Design Engineering January/February 2015

14 Inside Autodesk’s latest CAD in the Cloud design applications

28 Study reveals wide-spread 45

underemployment of engineering degree holders in Canada Toronto-made smart-bicycle gives directions and watches riders’ back in traffic

$10.00 | January/February 2015

Compensation map reveals average mechanical engineering salaries in major Canadian cities

PM 40069240

ENGINEERING Salary Guide

1-DES.indd 1

15-02-10 2:08 PM

Colour

is the new black.

Deliver it all – in black-and-white and colour – with the HP Designjet T3500 Production eMFP.1 The most productive large-format MFP2 offers advanced copy and scan features and low-cost, unattended operation. Built for rigorous IT demands and top security.

Find out more: hp.ca/newdesignjets

Prints up to E/A0 size

1. Compared with large-format colour MFPs under $25,000 USD. Based on the fastest-rated colour speeds as published by manufacturers as of January 2014.

Test methods vary.

2. Ibid

2-3-DES.indd 2

© 2015 Hewlett-Packard Development Company, L.P.

15-01-30 7:58 AM

any, L.P.

2-3-DES.indd 3

15-01-30 7:58 AM

X-life products from Schaeffler feature optimized roller geometries and raceway finishes that are so precise, their service life far exceeds the conventional standard — as much as 70% in the case of our cylindrical and spherical roller bearings.

Bottom line: Maximum efficiency for your gearboxes.

Only X-life. Only from Schaeffler.

Need more details?

Please contact us at 803-396-3644 or ads.ind@schaeffler.com www.schaeffler.ca

Superior-quality products.

Comprehensive reliable solutions.

Š2015

4-5-DES.indd 4

15-02-09 2:16 PM

r , d d

Contents | Volume 61, No. 01

IN THE NEWS

8

Linamar plans $500 billion expansion

8

RMT Robotics now Cimcorp Automation

8

Magellan signs $250M deal with P&WC

8

8

Waterloo researchers step closer to a viable Lithium-Sulphur battery UBC engineers develop cheap, hand-held biochemistry lab

10

Voxel8 unveils first multi-material 3D electronics printer

12

UofT engineer’s spray-on quantum dot process could lead to ubiquitous solar power

Columns

14

14 CAD Report Fusion 360 Ultimate and AutoCAD 360 manifest Autodesk’s noteworthy if shaky move toward CAD in the cloud 18 CAD Beat Midwestern Manufacturing’s pipelayer attachment benefits from 3D scanner’s accuracy 36 Motion Control Unorthodox dual gantry milling machine realizes 35 percent cycle time improvement for aerospace manufacturer

18

39 Idea Generator The latest industrial products including automation, fluid power and power transmission 45 Canadian Innovator Toronto-based Vanhawk’s smart-bike tracks performance, gives directions and notifies you if it’s stolen

20 24

Features READER SERVICES Annual Subscription Rate In Canada: $53.95 (1 year) $72.95 (2 year) Outside Canada: $101.95 (1 year) Single Copy In Canada: $10.00 Outside Canada: $22.00 Directory Rates In Canada: $28.00 Outside Canada: $46.00 Reader Service Contact Information ecallaghan@bizinfogroup.ca Toronto: 416 442 5600 X 3538 Elsewhere: 1-866-543-7888 Mail: Annex Publishing & Printing Inc. Design Engineering Circulation Dept 80 Valleybrook Drive North York, ON M3B 2S9 Printed in Canada

www.design-engineering.com

4-5-DES.indd 5

5

30

20 The IIoT Challenge Evolving to the Industrial Internet of Things will require a platform-based design, an open architecture and real-time Ethernet 24 A Proactive Approach Maintaining safety in industries with hazardous locations starts with the design and operation of the equipment used

28 34

28 Canada’s Engineering Underemployment Crisis OSPE study finds a high number of engineering graduates in Canada work in positions that don’t require university degree 30 A Question of Experience University co-op programs provide the key to opening Canada’s deadlocked engineering labor market 34 Engineering Salary Guide Compensation map reveals average mechanical engineering salaries across Canada

45 36 January/February | 2015

15-02-10 2:09 PM

6 EditorialViewpoint

Made in Canada

www.design-engineering.com

Y

ou can’t get experience without a job and you can’t get a job without experience.

This old truism has been repeated many times by those entering the job market for the first time or transitioning to a new career. And for most jobs, being under-qualified isn’t the end of the world. In the licensed professions,however, where day-to-day decisions may have disastrous consequences if made by the unqualified, moxie doesn’t cut it. Most aspiring professionals must complete some form of on-the-job apprenticeship to practice.

After two years of medical school, for example, would-be doctors begin a supervised internship followed by several years of residency before they’re considered full physicians. Similarly, Canadian law school grads are required to article for two years before becoming licensed to practice law. Even nurses and teachers typically have an internship as part of their education.

For would-be engineers, however, a structured apprenticeship isn’t necessarily a component of their education. With a few notable exceptions (e.g. University of Waterloo), most engineering departments offer optional and highly competitive co-op or intern programs. For those who don’t land a co-op position, their job prospects after graduation may be significantly diminished. According to the Ontario Society of Professional Engineers’ 2014 study From Classroom to Career: A Snapshot of Employment and Underemployment Among Ontario’s Engineering Graduates, employers surveyed for the report, “overwhelmingly prefer to hire engineering graduates that have co-op experience.”

In a balanced or supply-surplus labor market, such a meritocratic co-op/internship process would be preferable, as only top students would have a high likelihood of becoming engineers. But as multiple articles and studies have found, employers are frustrated by a growing shortage of experienced engineers.

The Engineering Labour Market in Canada: Projections to 2020—a 2012 study conducted by Engineers Canada and Randstad Engineering—points to “market imbalances” in which “an abundance of Canadians seeking work as engineers coexists with an acute shortage of engineering skills.” At the same time, the report projects that large numbers of engineers will reach retirement age over the next decade and “account for over 95,000 job openings…Managing this process and recruiting to meet this replacement demand is a priority.”

Bringing in experienced engineers from other countries hasn’t helped to fix things.

OSPE’s 2014 study Crisis in Ontario’s Engineering Labour Market: Underemployment Among Ontario’s Engineering-Degree Holders, found that in Canada, “just over 20 per cent of women and internationally trained engineers (ITEs) with engineering degrees actually work as engineers or engineering managers.” In earlier studies, OSPE research found that most Canadian employers have difficulty assessing the relevancy and quality of ITE’s previous, non-Canadian experience.

So with Baby Boomer engineers set to retire combined with the surplus of engineering graduates and internationally trained engineers who lack relevant experience, it’s up to employers to step up. No matter the industry, they need to engage in “bridging” programs for internationally trained engineers or co-op/internships for engineering undergrads, so that, five years from now, there are ample candidates available to fill those positions. Or, as OSPE CEO Sandro Perruzza succinctly asks in this issue’s feature “A Question of Experience” (p.30), “How much longer do you have to wait before you realize that it’s better to develop your own talent?”

Mike McLeod

@

Publisher Alan Macpherson (416) 510-6756 AMacPherson@design-engineering.com Accounts Manager Taebah Khan (416) 510-5230 tkhan@design-engineering.com Technical Field Editor Pat Jones, P. Eng. Art Director Kathy Smith (416) 442-5600 ext. 3215 KSmith@plant.ca Market Production Manager Cheryl Fisher (416) 510-5194 CFisher@bizinfogroup.ca Circulation Manager Mary Garufi (416) 442-5600 ext. 3545 MGarufi@bizinfogroup.ca Annex Publishing & Printing Inc. President & CEO Mike Fredericks mfredericks@annexweb.com Vice President Annex Business Media East Tim Dimopoulos (416) 510-5100 tdimopoulos@canadianmanufacturing.com Publications Mail Agreement #40069240 ISSN: 0011-9342 (Print), 1929-6452 (Online) Privacy Notice: From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 E-mail: privacyofficer@businessinformationgroup.ca.

Mail to: Privacy Officer, 80 Valleybrook Drive, North York, ON M3B 2S9 Subscriber Services: To subscribe, renew your subscription or to change your address or information contact us at 1-800-387-0273 ext.3552. Subscription Price: Canada: $53.95 for 1 year; $72.95 for 2 years; $10 for single copy. Outside Canada: $101.95 for 1 year; $22 for single copy. Directory/buyer’s guide: Canada $28; Outside Canada $46.

Design Engineering, established in 1955, is published

by Annex Publishing & Printing Inc., 6 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues.

Tel: 416-442-5600, Fax: 416-510-5140 80 Valleybrook Dr., Toronto, ON M3B 2S9.

Contents of this publication are protected by copyright and must not be reprinted in whole or in part without permission of the publisher. DE receives unsolicited features and materials (including letters to the editor) from time to time. DE, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. DE accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. DE is indexed in the Canadian Business Index by Micromedia Ltd., Toronto, and is available on-line in the Canadian Business & Current Affairs Database.

We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.

I enjoy hearing from you so please contact me at MMcLeod@design-engineering.com and your letter could be published in an upcoming issue.

January/February | 2015

6-7-DES.indd 6

Editor Michael McLeod (416) 442-5600 ext. 3231 mmcleod@design-engineering.com

www.design-engineering.com

15-02-10 2:11 PM

Get in gear! with Ironhorse gearboxes IronHorse worm gearboxes are manufactured using only the highest quality materials and are designed to withstand the toughest international and U.S. testing standards. Our gearboxes interface with C-face motors and provide reliable speed reduction, increased torque and dual load capabilities wherever it is needed.

Cast Iron Gearboxes

Cast-iron gearboxes are available with right-hand and dual (both right and left) output shafts, and hollow-bore outputs.

Features • • • • • • •

Three output types: Dual Shaft, Right Hand Shaft and Hollow Shaft Four frame sizes: 1.75”, 2.06”, 2.37”, 2.62” models with parallel or right-angle gear shafts Six ratios: 5:1, 10:1, 15:1, 20:1, 40:1, 60:1 One-piece cast iron gear box housing, 1045 carbon steel shaft Double-lipped embedded oil seals to prevent gearbox leakage Universally interchangeable compact design ensures easy OEM replacement One year warranty

Starting at:

$147.00 u.s.

NEW! Aluminum Gearboxes

Our new aluminum gearboxes are lightweight and durable, built with hardened steel worm shafts and hollow-bore outputs.

Features • • • • • • • •

Five frame sizes: 30, 40, 50, 63, 75 mm Two ratios: 10:1 to 100:1 (in most sizes) Input faces: 56C, 145TC, 182/4TC reversible design Aluminum alloy housing for lightweight design Two bearings on input and output shafts Double-lipped embedded oil seals to prevent gearbox leakage Multiple mounting holes for all angle mounts One year warranty

Starting at:

$88.00 u.s.

Orders over $49 get

FAST FREE SHIPPING

Our shipping policies make it easier than ever to order direct from the U.S.!

Research, price, buy at: www.automationdirect.com/power-transmission

Fast free standard shipping* is available for most orders over $49 U.S., and that includes the brokerage fees (when using an AutomationDirect nominated broker). Using our choice of carrier, we can reach most Canadian destinations within 2 to 3 days. Order by 6pm ET and in-stock orders ship the same day! *2-day free shipping does not apply to drop-ships, or orders requiring LTL transport, but those shipments can take advantage of our negotiated super-low flat rates (based on weight) that include brokerage fees.

See Web site for details and restrictions at: www.automationdirect.com/canada

For more information go to: www.AutomationDirect.com/Canada

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.

6-7-DES.indd 7

1-800-633-0405

the #1 value in automation

15-02-09 3:36 PM

8 DesignNews UP FRONT Linamar plans $500 billion expansion Canadian auto parts manufacturer Linamar Ltd. announced a $500-million expansion to its Ontario operations in January. The company says the expansion will help the company focus on producing lighter, more efficient transmission and power train parts.

To assist the company, the Ontario government will provide a $50-million grant added to a $50.7 million repayable loan from the Canadian government. The province’s grant to Linamar is the first from its 10-year, $2.5-billion Jobs and Prosperity Fund. The company said, the $101 million from the two governments will be used to purchase new equipment and fund product R&D. www.linamar.com

RMT Robotics now Cimcorp Automation Effective January 1, 2015, Grimsby, Ontario-based RMT Robotics, Ltd. has changed its name to Cimcorp Automation Ltd., a manufacturer and integrator of turnkey robotic gantry-based order fulfillment and tire handling solutions. Going forward, the company says it will use its combined resources to ramp up collaborative R&D initiatives and continue software development.

