salary dropped
in 2011 Sixty-six percent received a
bonus, overtime, or special
compen-sation last year which amounted to 1
to 5% of annual base pay for 43% of
respondents
The top three reasons
respon-dents would consider changing jobs
are also unsurprising: Most would
take another position for more pay
(73%), better balance between work
and home life (48%), or more
vaca-tion time (23%) When asked how
employers could improve work-life
balance, 46% said working from
home would accomplish this goal
and 39% said more flexible work
hours would help
It was also interesting to hear
re-spondents’ views on entrepreneurship
in the current environment where
everyone from the U. S President on
down to the local community
col-lege chancellor celebrates new
start-ups Sixty-five percent of respondents
claim to have considered becoming
self-employed But many feel they
lack the tools and skills to succeed, or
aren’t willing to give up the benefits of
Senior engineers, chief engineers, lead engineers, and principal engineers are making more money than their juniors, and the rate of growth in salary over the last six years is healthy as well,
up 9% since 2007.
It pays to rise through the ranks in the engineering department Not only are salaries for technical directors, director of engineering, and engineering managers high, they have grown 35% since 2007
to an average of
$111,330.
Transportation-equipment makers had the biggest growth in average salary over the last six years compared to other industries, with salaries increasing by 18.4%.
APRIL 19, 2012 MACHINE DESIGN.com 21
Trang 25Average salary by title (2012)
Consulting engineer, scientist Test engineer
Manufacturing, production engineer Systems engineer, applications engineer Design engineer, project engineer, R&D engineer
QC evaluation test manager Hardware or software engineer Applications, systems engineering manager Chief engineer, senior engineer, lead engineer, principal engineer Group leader, project team leader, project manager
Technical director, director of engineering, R&D engineering manager Department head, section head
Vice president, vice president of engineering President, owner, CEO, other executive management
a steady paycheck and health care A handful of respondents had previously been self-employed and went back to the office grind We had too few of these responses
to draw meaningful conclusions about why they threw in the entrepreneurial towel But typical explanations included because their companies had been bought, they wanted stability, or start-up costs and investments were too high
Looking to the future, 63% see economic conditions improving this year, but they remain split on whether any economic recovery has taken place Forty-nine percent say their employer has recovered financially from the recession Yet 49% say the current economy makes them unsure of their own job’s stability In re-sponse to the economy, 63% have cut back on spending, 56% are updating their resumes, and 26% are actively looking for new jobs
Growing industries
We looked at average salaries by industry in 2007 and compared the stats to results from 2012, then calculated the growth in average salaries RS# 116
It pays to be the boss Salaries are highest for those with the most seniority including president and CEO, vice president, and technical director
or director of engineering.
Average salaries don’t follow a natural progression
of rising with more experience according to our results this year.
APRIL 19, 2012
Trang 26Salaries by industry
0 $20,000 $40,000 $60,000 $80,000 $100,000
Computer and electronic-product manufacturing
Electrical equipment, appliance, and component manufacturing
for each industry In 2007, one of the highest paid industries was
medi-cal equipment and supplies manufacturing At the time, we might have
predicted that medical manufacturing was a recessionproof industry,
as “everyone gets sick.” While salaries did grow in the industry by 6.8%
from 2007 to 2012, this was among the smallest growth rates compared
to those of other industries For example, our numbers show that salaries
rose by 15.6% in the machinery manufacturing segment and by a
whop-ping 18.4% in transportation-equipment manufacturing Also showing
outstanding growth between 2007 and 2012 were salaries in electrical
equipment, appliance, and component manufacturing, which all grew
by 12.3%, and salaries in computer and electronic manufacturing, which
grew by 14.4%
It’s hard to say what factors account for these numbers Do rising oil prices
affect salaries in transportation-equipment manufacturing? And has
down-sizing and offshoring in the electronic-manufacturing sector left those who
RS# 117
The industry with the highest average salary this year is computer and
electronic-product manufacturing, followed closely by
APRIL 19, 2012
Trang 27Quantities from 1 piece
to small production runs
still work in those positions more valuable, therefore higher paid? Let us know what you think
Finding jobs
