Design Engineering October 2014

14 What’s new in SolidWorks 2015 24 Canadian exhaust designer uses simulation to reduce iterations

45 Canadian ExactFlat CAD

software removes the guesswork from textile design

$10.00 | October 2014

On the

FLY

PM 40069240

Temporal Power’s flywheel design is putting the Mississauga-based firm on the global energy management map

1-DES.indd 1

14-10-08 9:35 AM

QUALITY X PERFORMANCE X MACHINE AVAILABILITY = OEE

INCREASE YOUR OEE

Motion Control

AC Drives

Robotics

Drive your overall equipment efficiencies higher with motioncentric solutions from Yaskawa.

• Contain large data arrays for recipe management and higher servo axis count.

• Higher performance through electronic camming.

• Change cam profiles on the fly.

• Ethernet IP and PackML for machine-to-machine productivity.

Looking for performance greater than what you have now?

Call Yaskawa today.

SEE IT ALL COME TOGETHER

Booth# S-1733

PACK EXPO International November 2–5, 2014 Chicago, IL USA

YA S K A W A A M E R I C A , I N C .

DRIVES & MOTION DIVISION 1 - 8 0 0 - YA S K A W A YA S K A W A . C O M Follow us:

2-3-DES.indd 2

For more info:

http://Ez.com/yai683

©2014 Yaskawa America Inc.

14-10-01 10:34 AM

Guide and protect moving cables and hoses on automated machinery. From the smallest micro Energy Chain to the world’s largest plastic Energy Chain , igus cable carriers are capable of long and short travel distances at high speeds in all axes. Delivered from stock, no minimum order value required, configured online.

Free samples available! ®

®

®

Plastics for longer life

®

2-3-DES.indd 3

14-10-01 10:34 AM

TM

www.schaeffler.ca Š2014

4-5-DES.indd 4

Superior-quality products.

Comprehensive reliable solutions.

14-10-07 12:42 PM

Contents | Volume 60, No. 5

IN THE NEWS

5

8 IMP Aerospace delivers 100th Aurora

8 Magna Closures

acquires Ontariobased Techform

8 3D scanning market to top $4B by 2018

8 10

3D bioprinter wins Canadian 2014 James Dyson Award KUKA Systems develops robotic riveting system for Boeing

10

Canadian DND awards iRobot “bomb-sniffing” robot contract

10

Self-powered water purifier wins Grand Challenges Canada grant

Columns 14 CAD Report What’s New in SolidWorks 2015: SolidWorks receives a major upgrade in 2015, signalling a renewed commitment by Dassault to its leading MCAD package

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: Business Information Group Design Engineering Circulation Dept 80 Valleybrook Drive North York, ON M3B 2S9

18

22 Hardwire Home Maker: Dremel’s sub-$1,000 3D Idea Builder takes complexity out of 3D printing at the cost of flexibility and versatility 34 3D Scanning Tracking the Path to Success: Quebec’s Soucy Track leverages Creaform 3D scanning technology to boost accuracy of the company’s custom-built farming machinery rubber track systems

22

38 Idea Generator The latest in industrial products including automation, power transmission, motors, drives and sensors 45 Canadian Innovator From CAD to Cutter: Canadian-made ExactFlat CAD module for SolidWorks and Rhino removes the guesswork from 3D textile design

READER SERVICES

14

24 28

Features 18 Color Me Awesome Canadian projection-mapping technology renders high-definition color textures on 3D printed models

34

24 Exhaustive Simulation Canadian exhaust system designer uses multiphysics simulation to reduce costly design iterations 28 On the Fly Temporal Power’s flywheel design is putting the Mississauga-based firm on the global energy management map

45

Printed in Canada

www.design-engineering.com

4-5-DES.indd 5

October | 2014

14-10-07 12:42 PM

6 EditorialViewpoint

Ghost in the CNC Machine

www.design-engineering.com

T

he past couple of months have seen two major milestones in the advancement of DIY design and manufacturing. At IMTS 2014 in September, crowd-sourced vehicle design firm, Local Motors, unveiled the Strati, a build-it-yourself car made largely of additive manufactured components. Over the course of the six-day show, the company’s crew 3D printed and assembled the finished vehicle for test driving.

Given the media buzz in the Strati’s wake, the company says it will soon sell kits, including the STL design files, as a limited edition product.