Cimcorp Oy was acquired by Kyoto, Japan-based Murata Machinery, Ltd. in 2014 to provide material handling solutions to a global client base. As outlined after the acquisition, both Muratec and Cimcorp—including its North American subsidiary—will continue business operations with no change to their current strategies. www.cimcorp.com

Magellan signs $250M deal with P&WC Magellan Aerospace has signed a 10-year agreement with Pratt & Whitney Canada for the supply of complex magnesium and aluminum castings.

Most of the castings will be produced by Magellan’s Haley, ON division.

Magellan, a manufacturer of aerospace engine and structure assemblies and components, said the $250-million agreement with the Montreal-based aerospace engine maker will provide revenue through 2023. In addition to the legacy casting programs, the agreement includes the production of castings for the PurePower engine family, which encompasses the Airbus A320neo, Mitsubishi Regional Jet and Bombardier CSeries programs. www.magellan.aero

January/February | 2015

8-13-DES.indd 8

Waterloo researchers step closer to a viable Lithium-Sulphur battery

C

hemistry researchers at Waterloo University announced a breakthrough in making lithium-sulphur (Li-S) batteries a feasible and better alternative to the lithium cobalt oxide cathode currently used in lithium-ion cells.

Sulphur is not only a cheaper, lighter and more abundant material, the researchers say, but Li-S also possesses a significantly higher energy density, opening the possibility of powering electric vehicles three times further than current cells. Such a battery would also lower the cost (and weight) of the most expensive EV component.

While the superiority of Li-S has been known for years, it also has major challenges. It’s main drawback has been that a sulphur cathode exhausts itself after only a few recharge cycles. Typically, the sulphur dissolves into the electrolyte solution as it’s reduced by incoming electrons to form polysulphides.

However, Chemistry Professor Linda Nazar and her research team in the Faculty of Science at the University of Waterloo discovered that ultra-thin nanosheets of manganese dioxide (MnO2) maintains the rechargable sulphur cathode.

Specifically, the researchers found the reaction is similar to the chemical process behind Wackenroder’s Solution discovered in 1845.

The oxygenated surface of the MnO2 nanosheet chemically recycles the sulphides in a two-step process involving a surface-bound intermediate, polythiosulfate. The result is a high-performance cathode that can recharge more than 2000 cycles.

“Very few researchers study or even teach sulphur chemistry anymore,” said Nazar, who also holds the Canada Research Chair in Solid State Energy Materials. “It’s ironic we had to look so far back in the literature to understand something that may so radically change our future.”

Postdoctoral research associate Xiao Liang, the lead author, and graduate students Connor Hart and Quan Pang also discovered that graphene oxide seems to work by a similar mechanism. They are currently investigating other oxides to find the best sulphur retaining material. www.uwaterloo.ca

UBC engineers develop cheap, hand-held biochemistry lab Engineers at the University of British Columbia’s Okanagan campus have developed a hand-sized biochemistry laboratory capable of detecting infectious diseases in microscopic drops of blood or the presence of chemical weapons and other biohazards.

Housed in a 3D printed enclosure, the small device integrates with a common smartphone to form an inexpensive and portable testing device that could be used in remote or resource-limited areas. www.design-engineering.com

15-02-05 1:52 PM

air cylinders More Sizes • More Styles • More Accessories Performance that Engineers havee Learned Learne to Trust 40” 35”

I

30”

's of 0 0 0 1 ave the They h p i h S o eady t tems R

! y a D Same ablechange r e t n I Totally e Now! d a r g p U

25” 20” 15” 10” 5” 0“

For the past 50 years, Clippard has been providing quality cylinders for thousands of applications around the world. Cylinders ble for millions of that are responsible s. Cylinders that production cycles. ding performance provide outstanding and payback.

513-521-4261 Cincinnati, OH

888-WAINBEE Wainbee Limited Mississauga, Ontario

8-13-DES.indd 9

the finest. fast!

On-li ne c make onfigurato s ord r simp ering le!

15-02-05 1:52 PM

| BK11-17USA |

10

DesignNews “It’s of great interest for use in can be manufactured for $5. In total, he places that do not have infrastructure says the cost of the entire laboratory for accurate testing in a timely fashcould be less than $100, potentially. ion,” says UBC professor, Homayoun In addition to the chip, Najjaran’s Najjaran, founder and principal engineering team also developed the investigator of the Advanced Control lab’s electronics. A rechargeable 3.7and Intelligent Systems (ACIS) Lab. volt battery supplies enough power to “To make it really valuable, you want manipulate the droplets of sample to be able to put the laboratory at the fluid. The device is monitored and point of care, and this system will do controlled via Bluetooth wireless comjust that.” mands from a smartphone.

The system uses several techPresently, the hand-held lab is simnologies developed by the (ACIS) ply a working prototype but researchlab. Foremost among them is a UBC’s smartphone lab prototype with, from left, Engineering ers are seeking an industry partner so digital microfluidic processor (i.e. Instructor Ali Ahmadi, PhD Candidate Mohamed Yafia they can refine the technology for lab-on-a-chip) that precisely con- Salem, Assoc. Prof. Homayoun Najjaran, and mechanical commercialization. In addition, the trols electrical fields to move sample engineering student Jessica Van Brummelen team is working with colleagues at droplets in and around a chip.

UBC, McGill University and other Typically, such chips are fabricated on glass wafers and cost $5 institutions — including Canada’s National Design Network apiece. In contrast, the UBC team’s lab-on-a-chip — developed in — to develop applications for the device. consultation with UBC professor of printmaking Briar Craig — uses Funding was provided by the Canada Foundation for Innoconductive ink screen-printed onto paper. This allows several yards vation (CFI) and the Natural Sciences and Engineering Research of the paper chips to be printed quickly and thereby reduces the Council (NSERC). The research also used UBC Okanagan’s price per chip. According to Najjaran, hundreds of the paper chips Applied Micro- and Nanosystems Facility, a laboratory supported Aurora-Where_the_Action_Is:Aurora 11/5/10 2:27 PM Page 1

by Western Economic Diversification Canada. www.ubc.ca

Voxel8 unveils first multi-material 3D electronics printer

Rod Ends and Spherical Bearings designed and manufactured to Aurora's exacting standards for quality and durability.

Registered and Certified to ISO-9001 and AS9100.

From economy commercial to aerospace approved, we've got it all !

Aurora Bearing Company 901 Aucutt Road Montgomery IL. 60538 Complete library of CAD drawings and 3D models available at:

w w w . a u r o r a b e a r i n g . c o m January/February | 2015

8-13-DES.indd 10

At CES 2015, Massachusettsbased start-up Voxel8 launched the world’s first electronics 3D printer, of the same name, capable of combining electronic components, conductive traces and polymer build material in a single print.

The creation of Dr. Jennifer Lewis, Wyss Professor of Biologically Inspired Engineering at Harvard University, the Voxel8 printer works the same as any FDM-style printer, depositing layers of PLA filament, stored in the machine’s base.

To that, the 3D printer adds a pneumatically driven, cartridge print head that dispenses conductive silver ink via a 250 micronwide nozzle. According to the company, the conductive ink dries quickly at room temperature and is 20,000x more conductive than the most conductive filled-thermoplastic filaments and more than 5000x more conductive than carbon-based inks.

The Voxel8 also features a removable build platform that allows designers to place electronic components (i.e. memory chip, LED, electric motor, etc) mid-build. After the platform is replaced, conductive ink connects the component leads to the rest of the circuit and the polymer encases the traces and components within the part.

For design, the Voxel8 developer kit was launched in conjunction with Project Wire, a browser-based application from www.design-engineering.com

15-02-05 1:52 PM

A

| BK11-17USA |

Cut I/O installation space up to 75 %.

The compact HD Bus Terminal series from Beckhoff.

The 12 mm I/O terminals offer 16 connection points.

The space-saving High Density Bus Terminals are available in various configurations, e.g.: 16 digital inputs 16 digital outputs 8 digital inputs + 8 digital outputs 8 digital inputs (2-wire technology) 8 digital outputs (2-wire technology)

www.beckhoff.ca/HD-BusTerminal

12 mm

High-Density Bus Terminals from Beckhoff: The first 16-channel terminals in a compact 12-mm terminal block format: Doubling of the packing density; increasing from 8 to 16 connection points Reduction in space requirements by 50 % or more Reduction in control cabinet size and assembly costs Wiring by means of tool-less assembly using direct plug-in technique Wide range of digital HD Bus Terminals Available for Beckhoff I/O systems in protection class IP 20: Bus Terminals and EtherCAT Terminals

IPC I/O Motion Automation

8-13-DES.indd 11

16-channel Bus Terminals Width: 48 mm

75 %

8-channel Bus Terminals Width: 96 mm

50 %

space saving

space saving

4-channel Bus Terminals Width: 192 mm Application example for 64 digital inputs or outputs

15-02-05 1:52 PM

12 DesignNews Autodesk. Developed specifically for the Voxel8, the online app imports 3D models and provides design tools to position wire placement and a library of standard electronic components.

The company is currently offering a limited release of the Developer’s Kit to ship in late 2015 for US$8,999. In addition to the printer and access to the Project Wire application, the initial release also includes cloud-based slicing software, four PLA filament spools, 10 conductive ink cartridges and one additional print bed. www.voxel8.co

UofT engineer’s spray-on quantum dot process could lead to ubiquitous solar power A researcher at the University of Toronto has invented a technique for spraying colloidal quantum dots (CQDs) — microscopic light-sensitive materials – onto flexible sheets of plastic film.

Illan Kramer, a post-doctoral fellow in UofT’s Edward S. Rogers Sr. Department of Electrical & Computer Engineering, says the new process is a major step toward making spray-on solar cells easy and cheap to manufacture.

“My dream is that one day you’ll have two technicians with Ghostbusters backpacks come to your house and spray your roof,” says Kramer.

Quantum dots are nanoscale bits of a semiconductor mate-

January/February | 2015

8-13-DES.indd 12

Dr. Illan Kramer and the sprayLD setup he designed to spray solar colloidal quantum dots onto flexible surfaces. (Photo credit: University of Toronto)

rial that can be tuned to capture and convert both visible and infrared light. Printed onto a flexible film, CQDs could be used to coat and produce power from nearly any surface. According to Kramer, a car roof wrapped with CQD-coated film, for example, could power three 100-Watt light bulbs.

Previously, producing CQD-coated surfaces required slow and expensive batch processing. Kramer’s technique, called sprayLD, applies a liquid containing CQDs directly onto film or plastic, similar to applying ink on a roll of news print. www.ece.utoronto.ca

www.design-engineering.com

15-02-05 1:52 PM

Ingenious solution, cabinet-free

Exactly

More exible and efficient automation with IndraDrive Mi With IndraDrive Mi, the intelligent drive system, you relocate the entire drive technology from the control cabinet straight into your machines. That saves space, sharply reduces the wiring costs and optimizes your energy balance. When combined with Ethernet-based communication and the integrated motion logic, you get the perfect all-round automation system – and with the most extensive certied safety functions. Utilize the exibility and intelligence of the IndraDrive Mi system for your route into Connected Industry.

IndraDrive Mi

Bosch Rexroth Canada 490 Prince Charles Drive South, Welland, ON L3B 5X7 www.boschrexroth.ca

8-13-DES.indd 13

15-02-05 1:52 PM

14 CADReport

A TURBULENT Ascent Fusion 360 Ultimate and AutoCAD 360 for Windows 8 manifest Autodesk’s noteworthy if somewhat shaky move toward CAD in the cloud.

By Ralph Grabowski

A

utodesk is doing a lot of different things these days as it hopes to ride atop another wave of success. It’s porting parts of its professional software to the cloud even as it makes consumer software that runs on 1.2 billion smartphones and tablets.

Which brings us to two recent offerings that are just that: Fusion 360 Ultimate will eventually become everything-and-thekitchen-sink for MCAD professionals, while AutoCAD 360 is like TinkerCAD for AutoCAD users. The two have one thing in common: Their prices are cheap compared to what we have come to expect from Autodesk.

Fusion 360 Ultimate Autodesk took a gamble when it wrote Inventor from scratch to compete against the Solidworks juggernaut. Previously, it had acquired its MCAD programs, such as The Engineer Works, AutoSurf/Designer, and Mechanical Desktop. Following the success of Inventor, Autodesk did it all over again with Fusion, its next generation MCAD program. Instead of developing it in secret like Inventor, however, Autodesk made the Fusion direct modeler a public beta by including it free with two releases of AutoCAD and Inventor.