For the last five years, we’ve asked readers how they found their current jobs The most common answer is consistently, “Tip from a friend or family mem-ber,” accounting for 23% of responses in 2012 and 29% of responses in 2008 The lesson here is that it pays to let everyone know what you do for a living and whether you are looking for new opportunities
Surprisingly, a lot of people still find jobs through newspaper listings This mode of job search has not fallen off much in the last five years despite news-paper readership itself dwindling In 2008, 12% of respondents found jobs in newspapers In 2012, 13% profited from this option One explanation: It is pos-sible those who chose this answer have not switched jobs recently
The percentage of engineers finding jobs online has risen over the last five years In 2008, 10% said they found job openings through online listings or job boards, and that number has grown annually, standing at 13% in 2012 The number of engineers finding listings on company Web sites has grown as well, from 3.6% in 2008 to 4.2% in 2012 In 2011 we added a question to see if any-
one found jobs from social media sites such as LinkedIn, Twitter, or Facebook
In 2011 the response was a big fat zero In 2012, we received five responses, or 0.6% Will these numbers rise again in 2013? It’s hard to predict, but as more young people enter the field, and as recruiters increasingly turn to sites such as
LinkedIn, responses that currently include “call from a headhunter,”
“network-ing,” and “tip from a friend” will no doubt point job seekers to online listings
Typical respondent
Seventy percent of those who filled out the survey have neering backgrounds Fourteen percent have electrical/electronic backgrounds and 2% have a materials background
mechanical-engi-Ninety-five percent of respondents are male, and 45% live in the North tral region of the U. S., which includes much of the Midwest We received the most responses from people with design engineer, project engineer, or R&D engineer titles
Cen-Twenty-nine percent of respondents have 20 to 29 years of experience, lowed closely by 10 to 19 years (25%), and those with 1 to 9 years of experience account for 21% of responses, which may explain why the overall average salary remained flat compared to years past MD
fol-RS# 118
As in previous surveys, the coastal regions of the U. S
earn higher average salaries.
APRIL 19, 2012 MACHINE DESIGN.com
24
Trang 28Accelerating Your Success.™
People Products Services The powerful combination of Avnet and
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RS# 119
Trang 29Thousands of enclosures
Hundreds of sizes
Next-day shipping
REPORTER’S NOTEBOOK
Machine Design added several questions to its annual
salary survey to see how engineers and their employees
are faring in this economy We also asked engineers how
companies could make their jobs more enjoyable if not
easier
What engineers don’t like
When it comes to annoying issues, engineers seem
to share many complaints with nonengineering
profes-sionals and workers The most common of these is poor
compensation (24%) and long hours (17%), not enough
people to get the job done (38%), lack of management
support (23%), and no potential for advancement (25%)
Completed a project milestone Company profit sharing Personal performance
Authored by:
Stephen J MrazSenior Editor
stephen.mraz@
penton.com
Trang 30Respondents didn’t have many
en-gineering-specific gripes The most
notable were: too much
nonengi-neering work (33%), uncertainty in
the engineering job market (19%),
time-to-market pressures (15%),
having to compromise on designs
(14%), and difficulty finding the best
components (3%)
We asked readers how their ployers had reacted to the economic uncertainty over the past three years
em-On one hand, some stats indicate things are going well Most engineers (57%) say they received raises and that their employers hired more en-gineers (49%), as well as more man-ufacturing workers (37%) and sup-
port personnel (32%) Other stats, however, are not as optimistic A fifth
of the respondents (21%) didn’t ceive their traditional bonus, more than a tenth (12%) had their salaries cut, more than half (52%) experi-enced a bump in health-care costs while a fifth (21%) had benefits such
re-as tuition reimbursement and 401k
What perks does your company provide?
Other Day care or day-care subsidy Certification reimbursement Sabbatical or extended vacation Health-club membership Company car or allowance Further education/training Stock-purchase plan Stock options Phone, fax, cable modem, or DSL line 401k match
Tuition reimbursement Health benefits
0 5% 10% 15% 20% 25% 30% 35% 40%
What bothers you most about your job as an engineer?
Other
Having to compromise design approaches
Finding the best components for a design
Not enough people to do the job
Not enough funding for projects
Time-to-market pressures
No potential for advancement
Uncertainty in job market
Too much nonengineering work
Long hours
Poor compensation It seems many
respondents say they are underpaid (24%) and overworked (38%) A significant number (25%) also find there is little chance for advancement in engineering.