At the opposite end of the spectrum, Cody Wilson and his non-profit, gun ownership rights group, Texas-based Defense Distributed, made headlines in early October with the debut of the “Ghost Gunner,” a small sub-US$1,500 desktop CNC machine. Better known for creating the Liberator—the world’s first 3D printed handgun—Wilson’s latest venture is specifically designed to create assault rifle parts free of serial numbers.

The machine’s name stems from the fact that such weapons, called “ghost guns,” bypass background checks and other existing state and federal gun ownership restrictions.

This is possible because, although current U.S. gun laws restrict the sale of firearms without a serial number, fashioning weapons for personal use has always been legal.

Presumably, the number of unregistered guns in circulation was restricted by the fact that gunsmithing skill was rare and the equipment needed, formally high-end milling and lathing machines, cost tens of thousands of dollars.

Today, however, most of the components needed to build the popular AR-15, for example—including stock, barrel, upper receiver, etc.—can be legally ordered from Internet-based providers. The only regulated component is a metal part called the lower receiver. Encompassing the trigger mechanism and clip well, the lower receiver requires a U.S. Federal Firearms License to sell. It also carries the stamped serial number and therefore has been a barrier to DIY gunsmiths.

However, the U.S Gun Control Act of 1968 does allow companies to sell rough lower receiver parts that are 80 percent finished. That’s where a machine like the Ghost Gunner comes in. Using a commonly available steel carbine drill bit for the spindle, Defense Distributed’s CNC machine mills the few holes and cavities needed to finish off the remaining 20 percent. Not only is the machine cheap, but it doesn’t require much skill. According to Defense Distributed, the Ghost Gunner mills wood, plastic and aluminum, out-of-the-box, without any prior CNC knowledge.

To Canadian ears, the fact that the organization wasn’t shut down within days of the Ghost Gunner debut may sound like lunacy—the U.S.’s “cowboy,” gun-obsessed culture run amok. To Wilson and firearm advocates like him, the machine represents a subversive tool, outmanoeuvring the web of dictatorial regulation obscuring the Second Amendment.

Whichever side you tend toward, it remains that as most advancement lures us toward greater dependence on—even addiction to—technology, desktop CNC machines, entry-level 3D printers and push-pull CAD still hold out the potential for self-reliance. For most in the gun advocacy crowd, a firearm—like a vehicle— represents, not unbridled violence, but independence and self-sufficiency. To me, both should be traceable and require a license to operate, but in an age when the average Joe can’t fix his own high-tech car, it’s reassuring that he may soon be able to design, print, machine and assemble one.

Mike McLeod

@

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

October | 2014

6-7-DES.indd 6

Editor Michael McLeod (416) 442-5600 ext. 3231 mmcleod@design-engineering.com Publisher Alan Macpherson (416) 510-6756 AMacPherson@design-engineering.com Group Editorial Director Lisa Wichmann (416) 510-5101 LWichmann@canadianmanufacturing.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 Cindi Holder (416) 442-5600 ext. 3544 CHolder@bizinfogroup.ca BIG Magazines LP Executive Publisher Tim Dimopoulos Vice-President of Canadian Publishing, Alex Papanou President of Business Information Group, Bruce Creighton 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 6 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. Published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. 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.

www.design-engineering.com

14-10-07 2:57 PM

Get more control with less energy

with our AC and DC drives

STARTING AT:

$

156 u.s.

GS2-10P2

STARTING AT:

$

99 u.s.

GS1-10P2

$

High-quality AC drives pay for themselves in a hurry Variable speed drives can improve your bottom line by reducing your motors’ energy consumption. An investment of as little as $99 can start paying off immediately.

•

GS1 AC drives (1/4 to 2 hp) offer simple Volts/Hertz control for general purpose applications. Built-in I/O, Modbus communications capability and programmable preset speeds increase it flexibility.

•

GS2 AC drives (0.5 to 10 hp) feature built-in PID control, dynamic braking and Modbus communications.

•

DuraPULSE AC drives (1 to 100 hp) add sensorless vector control, a removable keypad that stores up to four different application programs and built-in discrete and analog I/O. Communicate via built-in Modbus or an optional Ethernet connection.

STARTING AT:

242 u.s.

GS3-21P0

DC drives for efficient control

Ironhorse DC drives are suitable for many control applications, all at prices that won’t break your budget.