Today, Fusion 360 is a stand-alone program. The name references the fusion of history-based and direct modeling, the fusion of desktop and server-based computing, and the fusion of code that works on two operating systems, Windows and OS X. Even though Autodesk likes to promote 360-branded products as running on the January/February | 2015

14-17-DES.indd 14

cloud, Fusion 360 runs primarily on the desktop: Local install, local computing and local file save. Only some operations are handed off to Autodesk’s servers, such as advanced rendering and file translation.

“We use server-side processing where appropriate, and local processes where appropriate,” explains Kevin Schneider, director of Fusion 360 at Autodesk.

There was a time when Apple was keen on high-end markets like engineering and film editing, but then switched focus to consumers. With a dearth of engineering software for Mac users, it comes as little surprise that Fusion 360 is popular there; 30% of Fusion 360 users are Apple customers, according to Mr Schneider.

More recently, Autodesk released an expanded version called Fusion 360 Ultimate that bundles together all the software that an MCAD designer might want. I am not sure why it was released in November, because the bundle today is sparse.

Autodesk is promising, however, to add more functions during this summer and beyond, and Fusion 360 Ultimate will be available for Macs in the near future.

As their respective feature sets stand today, here is the difference between the two programs: Fusion 360 ($300/yr) includes 2.5-axis machining and costs, while Fusion 360 Ultimate ($1,200/yr) includes 2.5- and 3-axis machining (so far). Autodesk lists the planned differences between the two programs at www.autodesk.com/products/ fusion-360/compare.

There is no large, up front perpetual license fee, as there is with Inventor.

Fusion 360 can also be rented month-tomonth for $40/mo, Fusion 360 Ultimate for $150/mo. It’s cheaper to go annual www.design-engineering.com

15-02-09 2:17 PM

CADReport 15

Figure 1: Fusion 360 Ultimate running on a Mac computer

after eight months. this year, they released a version for WinSo, what is planned for Fusion 360 dows 8.x (and 10), called AutoCAD 360, Ultimate? Schneider says Autodesk wants as a “Metro” app. This means that it its new MCAD software to address all the doesn’t work with Windows 7 (or earlier) ways of making things, such as 3D print- or with Windows Phone. Autodesk calls ing, composite machining, additive AutoCAD 360 a “portable DWG reader manufacturing, integrated electronics, and editor for AutoCAD,” and so I looked and custom products with short lifecycles. at how well it performs in each of those It currently handles 2-3-axis machining; areas.

5-axis will be added in mid-2015.

Also by the middle of 2015, Fusion 360 is a work in progress Fusion 360 gets more functions in several areas. Fusion currently and so I wouldn’t jump in just yet. It stores versions automatically, but bares watching to see if Autodesk will gain the ability to generate design variations by branching the can make good on its promise... base design. A sheet metal module will be brand-new to Fusion, and later in Portable: Portable it certainly is, as 2015 Autodesk will add simulation. there are versions of AutoCAD 360 writWhile it seems that Autodesk is writing ten for Android, iOS, Web browsers, and all of the add-ons, there will be some now Windows 8 tablets running Intel or third-party apps, such as rendering by ARM CPUs. I tested it on a 12-inch Sony Keyshot, a parts library and access to a tablet running Windows 10 pre-release, quoting system. with a dual-core 1.2GHz CPU and 4GB Fusion 360 is a work in progress and RAM. so I wouldn’t jump in just yet. It bares Being a Metro app, I needed to downwatching to see if Autodesk can make good load it from the Microsoft store, which on its promise to add all those new func- meant that I needed a Microsoft account. tions over the next half year.

To run the software, I also needed an Autodesk account. Upon starting it up, I AutoCAD 360 for Windows 8 found that the user interface accommoFor several years, Autodesk made simpli- dated my fingers through several large fied versions of AutoCAD for mobile icons. devices known as AutoCAD WS. Early Tapping one button gave me access to www.design-engineering.com

14-17-DES.indd 15

January/February | 2015

15-02-09 2:17 PM

16 CADReport or red), and undoing/redoing.

A slide-out panel accesses layer toggling, block insertion, views, properties and DesignFeed, Autodesk’s social media system.

DWG Reader: AutoCAD 360 opens files from Autodesk’s hosted service and from Dropbox, but not files stored on the tablet. Drawings are opened in 2D initially; switching between 2D and 3D views is slow, because the drawing is reloaded with each switch over.

When I checked DWG compatibility, I was dismayed at how badly AutoCAD 360 did. Nothing is filled in, and so wide polylines, solid hatch patterns, and even TrueType text are outlines.

The program does correctly display Figure 2: AutoCAD 360 for Windows 8 editing an object, with the layer toggle panel on the right. some objects, like traces and vertical text. Other objects are not displayed further functions. For instance, the Create button instance at all, draw order is ignored, and I had uneven luck in seeing draws lines, polylines and other 2D objects. I could not draw xrefs. in 3D mode. There are other buttons for placing markups, To be fair, the files most likely to be viewed on job sites are making measurements, specifying the color (just black, white, going to be 2D drawings that contain simple linework and

Absolut zuverlässig!

(Absolutely dependable!)

1 . 8 0 0 . 6 6 8 . 4 3 7 8 • w w w. n o r d . c o m

14-17-DES.indd 16

15-02-09 2:17 PM

CADReport 17 dimensions, and these display correctly.

Editor: The emphasis in AutoCAD 360 is on viewing, not editing, and so it was easy to pan 2D drawings with one finger, and zooming with two. In 3D mode, one finger rotates the model about a fixed point, two fingers zoom, and three pan.

There is no quick zoom-extents by double-tapping; instead, I had to access the side panel, which takes four taps.

was a problem exporting the drawing” with no further information. The Share option did allow me to email the DWG file.

The program recognizes CBT color tables, so the look of plots can be customized.

When I exited the drawing, all changes were saved, whether I wanted them saved or not. (Tip: To exit the drawing, click the Windows pancake button, and then choose App Commands.)

In addition to the free version of AutoCAD 360, there is a subscription-only Pro version that adds functions like Because AutoCAD 360 is free, it is worthwhile starting new drawings, displaying coordinates and someinstalling to see if it works with your drawings on thing called “advanced drawing and editing tools” whose your Windows 8 tablet. Avoid paying for the Pro benefits Autodesk doesn’t describe.

The Pro plan costs $50/yr, while Pro Plus is $100/yr to version until the many problems are fixed. give you 75GB more online storage and the ability to store and load drawings that are 33% larger than under Pro. Initially, I couldn’t find the editing commands; they were Because AutoCAD 360 is free, it is worthwhile installing hidden until I selected an entity. This free version of AutoCAD to see if it works with your drawings on your Windows 8 360 limited editing to move, copy, rotate, scale and delete. tablet. Avoid paying for the Pro version until the many probOnly blocks already in the file can be inserted; once inserted, lems are fixed.

DE however, I could not move them. Fortunately, editing can be www.autodesk.com done off-line, unlike some server-based programs.

AutoCAD 360 “plots” only to PDF and DWF files, which Ralph Grabowski is the author of 140 books on computer-aided are delivered by email. It cannot print to local or networked design, and a CAD journalist whose work appears on his blog, printers. When I tried plotting, the program complained “There worldcadaccess.typepad.com

German engineers wrote the book on dependability.

Around the globe discriminating designers and end-users know there is no substitute for NORD when it comes to dependability.

Wherever our products are deployed in demanding applications, industry places its trust in our precise German engineering.

They know we will never compromise on the reliability of our products. And that they won’t have to compromise either.

Choosing NORD is your guarantee of lasting performance.

You know our name and you’ve got our word on it.

I n n o vat I o n b e y o n d t h e o r d I n a r y

14-17-DES.indd 17

15-02-09 2:17 PM

18

CADBeat

Lowering the BOOM Midwestern Manufacturing’s pipelayer attachment benefits from 3D scanner’s accuracy.

I

n 1953, U.S.-based Midwestern Manufacturing introduced the world’s first hydraulically operated side boom pipelayer attachment. Over the past 50 years, these side booms have continuously set the highest standards for safety, reliability, ease of operation and cost-efficiency in the pipeline industry.

Midwestern side booms are engineered and manufactured to satisfy the requirements of each job and the needs of customers across the globe. The company converts new and used tractors into the industry’s most reliable pipelayers. It also provides some of the finest hydrostatic fill and test pumps and hydraulic tail-end mounted winches on the market. Midwestern’s side booms fit on Caterpillar, John Deere, Case and Komatsu tractors.

To accurately and efficiently design and integrate their side boom attachments onto a platform, however, Midwestern needed accurate and detailed 3D models. The main project involved the complete 3D scanning of the outside surface of a dozer (platform) along with detailed scans of the engine door, engine compartment, cab door and operator’s station. Some reverse engineering of the dozer (platform) also had to be performed January/February | 2015

18-19-DES.indd 18

Top: Creaform Application Engineer Pierre-Luc Delagrave scanning a bulldozer with the company’s MetraSCAN 210 optical CMM scanner.

The scanned 3D data (bottom) was used to design and integrate a side boom built by U.S.-based Midwestern Manufacturing. www.design-engineering.com

15-02-05 1:49 PM

CADBeat

19

in order to convert the scanned data into a detailed 3D model. provide a superior product in our industry and to remain the In the past, Midwestern used other technologies to create 3D world leader in side boom attachments,” he says. “This is espemodels; however, a higher level of details became necessary. As cially important in today’s world, where platform models are a result, using reverse engineering files with insufficient accuracy changing more rapidly than ever before.”

DE to manufacture side booms eventually caused fitting issues on www.sidebooms.com www.creaform3d.com tractors and additional project delays and costs.

Always looking to provide the best results to its clients within the shortest time frames possible, Midwestern obtained This article was provided by Creaform.

Creaform’s advanced 3D measurement solutions. For this specific project, the scan was performed inside Midwestern’s facilities using the MetraSCAN 210 optical CMM We drive automation for your success. scanner and the MaxSHOT 3D optical coorWe are your partner to inspire innovation. dinate measuring system. The dozer had to We shape the future together. be driven up onto railroad ties to elevate it and facilitate its scanning.

“Without the Creaform solutions, it would WE ARE THE ENGINEERS have been impossible to reach the level of accuOF PRODUCTIVITY. racy and the level of details we needed in order to manufacture a new, fully integrated side Festo Canada boom attachment that would allow optimum years 2015 functionality, visibility, accessibility, serviceability and safety,” said Doug Garner, vice president of engineering at Midwestern. “In addition, the fact that the files were so accurate minimized considerably the amount of modifications we had to apply to the platform.”

“The detailed 3D scans and 3D models allow us to accurately design and integrate our side boom attachment onto the existing platform,” he added. “It also allows us to completely visualize the design before final approval and production.”

Creaform’s technologies reduce the amount of engineering time actually spent to complete a project, which, in turn, allows Midwestern to focus on the actual side boom design. Therefore, from a financial perspective, these time savings help to reduce substantially the costs related to engineering and side boom attachment development. How much time did Midwestern save using Creaform’s technology?

40 years at the forefront “It’s hard to precisely say,” Garner explained. of industrial automation “It saves us a lot of time upfront since we don’t in Canada. have to physically measure and recreate the dozer (platform) in CAD. But more importantly, we gain a much higher level of detail and accuracy from the scan—all of which ultimate helps us optimize our design process.”

Garner described his experience with the Creaform technologies as providing amazing detail and accuracy.

“By using the 3D scanning technology and www.festo.ca reverse engineering process, we are able to

40

18-19-DES.indd 19

15-02-05 1:49 PM

20 Automation

The IIoT Challenge Evolving to the Industrial Internet of Things will require a platform-based design combined with an open architecture and real-time Ethernet.

By Brian Phillippi

T

he idea of a smarter world where systems with sensors and local processing are connected to share information is taking hold in every single industry. These systems will be connected on a global scale with users and each other to help users make more informed decisions. Many labels have been given to this overarching idea, but the most ubiquitous is the Internet of Things (IoT), including everything from smart homes, mobile fitness devices and connected toys to the Industrial Internet of Things (IIoT) encompassing smart agriculture, smart cities, smart factories and the smart grid.

IIoT can be characterized as a vast number of connected industrial systems that are communicating and coordinating their data analytics and actions to improve industrial performance and benefit society as a whole. Industrial systems that create an interface between the digital world and the physical world through sensors and actuators that solve complex control problems are commonly known as cyber-physical systems. These systems are being combined with Big Analog Data solutions to gain deeper insight through data and analytics.