RS# 120
Trang 31Our New Standard in Geared AC Motors
• 2 Times More Torque
• High Strength, Long Life
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REPORTER’S NOTEBOOK
matching funds, cut And almost half (45%) saw workers laid off So the engineering landscape is hardly ho-mogenous Some areas an industries are doing well, while others struggle
That perfect job
When asked what it would take
to get them to change jobs, neers went for the money The vast
engi-majority said they’d do it for a bigger salary (72%), a large signing bonus (15%), or more vacation time (23%) The most critical factor for others (49%) was the desire for a better bal-ance between work and home life, and it’s doubtful they want to spend more time at the office (More on this later) Some respondents seem
to want that prefect new job to
Taking continuing education classes Considering starting my own business Actively looking for a new job Cutting back on spending Updating my resume
0 10% 20% 30% 40% 50% 60%
How long were you out of work?
No
Yes
Have you been unemployed in the past three years?
Over 25 months
19 to 24 months
13 to 18 months
6 to 12 months Less than 6 months
Is your company positioned to recover?
No
Yes
Will the economic conditions in the overall marketplace improve in 2012?
Other
I see no indications we’ll recover soon
We have a 50/50 chance to recover I’m optimistic we’ll recover Yes, we’re already recovering
Engineers have fared better than the general public when it comes to unemployment, but then unemployment among college grads has always been much less than among the general public (about 4 to 5% instead of 8 to 12%) They also seem to have it easier in finding another job once unemployed Still 5% of those taking the survey have been out of work for over two years.
RS# 121
APRIL 19, 2012
Trang 32Brushless Motor Advantages
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nificantly change their lives Many
clearly wanted a complete career
change (15%), while others wanted
to relocate (11%), get more
responsi-bility (15%), or work with new
tech-nologies (18%) And a few engineers
(5%), hopefully the more junior ones,
say all it would take to get them to
switch companies is a new title
So what would it take to balance
work and home life? The most
pop-ular responses were being allowed
to work from home (46%), flexible
work hours (40%), and fewer hours
or less overtime (28%) Another ular answer, on-site exercise facilities (22%), seems more like a perk than a way to balance work and home life
pop-Others want more time to spend cializing with coworkers (9%) Ad-ditional responses included less travel (10%), options for part-time employment (5%), on-site day care (4%), and shared transportation such
so-as reimbursement for public transit, carpool coordination, and company vans that pick up and deliver employ-ees to work (5%) MD
My skills are too specialized
I don’t know where to start I’m an engineer, not a business owner Not interested in working for myself
Which of these has your company
done over the last three years?
None of these
Hired support personnel
Hired manufacturing personnel
Hired engineers
Laid off more than 20 of the workers
Laid off 11 to 20 of the workers
Laid off up to 10 of the workers
Reduced nonhealth care benefits
Increased worker contributions for health care
Cut executive pay or bonuses
Withheld traditional bonuses
Forced use of vacation time
Cut salaries by cutting work hours or using furloughs
Reduced salaries
Raised salaries The last three years
have been tough and companies have taken strong steps
to stay profitable
Still the majority
of respondents say they’ve had salary increases But 12%
say salaries have gone down, 21% say traditional bonuses have disappeared, over half (52% say they’re paying more for health insurance, and 45%
have seen at least
a 10% reduction
in workers at the places they work.
RS# 122 APRIL 19, 2012
Trang 33Get the Original from Avago Technologies!