•

Excellent low speed control and stability

•

Configured with potentiometers – no parameters or programming needed

•

DC motors coupled with DC drives provide exceptional low speed torque and power

Research, price, buy at: www.automationdirect.com/drives

STARTING AT:

$

59 u.s.

GSD3-240-2CL

Also Available LR Series Line Reactors

High-Speed Class J Fuses

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

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

AC Motor Soft Starters

Free standard shipping is available for orders totaling over $49 U.S. (except for orders which require LTL shipping, see Web site for details). Also, save on brokerage fees when shipping standard ground to Canada - allow AutomationDirect to choose the broker.

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

Optional Drive Related Items

1-800-633-0405

Replacement Fans

the #1 value in automation

14-10-07 2:57 PM

8 DesignNews UP FRONT IMP Aerospace delivers 100th Aurora

In September, IMP Aerospace delivered its 100th CP-140 Aurora, a multi-role, long-range patrol aircraft designed to support Canadian forces and conduct surveillance domestically.

The Aurora fleet entered service in 1981 and is now in its sixth Third Level Inspection and Repair cycle. The company says it has incrementally modernized the aircraft — replacing the wings and horizontal stabilizers, as well as installing state-of-the-art navigation and flight instruments, communications and mission systems — to extend the Aurora fleet’s operation beyond 2030. www.impaerospaceanddefence.com

Magna acquires Techform Magna International Inc. announced that its subsidiary, Magna Closures, will acquire Ontario-based Techform Group of Companies, an automotive supplier of hinges, door locking rods and other closure products. On completion of the transaction, Magna will acquire Techform’s facilities in Penetanguishene, ON; Portland, Tennessee; and Hefei, Anhui China. The transaction is scheduled to close in early October 2014. www.magna.com www.techform.com

3D Scanning Market to top $4B by 2018 Industry analyst firm, ReportsnReports.com, estimates the global 3D scanning market will grow to $4.08 billion by 2018, at an estimated CAGR of 14.6% from 2013 to 2018.

According to the firm’s report (3D Scanning Market Worldwide Market Forecasts and Analysis 2013 – 2018), there has been an accelerated growth in 3D scanning adoption because the conversion of point clouds to CAD data is becoming easier, prices are lower and hardware and software used is more efficient.

Major 3D scanning market players include Faro Technologies, Konica Minolta, Creaform, Surphaser, Autodesk, 3D Systems and 3D Digital Corp.

ReportsnReports.com

October | 2014

8-13-DES.indd 8

3D bioprinter wins Canadian 2014 James Dyson Award

T

he PrintAlive Bioprinter, a 3D printer that produces artificial skin grafts for burn victims, has been awarded the top prize in the Canadian leg of the 2014 James Dyson Award, an international student product design contest.

Developed by University of Toronto mechanical and biomedical engineering graduate students, Arianna McAllister and Lian Leng, the PrintAlive represents a major step forward in producing “highresolution human microtissue arrays,” the printer’s creators say and could significantly speed burn victim recovery time.

Similar in concept to a conventional 3D printer, the PrintAlive doesn’t create a skin graft in the traditional sense, but instead produces a kind of “living bandage” hydrogel. As its build material, the system extrudes a biopolymer infused with human keratinocytes and fibroblasts in a 3D structure that mimics epidermal and dermal skin layers.

According to its inventors, the PrintAlive has the potential to overcome the limitations of existing severe burn treatments. For example, traditional skin grafts are limited in size and can introduce infection or rejection issues, while techniques that grow skin cells to be applied over a larger area take weeks for cultivation. By contrast, the UofT technology could produce large custom-built hydrogel sheets rapidly using the patient’s own skin cells.

For winning the Canadian stage of the award, the UofT team will receive $3,500 to further develop the technology. Currently, the PrintAlive is in the process of clinic testing and pre-commercialization.

In addition to the winner, four runner-ups will go on to compete in the international award. Runners-up include: EcoSat: A small CubeSat that will test the diamagnetic properties of pyrolytic graphite in low gravity.

EyeCheck: A camera and smartphone app system that can quickly diagnose vision problems, as well as provide eyeglass prescriptions.

The Skorpion Rock Drill: A mobile mining drill carrier designed to replace heavy “jackleg” hand-drills that account for nearly one-third of all underground injury claims.

Suncayr: A pen-like marker containing UV sensitive dyes that www.design-engineering.com

14-10-07 12:43 PM

1 2 0 l/min!