Imagine industrial systems that can adjust to their own environments or even their own health. Instead of running to failure, machines schedule their own maintenance or, better yet, adjust their control algorithms dynamically to compensate for a worn part and then communicate that data to other January/February | 2015

20-23-DES.indd 20

machines and the people who rely on those machines. By making machines smarter through local processing and communication, the IIoT could solve problems in ways that were previously inconceivable. But, as innovation grows so does the complexity, which makes the IIoT a very large challenge that no company alone can meet.

This challenge becomes even more daunting and complex when comparing the requirements of the industrial Internet to those of the consumer Internet. Both involve connecting devices and systems all across the globe, but IIoT adds stricter requirements to its local networks for latency, determinism and bandwidth. When dealing with precision machines that can fail if timing is off by a millisecond, adhering to strict requirements becomes pivotal to the health and safety of the machine operators, the machines and the business.

Adaptability and Scalability As the IIoT comes to fruition, it will be a big change for historical industrial systems. The traditional design and augmentation of industrial systems are characterized by either (1) designing a proprietary or custom end-to-end solution or (2) adding functionality by repeatedly tacking on vendor-defined black boxes.

The tack-on solution can be quick to implement, but at what cost?

One of the biggest advantages of the IIoT is that data is easily shared and analyzed for better decision making.

For example, in a vendor-defined condition monitoring www.design-engineering.com

15-02-05 1:51 PM

20-23-DES.indd 21

15-02-05 1:51 PM

22 Automation solution, the data being acquired and analyzed is not easily flexible enough to evolve and adapt. The way forward involves available; the system is limited to sending simple alarms to a platform-based approach; a single flexible hardware architecprevent a catastrophic failure. Data may be available after an ture deployed across many applications removes a substantial event to analyze and determine what went wrong, but by then, amount of the hardware complexity and makes each new probtime, money and more may have been lost. If the condition lem primarily a software challenge. The same principle must monitoring data is not continuously analyzed and made avail- be applied to software tools to form a powerful hardwareable through an open, standardized interface, there is no pos- software platform that creates a unified solution. An effective sibility of adjusting control algorithms based on the data collected platform-based approach does not focus on hardware or software or correlating the collected data to control events to improve but instead on the innovation within the application itself. efficiency or prevent system downtime.

The opposite is true for end-to-end solutions. All By making machines smarter through local of the components and the end-to-end solution can work in harmony, but the underlying issue still remains. processing and communication, the IIoT could When an end-to-end solution is built, the communisolve problems in ways that were previously cation protocols are uniform and data can be shared inconceivable. But, as innovation grows so does easily.

But at that point, the solution itself essentially the complexity, which makes the IIoT a very large becomes the black box due to proprietary communicachallenge that no company alone can meet. tion protocols. As soon as an update is required, the engineer faces the dilemma of tacking on a solution that may not communicate well with the whole system or of Platforms to develop the IIoT exist today. The platforms starting the process over and creating a new end-to-end solution. that system designers choose need to be based on an IT-friendly IIoT systems need to be adaptive and scalable through software OS so they can be securely provisioned and configured to or added functionality that easily integrates into the overall properly authenticate and authorize users to maintain system solution. When the entire system is a black box, this cannot integrity and maximize system availability. These platforms occur. There has to be a better way to integrate disparate systems can achieve this through an open OS that helps security experts and reduce system complexity without sacrificing innovation. from around the world unite and develop the latest in embedded security.

Security and Maintenance These platforms also need to be based on standard Ethernet Adaptability and scalability are only the first of many challenges technologies and incorporate evolving standards to enable a presented by the IIoT. Systems management and security are more open and deterministic network that meets IIoT latency, also paramount. As massive networks of systems come online, determinism and bandwidth requirements while maximizing these systems need to communicate with each other and with interoperability between industrial systems providers and the the enterprise, often over vast distances. Both the systems and consumer IoT. the communications need to be secure, or millions of dollars’ Organizations like the Industrial Internet Consortium (IIC) worth of assets are put at risk. One of the most prevalent document use-cases and ensure interoperability. Additionally, examples of the need for security is the smart grid, which is on the IEEE has formed the Time Sensitive Network task group to the leading edge of the IIoT. As information on the grid becomes evolve IEEE 802.1 to meet these requirements. more accessible, so does the damage a security breach can inflict.

The ongoing design of the IIoT represents a massive business In addition to being secure, these systems need to be con- and technology opportunity for all of us. Organizations like the tinually modified and maintained to meet ever-changing IIC, IEEE and AVnu are working hard to define the IIoT. They functionality and system-maintenance requirements. As more are actively gathering use-cases to better understand how best capabilities are added, software updates are needed or more to enable more innovation. systems must be added. Soon a tangled web of interconnected Engineers and scientists are already implementing systems on components starts to form. The new system has to integrate the leading edge of the IIoT, but they still face many unknowns not only with the original system but also all of the other and much work ahead. Start concentrating on a platform-based systems. Imagine modifying and updating thousands or mil- approach and become part of the IIoT generation by getting lions of systems located all over the world, including some in involved with these bodies to define the future and ensure that remote locations. businesses focus on innovation and not simply integration. DE www.ni.com/trend-watch

The IIoT Investment Developing and deploying the systems that will make up the IIoT represent a massive investment for decades to come. The only way to meet the needs of today and tomorrow is not by predicting the future but by deploying a network of systems January/February | 2015

20-23-DES.indd 22

Brian Phillippi is a product marketing manager at National Instruments. This article was adapted from “Industrial Internet of Things,” a report from National Instruments’ Trend Watch 2015 series. www.design-engineering.com

15-02-05 1:51 PM

You see the world differently –

including your retirement

See the difference lower investment management fees could make to your retirement savings. Join the

My group advantage app

group plan sponsored by Engineers Canada for professional engineers

Let the numbers speak for themselves.

Visit www.engineerscanadafsp.grsaccess.com/app Sponsored by:

and geoscientists.

Scan this QR code to get the app

Find out more – call

May not work on all mobile devices

1-866-788-1293 ext. 5786 and reference plan number 35408.

Great-West Life and key design are trademarks of The Great-West Life Assurance Company (Great-West Life), used under licence by its subsidiaries, London Life Insurance Company (London Life) and The Canada Life Assurance Company (Canada Life). As described in this advertisement, the group retirement and savings products are issued by London Life and the payout annuity products are issued by Canada Life.

20-23-DES.indd 23

15-02-05 1:51 PM

24

ShopTalk

A PROACTIVE Approach Maintaining safety in industries with hazardous locations starts with the design and operation of the equipment used.

By Dana Parmenter

W

hen it comes to hazardous or dangerous locations, the oil and gas industry receives the most attention in North America. The industry is both praised for its economic growth potential and spurned for the perceived risks.

To mitigate the risks, it’s important that both the designer of the equipment and those involved in its install, repair and operation have a thorough understanding of the requirements. The very nature of these locations means there are explosive elements that require specific safety features to ensure the machinery can be used safely. Certification of products, and even personnel in some cases, is required by law in most jurisdictions.

Incorporating safety features into the initial design, ensuring proper testing and certification of products and training of personnel operating the equipment should always be considered best practice and included as an integral part of overall product development.

As growth in hazardous locations industries in North America and around the globe continues at an increased pace, so has the demand for equipment, repair and personnel. This increase in demand has had many positive and important contributions to the economy.

Unfortunately, this exponential rise has also come with an increase in injuries and deaths to those working in the field, the communities where these sites are located and through which hazardous materials are transported via pipeline, road and rail.

It is often claimed, and easy to assume, the rise is simply the result of the much higher numbers of people employed in these industries, increased mechanization and the greater number of January/February | 2015

24-27-DES.indd 24

hazardous locations.

However, data available indicates this rise is not simply due to volume alone but also to much more subtle and often overlooked factors. The use of non-seasoned or untrained workers; equipment that is not certified or unfit for the designated purpose; and improper storage, repair and maintenance are often the underlying cause of these accidents. It’s not surprising, then, that both companies and individuals are seeking strategies to assure safety of their property, workers and the communities in which they operate.

Product Certification Demand for equipment for hazardous areas is largely in response to the global increase in oil and gas production which has surged in recent years often leading to longer than expected lead times for important new equipment. It has also led to an increase in equipment manufacturers, many of whom are unfamiliar with the requirements for hazardous locations products.

Product certification is often viewed as a necessary evil to bring a product to market rather than the important safety function that it actually is. When designing equipment for use in hazardous locations, it is imperative to understand the safety standards adopted by each jurisdiction where a product might be used. These requirements must act as the foundation to any design, as certification will be necessary and safety requirements can have implications that effect functionality.

Demonstration of compliance requires testing and approval by a Certification Body or Notified Body accredited to issue the certificate for the designated target region. It’s critical that manufacturers and designers consider the intended use of the product at the initial design phases rather than the weeks before production once www.design-engineering.com

15-02-09 2:22 PM

ShopTalk the functional design is complete. This includes considerations such as what protection concept will be employed to assure safety of the equipment, as well as what type of hazards and operating environments the product will be exposed to.

Beyond selecting certified products, purchasers and operators of hazardous location equipment have the additional responsibility of assuring the certification actually meets the requirements of the intended installation location as products are certified for use in very specific locations and conditions. To effectively implement and assure proper equipment use requires knowledgeable and competent staff. One of the best ways to assure uniform understanding and compliance is a thorough and ongoing personnel certification program.

25

Equipment Repair and Inspections The past decade has seen new equipment, infrastructure and businesses entering the market faster than any previous time.

Current standards and regulations have increased the requirements of the equipment being produced for hazardous locations improving worker and workplace safety. The demand is so great that often new equipment supply is not sufficient to meet the demand.

The volume of equipment in service and the shortage of new equipment create a unique challenge as equipment that was previously mothballed is being re-commissioned. This equipment is often in a state of disrepair and in some cases no longer compliant with standards or safety regulations. Further, the sheer volume of equipment in use and the increasing age of infrastructure brings with it greater need for inspection, repair and maintenance.

Effective safety measures must encompass best practices in all three of these key areas.

Maintaining equipment integrity and ensuring the safety of personnel is the ultimate goal of any inspection, repair and maintenance program. If handled improperly, repairs performed may invalidate a product’s certification or worse negate some or all of the protection measures in place to assure it doesn’t cause a fire or explosion. Equipment that is not maintained also carries similar risk due to various influences such as environmental damage or neglect. Failure to monitor and correct these challenges

Personnel Certification While there is often significant time and investment in the certification of the products for use in hazardous areas, the knowledge and capability of the individuals tasked with sourcing, installing and maintaining the equipment is often less thorough. Safety provided by certified products can quickly be undermined by improper installation or maintenance by unknowledgeable staff.

Larger companies in the oil and gas industry often have comprehensive training programs in place. However, industry growth and outsourcing has led to a boom in small service companies often without these elaborate health and safety programs or the resources internally to provide them.

In addition, oil and gas growth in “nontraditional” locations such Nova Scotia, New Brunswick and Newfoundland has further posed difficulties as the historical knowledge from experience found in long time producing areas such as Alberta or Texas do not exist in these “newer” oil regions. Stakeholders should aim to assure that not only their own, but their IEC suppliers and contractors personnel, are encoders capable and competent.

The best way to assure competence is parhelp to optimize ticipation and certification of staff involved in automation systems hazardous areas to a personnel competence and reduce costs. Rely on this scheme such as IECEx Personnel Competence proven technology to strategically program. Independent third party personnel improve your productivity and profitability. competence schemes assure a demonstrated Our mission is to exceed all your expectations knowledge of the required skills and uniformity with superior quality, value, service and reliability. of all participants.

Utilization of a scheme such as IECEx perOur exclusive sonnel competence assures companies who demonstrates our commitment to your satisfaction. outsource elements of their business a consistent and measurable method of assuring their subcontractors and providers have a skill set 22 Commerce Place, St. Catharines consistent with their own, limiting costly ON, Canada L2S 0B3 Industrial Encoder Corporation mistakes resulting from the competence of Phone Toll Free 1-888-277-6205 Member of the GESgroup of companies hired staff. This also extends past initial comFax Toll Free 1-866-278-1301 missioning to life cycle services such as equipinfo@globalencoder.ca ment repair, inspection and maintenance.