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RS# 123
Trang 34High-Precision Ball Screws
Precisely The Way You Want Them
Get Your Free Catalog Steinmeyer-USA.com/ballscrews
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• Advanced manufacturing technology
Called Stress Wave Energy (SWE) analysis, the new technique differs
from traditional vibration analysis in the type of vibrations it monitors The
SWE approach is based on high-frequency, structure-borne sound rather
than machine vibrations, so it filters out noise (unwanted signals)
gener-ated by the machine’s normal motions Instead, SWE looks at the amount
of friction and level of impacts Once it detects an impact, its energy
con-tent is measured to establish a trend that predicts how the machinery will
deteriorate over time
In one case, an SWE sensor combined with an artificial-intelligence
monitor demonstrated accurate diagnostics for a helicopter gearbox SWE
results caused by 10 intentionally set faults led SWE to predict a 100%
probability that technicians could find gear or bearing damage after
an-other hour of operation Further testing on healthy machinery showed
that the false-alarm rate was below 0.1% during 1,000 hr of operation In
addition to detecting faults, the software developed for the StressWave
system can locate a fault, isolate its cause to either a gear or a bearing,
dis-play the percent degradation, and estimate the remaining useful life
Another demonstration was carried out on airport surface-detection
equipment (ASDE) The mechanical drive of an ASDE-3 radar antenna uses
a motor with an intermediate shaft linked to a main shaft While originally
designed as intermittent-use radar, the ASDE-3 now works 24/7
Acoustic waves reveal
potential mechanical failures
The StressWave System from Curtiss-Wright, Parsippany, N. J., tracks stress-wave energy to predict possible problems or defects in mechanical equipment used in radar antennas The system monitors friction and impacts, while filtering out the machine’s normal motions and vibrations.
vibra-tion analysis does
not clearly
analy-sis cannot tell if
vibrations are due
friction and shock
Acoustic waves…continued on page 33
RS# 125 APRIL 19, 2012
Trang 35UPTIME, ALL THE TIME
EPIC ® connectors can stop electrical failures before they stop your packaging lines.
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RS# 126
Trang 36Ultra-High-Performance Stages
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REPORTER’S NOTEBOOK
The light used was unpolarized, broadband illumination from 21
tungsten halogen lamps with a color temperature of 3,050 K The lamps
generated an illumination power density of about 30 W/cm2
Nearby nanowires that did not overlap did not weld together, nor was
the material the wires were laying on affected The new technique could
lead to new ways to make nanowire meshes bound to flexible and
trans-parent polymers and plastics To test that theory, researchers sprayed a
solution containing silver nanowires onto a sheet of Saran Wrap After
shining the lamps on treated Saran Wrap, the engineers ended up with
a thin web of welded nanowires connected to the flexible Saran Wrap
They crumpled then unfurled the plastic sheet, and found that the web
maintained its electrical properties In other words, the wires and
con-nections were flexible The engineers note that trying to replicate the
effect using heat to weld the wires would have melted the Saran Wrap
before the wires were fused
Researchers predict this technique for building meshes could lead to
window coatings that generate electricity from solar radiation while
re-ducing glare inside It could also lead to low-cost, large-scale techniques
for nanowiring LEDs, solar cells, ICs, and touchscreen displays MD
Welding
nanowires with
ordinary light
A group of nanowires were
welded together using
nothing but a bright burst
of light Photo: Stanford
Researchers at Stanford University have discovered a way to weld metal
nanowires together using nothing but relatively ordinary light They
found that by placing one nanowire touching another, then shining a
light on them, creates waves of light, also called plasmon waves These
waves create hot spots wherever the nanowires touch The hot spot fuses
the two metal wires together This action also eliminates the hot spot as
the plasmon waves now treat the two wires as one So the welding is
self-limiting and stops itself
Two prognostics sensors with bolt-on mounts were placed on the
inter-mediate shaft to detect SWE from the bearings at the bottom and top of
the shaft While initial readings were in the green zone, the measurement
climbed into the yellow zone after 30 days of operation, indicating an
early stage fault At 60 days, SWE data remained approximately the same
as at 30 days, indicating the damage had progressed no further In this
case, the prognostics tools led maintenance personnel to be aware of the
developing fault, but didn’t require taking the equipment out of service