10 Flows to

3

5

4

1 Next Gen Electronic Valves with Flows to 100 l/min!

2 ”GV” Series High Flow Poppet Valves 3 Electronic Valves for Analytical Industries 4 ”HV” Toggle & Stem Valves 5 “EGV” Electronic High Flow Poppet Valves 6 “PQ” In-Line & Elbow Flow Controls 7 High Flow “E” Electronic Valves 8 Manifold Mount Multi-Check Valves 9 Electronic Valves for Oxygen Applications

Introducing

6

new products new solutions

8 7

9 Clippard Instrument Laboratory, Inc. 877-245-6247 • www.clippard.com

Wainbee Ltd. 888-WAINBEE • www.wainbee.com more info

8-13-DES.indd 9

14-10-07 12:43 PM

| TS11-03USA |

10

DesignNews change color when the sunscreen washes or wears off.

According to the award’s organizer, the James Dyson Foundation, 600 entries were received for the international prize from 18 countries. The international winner, announced November 6th, 2014, will receive CAD$50,000 plus another CAD$18,000 for the student’s university department.

The judges for the Canadian 2014 James Dyson Awards included Lucas Cochran, technology correspondent on Discovery’s DAILY PLANET; Mario Gagnon, founder of ALTO Design, Canada’s largest design engineering firm; and this article’s author, Mike McLeod, editor of Design Engineering magazine. www.jamesdysonaward.org

Self-powered water purifier wins Grand Challenges Canada grant In September, Canadian engineering start-up, Formarum, received a $112,000 grant from Grand Challenges Canada (GCC) for its self-powering water purification device. The Toronto-based company was one of 22 Canadian projects to receive backing by the Government of Canada-funded organization, which supports sustainable technology, social and business solutions to health challenges in developing nations.

Requiring no outside power source, the company’s Dive purifier incorporates a small turbine generator that produces electricity internally from the water flowing through the device. The electricity powers Dive’s automated copper–silver ionization process, which treats the water as it flows. The system also automatically adjusts the disinfection rate based on water flow rate.

Once connected to a pipeline, the device functions without technical expertise or a dedicated power supply.

Invented by Ryerson University chemical engineering graduate and Formarum’s CEO and founder, Seyed Nourbakhsh, Dive is currently also in development as a recreational pool water purifier. According to Nourbakhsh, the system not only removes the labour intensiveness of pool maintenance but also offers an alternative to chlorine for control algae and fungus growth. www.formarum.com

KUKA Systems develops robotic riveting system for Boeing When the Boeing 777X twin-aisle passenger jet goes into full production for its debut in 2020, each fuselage will be built using KUKA Systems Aerospace Group’s robotic pulse production line, known as the Fuselage Automated Upright Build (FAUB) system. According to the company, the system will assemble fuselages for the current 777 models and then become the baseline manufacturing process for the wide-body 777X. The pulse line uses guided KUKA robots equipped with end effectors manufactured by another KUKA company, Alema October | 2014

8-13-DES.indd 10

Automation, to do the riveting currently performed by workers using handheld tools. The robots will work on the forward and aft sections, installing up to 60,000 fasteners per 777 fuselage.

For KUKA Systems, the project is one of the largest it has undertaken in the aerospace sector. The FAUB system, which was pre-assembled and integrated at KUKA Systems in Sterling Heights, MI, is undergoing the final phase of testing and production readiness in a Boeing facility in Anacortes, WA. www.kukanao.com

Canadian DND awards iRobot “bomb-sniffing” robot contract Canadian Department of National Defence (DND) announced that it has awarded iRobot Corp. multi-year contracts worth $9.6 million for 20 of the U.S.based robotics firm’s 510 PackBot CBRN Recce Systems, plus training and product support.

The iRobot system is a modular expansion to the company’s 510 PackBot MultiMission robot platform modified to meet the specific requirements of the Canadian DND. It includes a CBRN suite that integrates five primary sensors to detect, alert and report on chemical warfare agents, toxic industrial chemicals, volatile gases, explosives and radiation. The robot also features enhanced mobility through the addition of rear flippers.

The robot is designed for missions including explosive ordnance disposal, reconnaissance, route clearance and data collection in industrial settings. All systems under the contract are expected to be delivered by April 2015. www.irobot.com

Canadian researchers develop nano-sensors for smartphone glass Researchers at Polytechnique Montréal say they have created 3D light-guiding systems, laser-written into a smartphone’s protective glass, that could one day be used for sensing everything from temperature to blood sugar levels.