Optimized Automation Systems

FIVE-YEAR WARRANTY

www.globalencoder.ca

www.design-engineering.com

24-27-DES.indd 25

January/February | 2015

15-02-09 2:22 PM

26 ShopTalk through regular maintenance can have catastrophic results.

Often, these tasks have been handled internally; however, in light of recent incidents in the field, regulations relating to engineering and inspection requirements are becoming increasingly more stringent and the required skills or volumes of these skills simply aren’t available. This leads us back to the importance of personnel certification. A comprehensive and forwardlooking program can help ensure the required resources in sufficient volume.

Utilization of a third party expert to accomplish these tasks is also a valid option. Third parties carry unique skills and knowledge that are tested by experience and time. They also typically hold the most up-to-date knowledge and training. Use of a third party for your inspection, repair and maintenance provides workforce flexibility and consistent quality.

Some programs, such as the IECEx Service Facility Certification scheme, offer a third party validated certificate of conformity that confirms an independent ExCB evaluated the facility and found it to have the appropriate equipment, trained staff and procedures to assure high degrees of confidence in performed repairs and ongoing compliance with its safety certificate.

A sound inspection, repair and maintenance program using the latest knowledge, facilities, tools and resources is mandatory

to help ensure safety and reduce the risk of costly accidents.

Accidents in industries with hazardous locations are disproportionately higher at smaller operators who lack the safety program or training to assure safe working. Understanding where you may have weakness and using third party resources available to help you identify these challenges or perform the tasks for you where you lack the confidence and skills helps guarantee the safety of all stakeholders.

While the very nature of these industries is dangerous, the number of accidents is still few and far between. Advancements in technology, health, safety and awareness over the past 10 to 15 years have created great gains in safe working practices.

However, with the ongoing boom in industries with hazardous locations, and the associated demand for people and equipment, we will see increased chances that aging or uncertified equipment, untrained labor and maintenance programs will increase the risk of a series accident. A proactive approach is required to address the gaps to help ensure the safety of personnel and equipment and a thorough policy to educate staff and assure safe practices are always encouraged and followed.

DE www.csagroup.org

Dana Parmenter is the Group Global Business Unit Director, Hazardous Locations for the Canadian Standards Association.

Tomorrow’s marking technology... Today!

I-MarkTM dot peen and scribe systems join CMTs wide range of products Everything you need in one easy package..

Contact Our New Canadian Representative: Automation Products

Get your quote today sales@marking-machines.ca

www.marking-machines.net January/February | 2015

24-27-DES.indd 26

800.469.6275 www.design-engineering.com

15-02-09 2:22 PM

Grow your business the SMART WAY!

B2B IN-DEPTH DIRECTORIES

We’ll help you get started.

CUSTOM CONTACT LISTS EMAIL MARKETING SERVICE FAX BROADCASTING

At Scott’s Directories, we don’t just help you find and reach your target audience. We help you integrate and enhance your customer database, as well as effectively communicate with them.

VIDEO SERVICE ADVERTISING OPPORTUNITIES CUSTOM PUBLISHING SPONSORED ARTICLES DATA APPENDS DATA HYGIENE DATABASE MANAGEMENT AND MORE...

1.877.517.6864 PARTNERS IN YOUR SUCCESS

SCOTTSDIRECTORIES.COM

Ref: SCTA25H

24-27-DES.indd 27

15-02-09 2:22 PM

28 CareerReport

Canada’s Engineering

UNDEREMPLOYMENT CRISIS

OSPE study finds an unacceptable number of engineering degree holders in Canada are employed in positions that don’t necessarily require a university education.

A

s unbelievable as it may sound, if you hold an engineering degree in Canada, it’s unlikely you’re actually working as an engineer. In fact, there is an unacceptably high chance you’re not working in a job that necessarily requires a university degree of any kind. And that’s only for male engineers trained in Canada. If you’re a woman with an engineering degree or were trained abroad, the likelihood you’re employed as an engineer is even bleaker.

These troubling findings are the culmination of a series of indepth reports conducted by the Ontario Society of Professional Engineers (OSPE) over the past year. In May 2014, OSPE presented From Classroom to Career: Employment and Underemployment Among Ontario’s Engineering Graduates, a report explored the disconnect between what employers say – that there is a shortage of workers who have the specialized skills they need – and the ongoing accounts we hear from individuals with engineering degrees who cannot find relevant or appropriate work.

In September 2014, OSPE published From the World to the Workforce: Hiring and Recruitment Perceptions of Engineering Employers and Internationally Trained Engineers in Ontario. This report’s core finding was that asymmetries or misalignments exist between the recruitment processes of employers and the job search practices of internationally trained engineers (ITEs).

The association’s latest study — Crisis in Ontario’s Engineering Labour Market: Underemployment Among Ontario’s EngineeringDegree Holders — goes one step further. Released in January 2015, the study focuses on individuals with engineering degrees who are working in jobs that don’t necessarily require a university degree.

Since there is no universally agreed-to definition of underemployment, the report defines the term as a state of employment in which an individual with an engineering degree has a job that doesn’t necessarily require a university degree of any kind.

Information referred to in this report is derived from the Canadian National Census 2011 National Household Survey (NHS).

According to the 2011 NHS, only about 30 per cent of employed individuals in Ontario who held a bachelor’s degree or higher in engineering were working as engineers or engineering managers.

Fully two-thirds of engineering degree holders were not working in engineering at all. Even more alarming, greater than 33 per cent had jobs that didn’t necessarily require a university degree.

OSPE considers this unacceptable, and an indicator of significant January/February | 2015

28-29-DES.indd 28

underemployment of those who hold engineering degrees.

By a wide margin, employed individuals with bachelor’s degrees or higher in engineering did not work in their field of study compared with those with medical, law, nursing or education degrees.

The percentage of people with engineering degrees who actually worked as engineers or engineering managers was lower in Ontario than in any of the five provinces to which it was compared, and Canada as a whole.

In Ontario, just 29.7 per cent of individuals with engineering degrees worked as engineers or engineering managers. This compares with almost 46 per cent of similarly educated individuals in Alberta, for instance.

Additionally, those who obtain their engineering degrees outside Canada faced, and continue to face, a troubling situation when it comes to employment. There was much greater underemployment in this group than among those whose degrees were from Canada.

If we assume that individuals with degrees from outside Canada are immigrants and internationally trained engineers (ITEs), just over 20 per cent worked as engineers or engineering managers.

Considering gender differences, just over 20 per cent of women with engineering degrees worked as engineers or engineering managers. Indicators are worse with respect to underemployment for this group. Well over one-third of women who had engineering degrees worked in jobs not necessarily requiring a degree. This was especially true for women with degrees from outside Canada as 50 per cent were unemployed.

These findings are discussed in much greater detail in the OSPE report available on the association’s web site, but they do lead to a number of questions, including: Are we graduating too many engineers in Canada? Are employers doing their part to generate entry-level positions? Did Canada’s immigration system contribute to the underemployment situation?

While beyond the scope of OSPE’s research so far, the answers to these and numerous other questions are critical to the health of the engineering profession in Canada.

DE www.ospe.on.ca

This article was adapted from OSPE’s report, Crisis in Ontario’s Engineering Labour Market: Underemployment Among Ontario’s Engineering-Degree Holders. www.design-engineering.com

15-02-09 1:37 PM

QTC METRIC GEARS

Supplying North America with Metric Gears

Meeting the Demand for Metric Dimensioned Gears With over 20,000 configurations of standardized items, Modules 0.2 thru 10, QTC METRIC GEARS is able to meet the increasing demand for metric dimensioned gears. Design Engineers rely on us not only for gears, but for technical information and gear calculations, 3D CAD models and detailed product specifications. If required, fast turnaround modifications can be made. Locate the gear you need, shop online and request your new Q430 Catalog today. We help you get the job done.

Find your gears at: qtcgears.com

QTC METRIC GEARS

2101 Jericho Turnpike, New Hyde Park, NY 11040 Tel. (516) 437.6700 • qtcsupport@qtcgears.com qtcgears.com

Engineered Solutions for a World in Motion

28-29-DES.indd 29

15-02-09 1:37 PM

30 CareerReport

A Question of

EXPERIENCE

By Mike McLeod

E

ngineers in Canada, and the firms that employ them, are caught in a Catch-22. According to studies conducted by the Ontario Society of Professional Engineers (OSPE) and Engineers Canada, the profession is locked in a labour supply and demand puzzle that could have serious consequences in the coming decade.

On the one hand, employers complain of a broad skills shortage, in particular a lack of engineers with at least 5-10 years of experience. But while industry struggles to find suitable candidates, it is also facing a looming deadline. A 2012 labor study conducted

by Engineers Canada projects that as Baby Boomer engineers reach retirement age, the number of experienced engineers in Canada will begin to decline significantly by 2020.

Part of the problem, says Ontario Society of Professional Engineers CEO Sandro Perruzza, is that employers are reluctant to hire those unable to “hit the ground running.” This leaves many engineering graduates struggling to find jobs in their field. In fact, OSPE’s recently released report Crisis in Ontario’s Engineering Labour Market (detailed on page 28), finds that only 30 per cent engineering degree holders in Ontario work as engineers— a percentage that doesn’t differ radically in other provinces.

“Industry has tried looking for engineers within Canada so they go to the government and say there is a skill shortage here,” he says. “So they asked to open the borders and let in engineers from other countries who have the skill set they’re looking for. Well, they have done that and we are currently immigrating as many engineers as we graduate, but as our studies show, [internationally trained engineers] have even less chance of landing a job in Canada.”

“So if the existing workforce isn’t there and looking [outside Canada] isn’t working, then how much longer do you have to wait before you realize that it’s better to develop your own talent,” he adds. “A co-op program is a great way to get a student who, while they are learning, comes into your company and also learns your work processes and culture. You develop a relationship with them and also see if they’re a good fit for your organization.”

January/February | 2015

30-33-DES.indd 30

University co-op programs provide the key to opening Canada’s deadlocked engineering labour market.

For Dr. Wayne Parker, P.Eng., Associate Dean of Cooperative Education and Professional Affairs at the University of Waterloo, that sentiment is central to the university’s engineering program philosophy. With nearly 7,000 students enrolled in 14 engineering programs, U of W requires all its engineering undergrads to complete up to two years worth of co-op placement as a graduation requirement and has done so since its founding in 1957. Today, in partnership with approximately 5,200 Canadian and international companies, the university operates the largest post secondary co-op program of its kind in the world.

The results, Parker says, speak for themselves. A survey of 2010 graduates conducted in 2013 for the Ontario Ministry of Training, Colleges and Universities, found that 92 per cent of U of W engineering degree holders landed a job six months after graduation and 95.9 per cent after two years. In addition, the university says, on average, co-op students earn 15 percent more post graduation.

“Employers come to co-op for a number of reasons: Some are doing talent scouting for permanent employment and some have short term needs for people to step in and take on particular tasks,” Parker says. “The best employment situations are when the students are given tasks that have real meaning and where, at the end of the day, the student and the employer can see that the work has made a contribution to the organization.”

Making sure students have a chance to contribute meaningfully during their placements is key, agrees Cheryl Hulme, Co-op Coordinator for Engineering at the University of Guelph. The biggest obstacle she finds when talking to prospective partner companies is overcoming a previous bad experience with a co-op student.

“If an employer has had a student who wasn’t suited for the position, didn’t get the support they needed or simply wasn’t ready to work, the employer is likely to say, ‘co-op students are more work than they’re worth; I’m not getting enough value,’” she says. “Some of that comes from the fact that a traditional co-op program just has four-month work terms. So an employer brings them in, trains them up and in 16 weeks, it is time for them to go. But as companies have become leaner and leaner, everyone who comes on board has to be adding value. In four month, it can be hard to find that value.” www.design-engineering.com

15-02-09 4:30 PM

OPEN HOUSE

fOR COnTinUinG EDUCaTiOn STUDEnTS

TRaNSfORM: iDEaS inTO planS Whether you want to transform your career, your prospects, or your life, The G. Raymond Chang School of Continuing Education at Ryerson University can help. With 88 career-related certificate programs and over 1,500 courses, seminars, and workshops to choose from, we offer many ways to achieve your goals.

Come to our Open House and meet with program representatives who can help you choose the best area of study to meet your career goals.

March 26, 2015 4:30 p.m.–7:00 p.m.

380 Victoria Street, Toronto (just east of Dundas subway station)

RSVP: ryerson.ca/ce/openhouse 30-33-DES.indd 31

15-02-09 4:30 PM

32

CareerReport In response, Hulme says the University of Guelph has moved toward 8-month work terms beginning after the second year for its engineering students. She says the longer term is not only more attractive to employers but also allows students to get up to speed in a position before they rotate back to their academic studies. At the same time, it still provides the opportunity for students to “sample” a spectrum potential career tracks before graduation.