until the next scheduled maintenance.MD
Acoustic waves…continued from page 31
RS# 127 APRIL 19, 2012
Trang 37Software lets aircraft fly through
production: After Korea’s three
major aerospace manufacturers —
Samsung, Hyundai, and Daewoo
— merged into Korea Aerospace
Industries (KAI), company
manag-ers took steps to improve
efficien-cies, reduce costs, and cut product-development
cycles They tapped Tecnomatix
eMPower to combine the aircraft manufacturer’s SAP R/3 enterprise resource-planning system, Meta-
phase product-data agement, and an in-house CAD/CAM system
man-“The goal is to get neering and production working together so we can simulate prod-ucts under development and the processes that will manufacture them,” said Kim Jung-Jin, a man-ager with KAI The new infrastruc-ture is already in place and will be used on a new helicopter project
engi-30 YEARS AGO — 1982
Safety button keeps plier jaws in place: Pliers have a spring-loaded
safety ton that keeps the tongue-and-groove segments
but-in the tion which they were originally set, even if the pliers are dropped Adjustments are made by pushing the button, letting the jaw move to a new po-
posi-sition Neverslip Tools Inc., Alvin,
Tex., makes the pliers in 10 and 12-in models
50 YEARS AGO — 1962
A transistorized desk calculator,
with no moving parts, is said to offer significant advantages over mechanical and electromechanical machines Designed for engineer-ing and business companies, the
CC 1200 calculator from Computron Corp., subsidiary Electrosolids Corp., Sylmar, Calif., adds, subtracts,
multiplies, divides, and reads out
an-swers with up to 16 digits Decimal point and sign are indicated auto-matically, and two problems can be worked simultaneously A memory feature stores and calls up constants
at the touch of a key MD
APRIL 19, 2012 MACHINE DESIGN.com
34
Trang 38Every 3.5 seconds, a Banner sensing solution is installed somewhere.
Being engineers, we’re trying to improve on that.
Solving automation challenges, one application at a time, for over 45 years
For nearly half a century, when industry has an automation challenge, they turn to Banner for solutions
And among the thousands of global sensing innovations engineered by Banner, many started as a
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Responses that have helped to create over 30,000 products and applications, with more on the way
Because at Banner, engineering is not just part of our name, it’s what we do Every second
bannerengineering.com
vision sensing wireless I/O lighting & indication
© 2012 Banner Engineering Corp
more sensors, more solutions
RS# 128
Trang 39Multiphysics tools let you build simulations that
accurately replicate the important characteristics
of your designs The key is the ability to include all
physical eff ects that exist in the real world Order a
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MAGNETIC BRAKING: Lorentz forces result in a braking
torque when a magnet is brought into the vicinity of a rotating
copper disk Shown are the eddy currents (arrow plot), and
electric potential fi eld on the disc and magnet.
REPORTER’S NOTEBOOK
COMPANY NEWS
TAKEOVER The Hirschmann Group, Fluorn-
Winzeln, Germany, has taken over
JauchSchmider GmbH KG The parent company, HM Holding GmbH, has established a new company, JS GmbH The submers-
ible single and multiple axes rotary tables and spindles for EDM of-fered by both companies will now
be combined The products are
supported by Hirschmann Engineering USA, based in
Schaumburg, Ill
SOFTWARE SELECTION OSAT Company will use Agilent Technologies’ Electromagnetic
Professional software, EMPro, and the Momentum 3D planar elec-tromagnetic simulator to design and simulate new antennas and circuits OSAT Co specializes in engineering analysis, testing, and inspection techniques Agilent Technologies Inc., Santa Clara, Calif., is a measurement company
in chemical analysis, life-sciences, electronics, and communications equipment
LASER ORDERED Jean Gallay SA, Geneva,
Switzerland, has ordered a
PARTNERSHIPS
Olympus Controls, Beaverton,
Oreg., is now an authorized
distrib-utor of Dunkermotor’s linear and
rotary motion control products
Dunkermotor is also partnering
with Motor Systems Inc., Milford,
Ohio, a high-tech distributor of
factory automation and control products Motor Systems will distribute Dunkermotor’s thrust-tube linear motors as well
motion-as its complete line of brushed and brushless-dc electric motors, gearmotors, and intelligent servo-motors
Laserdyne 795XL BeamDirector equipped with a fiber laser from
Prima Power Laserdyne,
Cham-plin, Minn Prima Power Laserdyne makes precision multiaxis laser machining systems Jean Gallay is known for its precision work in the aerospace and power-generation industries
RS# 129 APRIL 19, 2012 MACHINE DESIGN.com
36
Trang 40WHAT WE BRING TOGETHER
IS WHAT SETS US APART
You’re looking for proven solutions for your
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