“We’re opening Pandora’s box at the moment,” says Raman www.design-engineering.com

14-10-07 12:43 PM

A

| TS11-03USA |

TwinSAFE: Machine Safety Simplified.

Combine safety PLC Terminals, safety I/O and standard I/O on one EtherCAT network.

www.beckhoff.ca/TwinSAFE TwinSAFE from Beckhoff: from I/O to drives it's the universal and flexible safety system.

TwinSAFE I/O for the EtherCAT Terminal system makes optimum use of the exceptional performance offered by EtherCAT: Compact: Safety PLC in a 12 mm terminal block Powerful: up to 128 safety devices per Safety PLC Versatile: integrated function blocks for emergency stop, protective door, two-hand control Modular: standard and safety I/Os integrated in a single system Flexible: “fieldbus-neutral” communication, eliminates dedicated safety networks Certified: solution up to SIL 3 according to IEC 61508, EN 954 Cat. 4 and DIN EN ISO 13849 PLe (approved for use throughout North America)

Safety inputs

Safety PLC

IPC I/O Motion Automation

8-13-DES.indd 11

Standard PLC

Safety outputs

Safety Drives

14-10-07 12:43 PM

12 DesignNews Kashyap, professor of electrical engineering and engineering physics at Polytechnique Montréal. “Now that this technique is viable, what remains is to invent new uses for it. This is why we are actively looking to partner with industry to develop this technology.”

To create these nano-sized, transparent systems, the research team used an infrared laser to etch three-axis transparent light pathways, or waveguides, within Corning Gorilla Glass, a strong, dense glass currently used in most smartphones.

Measuring only a few microns in diameter, but up to a meter long, the channels are imperceptible to the naked eye but act as conduits for the light given off by the smartphone display. Analyzing shifts in the light as it passes through the waveguides allows for novel sensor applications.

As a proof of concept, the research team created a heat sensor composed of two waveguides, one straight and one curved.

As the glass heats up, the waveguides get longer as the glass expands. By measuring how the light that emerges from one waveguide interferes with light from the other, the device can measure the temperature of anything it touches.

The team also created a smartphone authentication system by employing waveguides with patterns of tiny holes. Using this method, each smartphone could have a unique photonic fingerprint to add another layer of security in, for example, finan-

October | 2014

8-13-DES.indd 12

cial transactions.

“It’s easy to imagine how the technology could also eventually allow computing devices to be embedded into any glass surface, such as windows, tabletops, telephone screens, creating totally transparent tactile surfaces,” says Jérôme Lapointe, lead researcher and doctoral student at Polytechnique Montréal. “It would be like adding a new dimension to the real world that our eyes can see.” www.polymtl.ca/en

www.design-engineering.com

14-10-07 12:43 PM

Upgrade your manufacturing capability without replacing your machine with the new Eaton Vickers AxisPro proportional directional valve designed specifically for machine control using on-board motion control, intelligent diagnostics, robust plug and play software and like-for-like replacement.

It’s a simple solution to enhancing the productivity of your machinery.

And, you can find Eaton Vickers AxisPro proportional directional valves at your local Motion Canada location. Our local sales and service specialists are experts in application and technical support,

Call. 800-526-9328 Click. www.motionindustries.com Visit. Over 550 Locations

providing the parts and the know-how you need to stay up and running.

The brands you count on from the people you trust…that’s Eaton and Motion Canada.

Call. 800-526-9328 Click. www.motioncanada.com Visit. Over 50 Locations

8-13-DES.indd 13

Téléphone 800 526-9328 Clic www.motioncanada.com

14-10-07 12:43 PM

14 CADReport

What’s New in SOLIDWORKS SolidWorks receives a major upgrade in 2015, signalling a renewed commitment by Dassault to its leading MCAD package.

By Ralph Grabowski

F

our years after Dassault Systems announced the successor to SolidWorks (a badly flubbed PR move that led to a frenzy of speculation as its dedicated users debated the future of the company’s midlevel CAD package), its future is now secure. At the September launch of SolidWorks 2015, Dassault executives reassured the assembled media that the MCAD program would be updated and supported for another 15 years, at least.