Unlike U of W’s program, however, University of Guelph’s isn’t mandatory. In total, the program ran 395 unique engineering workterms last year. Having an optional program, she says, tends to attract only highly motivated and committed students who have had an opportunity to consider all their options.

“And in some engineering programs, students go out in the January of their first year so their feet are barely wet in university life,” she says. “Our students don’t go out until they finish two full years of their program. So not only have they taken half their courses but they have also begun to think about what they really want to do.”

Rather than break work placement into alternating four or eight month stretches, some engineering programs prefer a paid internship model. In Ryerson University’s Industrial Internship Program, for example, students work for 12 to 16 months after their third academic year. When the term is up, they return to

university to complete their degree.

Dr. Liping Fang, P.Eng, Associate Dean, Undergraduate Programs and Student Affairs at Ryerson University says that while internships limit students to a single employer, they also provide ample time for students to become fully contributing employees. Currently, approximately 30 percent of the Toronto university’s engineering track students seek internships.

This extended placement also benefits employers, Fang says, by reducing the cost of recruitment, as many interns are offered permanent positions by the end of their term. In addition, he says employers, whether they participate in a co-op or internship program, can offset some of the costs associated with hiring an engineering student through the Ontario Co-operative Education Tax Credit and the Natural Sciences and Engineering Research Council Awards.

“In Canada, we have a lot of new graduates from engineering programs but we have companies that want people with five years experience,” says Fang. “For people graduating in this type of program, they may not get five years, but this way companies are providing experience gaining opportunities. I think this is one way to fill this five-year experience gap.”

DE www.ryerson.ca/mie/IIP www.recruitguelph.ca/cecs http://uwaterloo.ca/engineering

Hire a

Bachelor of Engineering co-op student

• Design focused, hands-on, collaborative engineering programs • No waiting for a match at Guelph. Just post, interview & hire!

• Students available for 4 or 8 months • “Expanded programs, state of the art facilities, extraordinary growth”

Post your jobs today!

www.recruitguelph.ca January/February | 2015

30-33-DES.indd 32

(519) 824-4120 x52323 www.design-engineering.com

15-02-09 4:30 PM

30-33-DES.indd 33

15-02-09 4:30 PM

CareerReport

BRITISH COLUMBIA

Edmonton, AB $70,080 $76,066 $81,922 Vancouver, BC $71,604 $77,668 $83,599

Victoria, BC $69,136 $74,939 $80,615

Calgary, AB $71,948 $78,095 $84,107

Work experience 1 Year

January/February | 2015

34-35v1-DES.indd 34

3 Year

W AN

ALBERTA

SA SK AT CH E

34

MANITOBA

Saskatoon, SS $64,117 $69,677 $75,116

Winnipeg, MB $62,686 $68,122 $73,440

Lo

5 Year

www.design-engineering.com

15-02-09 1:49 PM

Mechanical Engineering Salary Guide A

ccording to a recently released compensation study, where Canadian engineers live and work has as much impact on how much they make as their chosen discipline and industry. The data presented here is adapted from Randstad Engineering’s 2015 National Compensation Survey. The firm is Canada’s leading provider of customized staffing and recruitment solutions for engineering and technical talent.

The numbers below represent the average salaries of mechanical engineers across 12 industries in 12 major cities. In addition, the numbers represent average salaries for mechanical engineers at 1, 3 and 5 years of experience. Randstad’s complete and comprehensive survey, available as a free download from the company’s web site, includes salary data for all engineering disciplines and across more than 30 Canadian cities. http://w.randstad.ca/design-engineering-salary-guide

QUEBEC

ONTARIO

Toronto, ON $70,118 $76,181 $82,111 London, ON $66,260 $71,875 $77,367

Montréal, QC $65,745 $71,475 $77,079

Ottawa, ON $69,164 $75,088 $80,883

NOVA SCOTIA

Québec City, QC $62,053 $67,386 $72,603

Halifax, NS $62,448 $67,902 $73,237

Kitchener, ON $65,665 $71,205 $76,625 www.design-engineering.com

34-35v1-DES.indd 35

January/February | 2015

15-02-09 1:49 PM

36 MotionControl

In TANDEM Unorthodox dual gantry milling machine with twin rotary 6-axis milling heads realizes 35 percent cycle time improvement for aerospace manufacturer.

By John Meyer

S

ince its founding in 1975, Triumph Structures – Wichita has made a name for itself in aerospace manufacturing circles not only for its extensive CNC capabilities but also its early adoption of technology. Operating in the heart of the “air capital of the world,” the contract manufacturing company specializes in complex, high speed, monolithic precision machining and subassembly of aluminum and titanium structural airframe components often with wall thicknesses represent the top players in both down to 0.020 inches. commercial and military aircraft, In total, its Kansas-based facility making Triumph Structures – houses 21 individual 5-axis machining Wichita a more value-adding supcenters, with a maximum length of 960 plier,” explains Harry Thurmond, inches. More than 20 other 3-axis and president of Triumph Structures 4-axis machines complete Triumph’s – Wichita. machining capability for aluminum “We had requirements for spars structures. Projects run the gamut of and stringers that often reached build-to-print precision machining of 22 feet in length, but we also do a aluminum and hard metal small-tovariety of production jobs on large parts, especially aircraft wing smaller sections such as bulkspars, skins, bulkheads and landing heads,” he adds. “This creates the gear components. need for fast, reliable and adaptable But, while its machine capabilities machine tools.” are substantial, the company often The company considered a varirequired a machine that could serve ety of options to expand on the multiple purposes. For example, many capabilities of their existing milling times Triumph needed to machine very machines, but ultimately turned to long parts with volumetric compensaits longtime partner and portal tion to manage material expansion and machine supplier, Michigan-based tool tip position over a very long cutting Zimmermann, Inc. Meeting Tricycle, often multiple days. umph Structures’ requirements, The company had extensive experihowever, necessitated that Zimmerence in this area, but it was determined mann modify one of its FZ100 that a single machine might be capable A view down the entire length of the workspace, showing machines with twin gantries, each of also running multiple smaller parts the twin heads and the break wall removed for continuous equipped with a three rotary axis or operate in twin fashion, occasionally machining of a single workpiece, with co-dependent head and independent Siemens using the entire machine bed with both gantry and CNC operability.

Sinumerik 840D sl CNC. heads working the same part in tandem.

“We had a variety of machine Clearly, the latter scenario would demand extremely close atten- styles available, but the best solution was a head with three tion to collision avoidance between the gantries, as well as the rotary axes, A-B-C integrated in a forked milling head,” explains consistency of surface machining at the points where the twin Zimmermann President Matthias Tockook. “This provided machining heads intersected. simultaneous 6-axis cutting in a very compact design, with no “We had grown steadily over the last decades, since our pole position, less overall axis rotation, a constant feedrate incorporation of 5-axis work in the 1990s, and were ready to capability and improved surface quality.” jump to a new level of competence for our customers, who The individual head machining time scenario was further January/February | 2015

36-38-DES.indd 36

www.design-engineering.com

15-02-05 1:55 PM

MotionControl

Triumph Structures — Wichita’s twin gantry portal milling machine features this unique head design, based on three rotary axes.

Paired with its twin, the heads are capable of full 6-axis machining with 125 RMS inside and 32 RMS outside finish.

detailed. If the maximum time was achieved using an A- and C-head with infinite C-axis, the alternative A-B-C integrated rotary axis head could accomplish the same work in 25 percent of that time.

In designing the final work envelope and machine structure, Zimmermann engineers determined the best solution was a removable break wall built into the midpoint of the machine bed, which would allow completely independent operation of the entire machine, literally running as two machine tools in one.

When removed, the machine bed could accept parts up to 960 inches in length and process them using the twin heads working in tandem and monitored for total collision avoidance by the two CNCs onboard.

Owing to the unique volumetric compensation feature of the Siemens CNC, where the execution of the machining is based upon the actual tool tip position, the point of intersection for the twin heads was found to be an easily addressed and resolved issue.

37

Surface integrity on the workpiece would be preserved, while machine and operator safety would remain paramount. The machine was built over a period of eighteen months. Parts were sent to Zimmerman to be fully tested prior to being erected on site.

According to Thurmond, the Zimmermann head design provides significant advantages in speed on the typical peaks and pockets found in aerospace structure machining, working in tandem with the look-ahead feature on the CNC. “It slows down and speeds up in anticipation of the next required surface contour,” he says. “Over long run times, this can translate into an improvement of 35 percent or better, because there is no deburring or polishing required. We routinely get better than a 125 RMS finish on inside pocket surfaces and up to a 32 RMS on the outside of the Series 7000 aluminums we run. Combined with the flexibility of the machine to work a single structure or individual workpieces simultaneously, we have been quite satisfied with the results to date.”

On longer runs, Thurmond adds, the chilled coolant used on the Zimmermann is helpful in minimizing thermal expansion of the material, a critical factor in long run machining work. An added advantage, the machine is used to produce workholding and fixturing devices. Lastly, the Zimmermann machine is equipped with test probes, so it can be used as a CMM to measure workpieces in process.

The 3-axis head avoids the pole position of the traditional 2-axis A-C head at A = 0º. In this Zimmermann head design, the B-axis moves +/- 15º inside a rigid curved guideway for handling the inner sloping and especially the pockets typically found on aero structures, so simultaneous 6-axis machining is achieved with high surface finish integrity.

The new machine is further equipped with a stationary clamping table, fixed mounted side walls, DemTec composite fill on the base and side walls for enhanced stability and vibration damping. Backlash-

One of two Siemens Sinumerik CNC units on the machine. With the doors closed and the break wall installed, each of the two work envelopes of the machine can run simultaneously yet completely independent of the other. www.design-engineering.com

36-38-DES.indd 37

January/February | 2015

15-02-05 1:55 PM

38

MotionControl free drives on both sides with rack-and-pinion mechanisms are sealed from contamination and guided on both sides. All axes have feed rates to 60m/min and accelerations to 4m/sec2. Each head can access a 60-position toolchanger on the machine.

For communication of data from the machine, Triumph Structures – Wichita integrates the CNCs into their Ethernet network via DNC and hard-wiring. Through a remote monitoring feature on the Sinumerik 840D SL CNC, Zimmermann is also able to maintain awareness of all conditions on the machine in real-time. The machine built for Triumph Structures – Wichita also includes Siemens servo motors and drives plus

HIGH PERFORMANCE SILICONE FEATURES SUPERIOR THERMAL CONDUCTIVITY Master Bond MasterSil 151AO is a two component, low viscosity silicone compound for high performance potting and encapsulation. It combines high temperature resistance, superior flexibility and outstanding thermal conductivity.

MasterSil 151AO has an exceptionally low viscosity and offers remarkable flexibility while maintaining high temperature and thermal cycling resistance Master Bond www.masterbond.com/tds/mastersil-151ao Tel: 1.201.343.8983 • Email: info@masterbond.com

DRYLIN® W - FOR ALMOST UNLIMITED DESIGN FREEDOM DryLin® W was developed to promote both design flexibility and quick assembly in both single and double rail configurations. DryLin® W is also available in several mounted assemblies eliminating the need for both shaft alignment and bearing assembly. All DryLin® W systems have lubrication-free liners, reducing friction and optimizing bearing life. Request a free DryLin® W sample linear guide kit from igus®. igus www.igus.ca Tel: 1.905.760.8448 • Email: webmaster@igus.com

spindles running at 73kW/95HP and 27,000 rpm in operation.

Commenting on the CNC selection, Zimmermann’s Tockook observed, “With all the challenges we had on this machine, including the axes of motion, the integration of the twin gantry movements, the substantial safety factors involved and the need for independent and also co-dependent gantry operations, we quickly determined that only twin Sinumerik 840D sl CNCs could handle this job.”

DE www.usa.siemens.com www.zimmermann-inc.com www.triumphgroup.com

CLIPPARD OFFERS MINIATURE PNEUMATIC PRODUCTS CATALOG FOR SCIENTIFIC/MEDICAL APPLICATIONS A leader in miniature pneumatics, Clippard provides the scientific/medical industry a variety of products and solutions. The product range is illustrated in a color brochure featuring the most complete line of miniature fluid power products for the medical, pharmaceutical analytical and dental fields. To get your copy today please visit our website at the address printed below.