The uncertainty primarily affected the chattering classes because, at 2.3 million users, SolidWorks continues to sell briskly, keeping its position as the #1 MCAD program. Now, the bulk of these sales are to educational institutions; subtract them out and there appears to be around 650,000

commercial seats. Dassault trumpets the number as often as it can, because arch competitor Siemens PLM only occasionally provides vague guidelines for second-place Solid Edge, such as “over 500,000” commercial seats, while Autodesk stopped reporting licenses of apparent third-place Inventor years ago.

What’s New in SolidWorks 2015 And so, in this light, Dassault imbued SolidWorks 2015 with a bevy of new and enhanced functions. After all, nothing says “We’re there for you” like lots and lots of enhancements from a software company.

Let me highlight a few that caught my eye.

Intended for building assemblies graphically, Treehouse is not so much new functionality as reintroduced since it was previewed years ago. Using its flowchart-

Figure 1: Creating assemblies by dragging and dropping parts in Treehouse.

October | 2014

14-17-DES.indd 14

www.design-engineering.com

14-10-07 12:44 PM

n S

CADReport 15

2015 like interface (See figure 1), we build assembly structures by dragging and dropping parts and assemblies into the interface—or by opening an existing assembly into Treehouse. After this, we can edit the parts to specify things like configurations, quantities and custom properties. The data can then be linked to SolidWorks Enterprise PDM. Chain patterns are a new type of assembly. Here, we pattern (array) parts along a path that can be opened or closed—think tank-treads or even gantry cable guides— in three modes: Distance, distance linkage or connected linkage. Once the assembly is complete, SolidWorks simulates the motion of the chains so that we can be sure it’ll operate correctly.

Something we saw introduced to Solid Edge ST7 this year, SolidWorks also automatically flattens 3D models to see how much material is needed. With an eye on the fashion industry into which Dassault sells specialty software, this flattening can be used towards clothing, footwear and upholstery design.

Over in the area of surfacing, surface curvature combs let us see how well surfaces connect. This is important for ensuring smooth transitions from one surface to the next.

Asymmetrical fillets means that we can specify two radii (instead of just one, as for traditional fillets), like two distances for chamfers. In this case, the resulting fillet looks like a quarter ellipse.

Patterns (arrays) no longer need to be regularly spaced; they can have variable distances defined by formulae. (I first saw this in the Russian KOMPAS MCAD program earlier this year, and so it’s interesting how quickly the function appeared elsewhere.) To make variable patterns, we first create a pattern table that defines the distances, which can be pasted into Solidwww.design-engineering.com

14-17-DES.indd 15

Works from a spreadsheet. The table defines distances between features (extrudes, revolves, fillets, domes, drafts and so on), as well which instances to skip for noncontinuous patterns. The values can be static, or calculated using mathematical functions, like sum, sine, log, pi and square root. I can see this one function needing an entire course to learn!

To make it easier to find references in 2D drawings, sheets can now be divided into zones. As a result, annotation notes, balloons and revisions tables refer to zone numbers, which are updated automatically should parts be moved to another zone.

Other new items that caught my eye are touch-ups that probably should have been added to SolidWorks years ago. These include drawing lines symmetrical to the midpoint; saving selection sets by name for reuse; customizing toolbars; drawing spline-shaped leaders; and setting word wrapping, paragraph spacing, and line spacing in paragraph text.

SolidWorks Links to MBD Along with adding functions to SolidWorks, Dassault continues on a parallel path, slowly writing modules that are independent of the MCAD program, yet help out designers using SolidWorks. The modules are independent because they are written with Dassault’s proprietary CAD platform — Enovia database (for the “file” system) and CGM kernel (for the modeling).

Consequently, they are inherently incompatible with the Parasolid kernel employed by SolidWorks. Being external modules also allows Dassault to charge extra for each, typically $2,000 apiece with a $500/yr subscription.

The newest module is SolidWorks MBD (Model-Based Definition). The idea is that 3D models should contain all the information needed to build the design, forsaking 2D October | 2014

14-10-07 12:44 PM

16 CADReport entirely. (See figure 2.) Now, MBD is the hot new term that isn’t as sexy as “social” or “cloud,” but is much more important; well, it has the potential to be that, but only now is getting attention along with slowly getting needed traction among design firms.

MBD is driven by government agencies, such as the U.S. Military’s MIL-STD-31000A specification, a 3D data format required for parts manufactured for military use.