Clippard www.clippard.com/scientific-a Tel: 1.877.245.6247 • Email: sales@clippard.com

PERFECT MESHING TIMING BELTS AND PULLEYS Perfect meshing timing pulleys are crucial for high performance and long service life. The B216 Timing Belt Pulley catalog from BRECOflex highlights our domestic custom pulley capabilities, available tooth pitches, and stock pulleys.

Our NJ production facility is designed around made-to-order pulleys for industry-leading standard and expedited delivery times.

Our objective is “100% customer satisfaction”!

BrecoFlex www.brecoflex.com Tel: 888-463-1400 • Email: info@brecoflex.com

To advertise your solution in this section call Taebah Khan at 416.510.5230 January/February | 2015

36-38-DES.indd 38

www.design-engineering.com

15-02-05 1:55 PM

IdeaGenerator 39 Automation Embedded PC Beckhoff Automation unveiled its CX5100 series of embedded PC controllers, featuring Intel’s latest 22-nm Atom CPUs (‘Bay Trail’). The fanless, rail-mountable controllers are offered in three different processor and housing sizes: Single-core, 1.46 GHz (CX5120); dual-core, 1.75 GHz (CX5130); or quad-core, 1.91 GHz Atom CPU (CX5140).

The basic interface equipment corresponds to that of the company’s CX5000 devices: Automatic recognition of K-Bus I/O or EtherCAT Terminals; two Gigabit-capable Ethernet interfaces; four USB 2.0 ports; a DVI-I interface and a “multi-option” interface that can be equipped to support a variety of fieldbus systems. The embedded PCs extended operating temperature ranges from -25 to +60 °C. www.beckhoffautomation.com/cx5100

PLC + HMI in One Unit Vision 1210™

Graphics Terminal Rockwell Automation released its PanelView Plus 7 Standard graphic terminal, available in screen size options ranging from 4 to 10 inches standard and 4-inch and 9-inch in widescreen formats. The terminals feature an SD card, to help configure multiple machines and access saved diagnostics, as well as virtual network computing (VNC) connectivity for secure application monitoring on mobile devices from remote locations. The Rockwell Automation software code library includes faceplates and add-on instructions (AOI) for the PanelView Plus 7 Standard operator interface. The terminals provide connectivity to one controller, and up to 25 screens and 200 alarms along with ATEX Certification. www.rockwellautomation.com

Automation Panel In addition to its widescreen panels, B&R Automation has added a line of second generation automation panel displays in conventional 4:3 format with single-touch operation. As part of B&R’s modular system platform, the panels can be combined with a module to create a panel PC. The panels can also be equipped with a Smart Display Link 3 receiver that allows the display to be installed at distances up to 100 meters from the PC. SDL3 then transmits all necessary data over an ordinary Ethernet cable. The 4:3 format units are available as 12.1- and 15-inch panels with XGA resolution and well as 19-inch panels with SXGA resolution. The panels’ LED backlight features a wide adjustment range to allow for dimmed user environments. www.br-automation.com

PLC WAGO announced the addition of its PFC200 PLC to the company’s Ethernet 2.0 series. The unit features multiple fieldbus ports; a 600 MHz ARM Cortex A8 processor; 256 MB on-board memory (32 GB removable) and an integrated web server. The PFC200 acts as a fieldbus gateway to communicate between MODBUS TCP/UD/RTU, CAN, PROFIBUS, Smart Grid and RS-232/ RS-485, eliminating the need for third-party converters. Configuration of fieldbus networks is facilitated by the WAGO-I/OPRO programming and visualization software tool. www.wago.us www.design-engineering.com

39-43-DESv2.indd 39

Starting at $1,676

12.1” Color touchscreen 800x 600 pixels (SVGA) Supports up to 1000 I/Os Including high-speed , Temperature & weight measurement NEMA4X/IP66/IP65

Unitronics, Inc. 1 Batterymarch Park Quincy, MA 02169 USA

Toll Free: 866-666-6033 usa.sales@unitronics.com w w w. u n i t r o n i c s . c om January/February | 2015

15-02-05 1:59 PM

40

IdeaGenerator Level Controller CARLO GAVAZZI has expanded its line of Conductive Level Controllers, which provide filling or emptying control of liquid levels between two different points. The company’s CLD2EB1BU24 controller provides three sensitivity ranges plus a fine tune adjustment from 250 ohms to 500k ohms. The controller features DIN rail mounting, universal 24-240VAC/DC supply voltage and a 17.5mm housing width. The company’s CLP2EB1Bxxx provides a single mid-range sensitivity adjustment from 5k ohms to 150k ohms. Mounted via an 11-pin DIN-rail mountable socket, four different models are available for operating voltages of 24VDC, 24VAC, 115VAC or 230VAC. All of the models provide one SPDT relay output, which is rated up to 8A, 250VAC. www.gavazzionline.com

Motors Motors and Gearboxes Maxon announced additions to its X drive and GPX planetary gearhead lines. The motor line now includes four more motor sizes — 14, 16, 22 and 26mm diameter models. The models are also

available in a long version that offers higher continuous torque and output power. In addition, the GPX planetary gearhead line has added sizes 14, 19, 26 and 37mm, all of which are designed with scaled gear stages. Each of the new 3-stage gearheads can be driven with the next smaller motor. In addition, the existing GPX 16 and GPX 32 models are available in various versions and can be equipped with ceramic axles to reduce wear. Lastly, the company’s ENX 16 Easy absolute encoder is available as an SSI or BiSS-C version, according to the customer’s requirements. http://dcx.maxonmotor.com

Servomotors Beckhoff Automation introduced its AM801x and AM811x servomotors which offer a low rotor moment of inertia, as well as quadruple overload capacity, and add a flange size F1

Precision Additive Manufacturing 3D Motion Control Subsystem and Component Solutions Subsystems with six degrees of freedom

Control Systems • Advanced control capabilities for coordinated motion • Innovative features for minimizing dynamic tracking errors • Velocity profiling maintains a constant vector velocity over complex profiles for total material distributing control • Powerful, user-friendly controllers and drives to enhance your complete process

Mechanical Systems • 3D motion down to nanometerlevel performance Aerotech motion products are currently used in a variety of additive manufacturing applications.

A 3D printed structure produced using an Aerotech motion system.

• Component-level solutions for cost effective, reliable motion • Integrated subsystems and turnkey machines customized to exact specifications

Photo provided by Professor Jennifer A. Lewis, Harvard University

Dedicated to the Science of Motion

• Full line of linear and rotary stages in both mechanicalbearing and air-bearing versions

Ph: 412-963-7470 Email: sales@aerotech.com www.aerotech.com AH1114A-PMG

AH1114A-PMG-Additive-Manufacturing-7x4_875.indd 1

January/February | 2015

39-43-DESv2.indd 40

12/11/2014 1:43:24 PM

www.design-engineering.com

15-02-05 1:59 PM

IdeaGenerator 41 with a 40mm edge length to the AM8000 servomotor series. Three overall lengths cover a torque range from 0.22 to 0.55 Nm. Combining the AM811x motors with Beckhoff’s EL7201-0010 and EL7211-0010 servomotor I/O terminals provides 2.8 ARMS and up to 4.5 ARMS respectively, at 50 VDC. Additionally, the AX5000 EtherCAT servo drive (1 or 2 channel, up to 3A continuous current per channel) can be used to control the AM801x servomotors, which are designed for 230VAC. Optionally, the servomotors are available with a backlash-free permanent magnet holding brake, feather keyway groove shaft, an absolute encoder and One Cable Technology (OCT). www.beckhoff.com

DieQua offers more gearboxes plus application experience to help select the best one for your needs

Helical Gearmotors • 1-75 HP Capacity • Motorized or Adapters • Right Angle or Inline • Shaft Mount Designs • Multi-Stage Ratios • Modular Design

Fluid Power Pump Drive The Drives & Motion Division of Yaskawa America, Inc. released its iQpump Micro intelligent pump drive control for variable-torque pump loads through 25 hp. The company’s family of iQpump drives offers comprehensive pump and motor protection, along with easy setup and diagnostics. The drive’s software allows for a range of pumping applications from constant pressure, flow, geothermal, multiple pump booster systems to wet well lift stations.

As process variables change, the unit automatically adjusts pump-operating conditions to meet system demand, while maintaining pump performance and protection. Available in NEMA 1 and NEMA-4X rated models, the system is also available in NEMA 3R configured packages. www.yaskawa.com

Hydraulic Couplings Kurt Hydraulics introduced a line of Push-On Hose and Push-Loc Hose Couplings for low pressure applications.

Spiral polyester material, inside the hose, locks onto the fitting and maintains it grip under pressure up to 250 psi and in temperature ranges from -20°F to +180°F (-29°C to +82°C). The tube material is Nitrile, RMA Class A and the hose cover is Nitrile PVC, RMA Class A. They are available in sizes ranging from 1/4-inch (ID) and 0.5-inch (OD) to 1/2 inch (ID) and 0.75 inch (OD). Hose color varies by diameter size and is available in reels of 250 and 700 foot lengths. The brass Push-Loc couplings are available in 22 different types and sizes. Sizes include 1/4, 3/8, 1/2, and 3/4inch male pipe rigid; 3/8 and 1/2-inch female pipe rigid; 1/4, 3/8, 5/8 and 3/4-inch female SAE swivel; 1/4 and 1/2-inch male pipe swivel; and 3/8 and 3/4 female JIC swivel. www.kurthydraulics.com

Micro Valve Viking AT unveiled what may be the world’s smallest proportional valve. About the size of a quarter, the device measures 5.5mm x 18.50mm x 22.61mm and works as a driving proportional flow valve for liquid hydrocarbons as well as air, nitrogen, helium and other gasses. Utilizing the company’s miniature ViVa valve actuator, the valve offers proportional control with less than 1 mW power consumption, the company says. The valve also delivers flow rates from 7 LPM at 140 psi and operates from 10 to 150 psi. www.vikingat.com www.design-engineering.com

39-43-DESv2.indd 41

Worm Reducers • 7 sizes, 28-110mm CD • Fret-free Connection • NEMA or IEC Adapters • Coupling Input • Aluminum Housings • 2-Side Worm Support

Planetary Gearheads • Precision or Economy • Inline or Right Angle • 40-155mm Frames • Low Backlash • 1 and 2 Stage Ratios • Lubricated for Life

Servo Worm Gearheads • 3 Backlash Levels • Shafts or Hollow Bores • Single or Dual Outputs • 11 sizes, 25-200mm CD • Capacity: 10-7000 Nm • 20,000 Hour Ratings

Spiral Bevel Gearboxes • 9 Sizes • 1-250 HP Capacity • Low Backlash Option • Ratios from 1:1 to 6:1 • Output Shaft Options • Machined Housings

Special Designs • Add-On Options • Modified Dimensions • High Speed Applications • Special Environments • Special Duty Needs • Custom Designs

www.diequa.com 630-980-1133

See our complete product line!

January/February | 2015

15-02-05 1:59 PM

42 IdeaGenerator Power Transmission Drive Nut The Amacoil-Uhing unveiled the Model RS drive nut, which runs on a smooth shaft without threads. The linear drive operates on the rolling ring linear motion principle. The point contact between the rolling ring bearing and the shaft assures there is no play or backlash during movement of the drive nut, the company says. Available in ten sizes, the drive nut is suitable for vertical or horizontal travel. Each of the ten sizes is available in five different linear pitch settings. Shaft rotational speeds may be up to 10,000 rpm depending on drive size. Linear travel speed ranges from 0.5 ft/sec up to 4.0 ft/sec, depending on drive size and payload weight. RS drive nuts offer axial thrust from 22 to 449 pounds. www.amacoil.com

roller bearings feature two rows of patented self-guiding rollers with a common sphered raceway in the outer ring and an optimized internal design. SKF CARB toroidal types are self-aligning radial bearings merging the benefits of standard “locating/non-locating” bearing systems typically found in continuous caster applications. All SKF’s caster bearings are designed to accommodate misalignment and normally supplied as full complement bearings to take advantage of their increased load rating. www.skfusa.com

Shaft Adapters Stafford Manufacturing introduced a line of rigid coupling adapters that can extend the length of shafts and adapt to different sizes and configurations to eliminate the need for major design changes when replacing motors and related drive components. The rigid couplings feature a clamp-type female end that fits securely over an output shaft and a male shaft extension in any length up to 16 inches. Available in 1/4 to 6-inch I.D. sizes, in steel or stainless steel, the shaft adapters are offered in stepup and step-down configurations with or without keyways and shaft extensions can be round, square, hex, D, threaded, keyed and tapered. www.staffordmfg.com

Caster Bearing SKF unveiled a line of caster bearings designed to cope with the axial expansion and contraction of rolls associated with induced axial loads and temperature fluctuations. The company’s spherical

100 Turns (In A Rotary Sensor)

Linear Slide Thomson Industries announced that it now manufactures its WH SpeedLine linear slides in North America to reduce delivery times.

The belt-driven positioning slide features an H-type roller guideway system designed to handle high forces and moments, the com-

The ML Series of absolute rotary sensors, made by the Contelec Division, packs models with 6, 10, 25, 50 or 100 mechanical turns into a half-inch profile.

Key specifications include: • Long life of >15 million turns • High resolution – better than 0.1% • Repeatability of 0.17% or better

Swiss made by

• Linearity to ±0.25% • Friction clutch on end-stops

For complete ML Series information, visit www.novotechnik.com/ml Novotechnik U.S., Inc. Telephone: 508-485-2244 Email: info@novotechnik.com

January/February | 2015

39-43-DESv2.indd 42

pany says. The units also feature steel reinforced belts and a centralized lubrication system. The product range can handle dynamic loads of up to 9,300N (2091 lbf) over stroke lengths of up to 11m (433 in) with acceleration up to 40 m/s2 (1575 in/s2) and speeds of up to 10 m/s (394 in/s). www.thomsonlinear.com www.design-engineering.com

15-02-05 1:59 PM

IdeaGenerator 43 Sensors Modular Encoder RSF Elektronik unveiled its MSR 40 modular rotary position feedback system that provides a quick way to measure angle on larger rotary axes. The optical kit style encoder provides a 200 micron grating pitch on a steel tape that has three ways of being applied to the axis of motion. Available with a minimum diameter of 150mm to a maximum of 1150mm, the encoder uses same reader head for all the various diameters. It is offered with analog 1 volt peak-to-peak interface as well as digital TTL interface with up to one hundred times interpolation.

All measuring tape versions of this encoder have a +/- 30 micron per meter accuracy associated with the circumference of tape. www.heidenhain.com

SIL2-Rated Sensors American Sensor Technologies (AST) has received SIL2 certification for its 4-20mA pressure transmitters with hazardous location ratings including explosion-proof, intrinsically safe and non-incendive areas.

The SIL (Safety Integrity Level) certification was conducted through Exida and meets IEC 61508 standards. Products available in SIL2

www.design-engineering.com

39-43-DESv2.indd 43

configurations including the company’s non-incendive pressure transmitters and pressure sensors; intrinsically safe pressure transmitter; intrinsically safe low pressure transmitter; submersible pressure sensor; flush diaphragm; submersible pressure transducer for chemical tank level; and explosion proof pressure transmitters www.astsensors.com

Mass Flow Meter Aalborg Instruments’ has upgraded its line of Mass Flow GFM meters and GFC controllers. Both product lines offer instrumentation grade ±1% accuracy for models up to 100 liters. GFM and GFC models are constructed of aluminum and brass for noncorrosive gases and 316 stainless steel for corrosive applications. Additional features include faster response times; additional 10% linearizer point added; 12-26VDC universal power supply; and 4-20mA to 0-5VDC output signals. In addition, the units are not affected by outside temperature and are manufactured with no left or right box. www.Aalborg.com

January/February | 2015

15-02-05 1:59 PM

Sterling Instrument

Your Partner in Innovation

Precision Gears and Gear Assemblies EXPLORE | DESIGN | BUY ONLINE www.sdp-si.com/precision

Design and production of precision gears, gear assemblies, gearboxes, differentials, speed reducers and other motion control products.

Engineering and Manufacturing Expertise • Prototype to Large Production Runs for OEMs 50 years of proven quality, reliability and service to aerospace and defense, satellites, military, medical, industrial and commercial OEM. Customized Design and Technical Support AS9100C Registered | Boeing Certified Sterling Instrument

2101 Jericho Turnpike, New Hyde Park, NY 11040 Tel. (516) 328-3300 • sdp-sisupport@sdp-si.com www.sdp-si.com

Engineered Solutions for a World in Motion

44-48-DES.indd 44

15-02-09 11:24 AM

Bike Design,

CanadianInnovator 45

21st CENTURY STYLE

Toronto-based Vanhawk’s smart-bike tracks performance, gives directions and notifies you if it’s stolen.

By Treena Hein

A

nyone who has ridden a bicycle in the city can tell you how difficult and dangerous it can be. Just try finding an unfamiliar destination when your life depends on your traffic focus being razor-sharp. It would be much easier and safer if you were riding a bike that provides easy GPS navigation guidance, and also alerts you to nearby objects. It would also be great if the bike could track and store your athletic performance data – distance travelled, calories burned and so on – and keep it for comparison.

It would be even better if the bike was networked with other bikes in the city, creating the option to optimize your route as the area is mapped and scored in real time for things like traffic congestion and road condition (with every bump detected with a gyroscope and magnetometer). The cherry on top is that if it’s been stolen, the same bike will alert the whole networked community, so that if your bike is detected nearby to another, you’ll receive its last-known whereabouts.

Meet the Valour, which offers riders all of this in a single sleek and lightweight package. “The initial concept was to create a light, carbon fibre bike with GPS and a mobile app that alerts you when it’s stolen,” says Niv Yahel, chief technical officer and co-founder of Valour-maker Vanhawks, based in Toronto. “As we worked towards this, Sohaib (Sohaib Zahid, co-founder and CEO) would ask me, “Is this really the bike of the future?”

Their thinking was propelled further in this direction a few months later when a colleague asked them to consider www.design-engineering.com

44-48-DES.indd 45

what prevents people from commuting by bike. That brainstorming led to the Valour as it exists today, a cycle-computer partnership system that learns from your rides – and the rides of other users. The Valour powers itself through efficient harvesting of cycling power, with a low drag dynamo hub, active rectifier and switched mode regulators. Power is stored in a lithium ion cell, but the system will still function while you are riding should the battery fail.

While the journey to a finished commercial product took a while, the prototype was hammered out at lightning speed, literally just before the fledgling company launched its wildly successful Kickstarter campaign that raised $820,000.

“I knew that in order for Vanhawks to pitch a convincing case, we needed to have a working prototype,” says Yahel. “In one weekend, I had to create an LED navigation system, blindspot detection system and speed monitoring, all of which communicated with a smart phone app via Bluetooth. I didn’t sleep, and managed to finish the prototype an hour before it had to go to the airport.”

As anyone can imagine, moving from initial prototype to high fidelity prototype involved many tasks, from software development, creation of smart phone apps and server architecture, to overall bike design, firmware creation and building printed circuit boards (PCB) to house the electronics.

“We learned you can burn a lot of time in systems integration if your specs are not laid out,” says Yahel. “For example, ignoring PCB identification, I can have the best-looking PCB with the best radio performance in the universe, but when you have January/February | 2015

15-02-09 11:24 AM

46 CanadianInnovator to stick it inside an enclosure, things like space constraints, position was raised to achieve a more upright riding position. enclosure material and how close things sit to the radios all The team also realized the Valour should have a standard round come into play.” seat post, allowing riders flexibility in type of seat and seat posiIn creating the system to detect objects entering the Valour’s tion. There are future plans for a proprietary fender system, and vicinity, the team chose to alert riders with hand vibration. This storage mounting solutions as well. provides an immediate heads-up regardless of where you’re looking, and doesn’t complicate the LED While the journey to a finished commercial product took GPS-enabled directional guidance interface that’s already on the handlebars. The other end of the a while, the prototype was hammered out at lightning system, ultrasonic range finding required a custom speed, literally just before the fledgling company solution that Yahel decided to tackle. launched its wildly successful Kickstarter campaign.

“It all went fine, except for the industrial design,” he says. “The tech is much larger than any other sensor on the Valour, and when you throw in the fact that the speakers sit at the back of the bike, over a metre from the The name Vanhawks (from the Dutch, ‘of the hawk’) was sensor, we had EM interference, failing electromagnetic compat- chosen because of the hawk’s intelligence, beauty and because ibility and a big challenge routing the electrical (and mechanical) of the long-standing partnership and companionship between cables through the frame, which is really skinny.” hawks and humans, dating back to 600 BCE. The overall bike design was also changed to better fit the needs “Our philosophy is not only to provide an elegant, intelligent of average urban commuters, with safety and riding fun equally and smart cycling companion,” says Zahid, “but to allow our emphasized. The team started with a unique split frame design customers to connect with their physical and online surround(to accommodate a Gates carbon belt instead of a bike chain) ings, all to make cycling safer, more enjoyable and an experience and lowered the centre of gravity by dropping the bottom bracket, to remember.”

DE so it’s easier for riders to put their feet down in traffic. The hand www.vanhawks.com

For Every Application...

Ellsworth Adhesives

1.800.888.0698 | ellsworth.com

Your Total Solution in Specialty Chemical Distribution

Ask the Glue Doctor®

January/February | 2015

44-48-DES.indd 46

Advertisers Index Advertiser

Website

Aerotech, Inc. Aurora Bearing Company Automation Direct Baldor Electric Company Beckhoff Automation Bosch Rexroth Canada Clippard Instruments Laboratory Inc. Columbia Marking Tools Daemar Inc. Designfusion Designatronics Inc. Design Engineering EXPO Diequa Corporation Drive Products, Inc. Ellsworth Adhesives Festo Canada, Inc. Great-West Life Assurance Co. Hewlett Packard (Canada) Ltd. igus Inc. Industrial Encoder Myostat Motion Control, Inc. NORD Drive Systems Novotechnik US, Inc. Ontario Society of Professional Engineers Quality Transmission Components Roto Precision Inc. Ryerson University Schaeffler Canada, Inc. Scott’s Directories Unitronics Inc. University of Guelph

www.aerotech.com 40 www.aurorabearing.com 10 www.automationdirect.com 7 www.baldor.com 48 www.beckhoff.ca 11 www.boschrexroth.ca 13 www.clippard.com 9 www.columbiamt.com 26 www.daemarinc.com 21 www.designfusion.ca 14,15 www.designatronics.com 44 www.dexexpo.com 47 www.diequa.com 41 www.driveproducts.com 37 www.ellsworth.com 46 www.festo.ca 19 www.engineerscanadafsp.grsaccess.com/app 23 www.loctite.com 2 www.igus.com 3 www.globalencoder.ca 25 www.myostat.ca 12 www.nord.com 16,17 www.novotechnik.com 42 www.ospe.on.ca 33 www.qtcgears.com 29 www.rotoprecision.ca 43 www.ryerson.ca/ce 31 www.ina.com 4 www.scottsdirectories.com 27 www.unitronics.com 39 www.recruitguelph.ca/ 32

Page

www.design-engineering.com

15-02-10 2:29 PM

maRK YoUR CaLEndaRs in 2015!

Winnipeg, mB – NEW April 7 – Victoria Inn Convention Centre Coquitlam, BC May 5 – Hard Rock Casino mississauga, on May 26 – Mississauga Convention Centre

Design Solutions for OEMs

a series of one day tabletop shows highlighting the latest design and manufacturing technologies for the oEm market An effective forum for face-to-face interactions where engineers, product developers, machine builders and systems integrators can discuss, network, solicit advice and ‘kick the tires’ on the latest technologies and applications that drive your business.

Featured technologies include: • CAD/CAE • additive manufacturing • reverse engineering • motors • drives • motion control • automation • fluid power • power transmission • adhesives & fasteners … and much more

Registration is required:

www.dEXEXPo.com

FREE admission FoR attEndEEs! to discuss exhibit and sponsor options, contact: Alan Macpherson Publisher 416-510-6756 dex@design-engineering.com

DEX full page ad 2015.indd 1 44-48-DES.indd 47

Taebah Khan Accounts Manager 416-510-5230 tkhan@design-engineering.com

15-02-10 2:19 PM 15-02-11 7:56 AM

Keeping Industry Up and Rolling

Nothing is more frustrating than shutting down a machine, even an entire production line because of a bearing failure. Baldor•Dodge® bearings represent the best quality and reliability industry has to offer.

From punishing mining applications to corrosive washdown environments, and everything in between, there’s a Baldor•Dodge bearing perfectly suited for the task at hand.

• Unmatched Quality

• Superior Reliability

Keep your machinery healthy, strong and efficiently rolling along with the widest choice of industrial bearings in the world…only from Baldor•Dodge. baldor.com

479-646-4711

• Energy Efficient

See us at Automation & Power World March 2-5, 2015 New.abb.com/apw

©2015 Baldor Electric Company

44-48-DES.indd 48

15-02-09 11:24 AM