Traditional 3D models contain only information that is inherent, such as the lengths of edges and volumes.

Design details are left to stacks of 2D drawings, which document 3D models through flattened views, dimen- Figure 2: Model-based definitions embed all information needed to manufacture 3D models sions and geometric tolerances, welding instructions plus embedded bills of material and their MBD promises to jettison all the 2D generation, automation accompanying balloons, all topped off with index sheets. This is and linking for a purely 3D deliverable that is loaded up with why marketing departments make a big fuss over how well their all the information that today is relegated to drawing sheets.

MCAD programs generate linked 2D drawings from 3D models, But this means updating MCAD systems to embed 3D PMI automatically. Because that’s the way it’s done, currently. (product and manufacturing information) and metadata into

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

14-10-07 12:44 PM

CADReport 17 ware developers.

This is not a simple transition, and so SolidWorks doesn’t do it. Instead, the new, separate module does it.

SolidWorks MBD attaches all that PMI data directly onto 3D models.

Output templates generate models and data suitable for different departments, such as procurement, request for quotations and manufacturing. And, in a tip of the hat the current practice, MBD also outputs drawings in 2D. With SolidWorks 2015, users will be relieved to see their favorite MCAD system imbued with new life through an impressive set of new functions.

The Profile Center Mate feature locates the centers of two items to each other regardless of their size or shape.

For those firms who need it, MBD will allow them to use a mid-level 3D models—information like design intent, GD&T, BOMs, MCAD system for high-end aircraft and military contracts. DE material definitions, and all this stuff that used to be external www.solidworks.com to the pure 3D model.

Clearly, generating self-contained 3D models requires a big Ralph Grabowski is a CAD journalist and blogger at switch in thinking and a big programming job by MCAD soft- worldaccess.typepad.com

12

CONTACT L

Improve yo

Scott’s Con North Ame mail, fax, te

EMAIL MAR

Improve co

Marketing valuable au your messa the leads th

DATA SERV

Maximize y ROI using Data Appe Research,

PART

SMS-A34-BIG-fullad-4c.i

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

14-10-07 12:44 PM

18

RapidPrototyping

COLOR Me AWESOME Canadian projection-mapping technology renders high-definition color textures on 3D printed models.

By Mark Barfoot, Hyphen

R

ecently, additive manufacturing/3D printing has been getting a lot of attention with its benefit of producing prototypes quickly to try out designs; creating fixtures to aid in production of components in a fast; and efficient matter and producing production parts for a variety of industries, from aerospace to medical to commercial and consumer products. More recently, with the advent of the lower cost “home-use” based machines, the power of 3D printing has now entered everyday life.

One complaint about additive manufacturing technologies, however, is that they are limited to a single color in the build.

Three current technologies, however, allow for color: • Stratasys’ Polyjet technology in its Connex 3 machine uses inkjet print heads to lay up primary colored photopolymers in a mixture to create a range of color parts. The resulting parts are hard and durable but have a limited color palette.

• 3D Systems’ Color Jet Printing (CJP) process spreads a layer of starch based powder and then sprays out a colored binder to harden the part. This provides full color models, but they require infiltrating with cyanoacrylate after printing to get them hard enough to handle. Even once infiltrated, their strength is only similar to a cured ceramic part.

• Paper 3DP by Mcor, the newest technology to offer color, takes regular full color printed paper sheets and glues them in a stack and cuts away the excess to create full color models.

If you don’t have any of these technologies, you have to resort to painting the parts manually to achieve the colors you need.

If companies want to compare different color versions to choose final color, distinct individual models have to be created.

October | 2014

18-21-DES.indd 18

Above: A 3D printed C7 Corvette model, created by Hyphen, sits on a video display platform composed of Christie Digital Systems’ MicroTiles.

Below: The Christie Interactive Design Studio projects a dynamic background and HD color textures onto the grey Corvette model.

A New Color Concept Christie Digital Systems Canada and its subsidiary, Kitchenerbased service rapid prototyping and environmental testing center Hyphen, have come up with a proof of concept for a new application, called the Christie Interactive Design Studio. With this system, you can take a standard gray 3D printed part and have projectors instantly provide the color and texture through projection mapping. A video display wall composed of Christie MicroTiles as a backdrop lets you “place” the part in any environment.

The result is a system that allows you to dynamically change the color, texture and style of your part on the fly, while further offering the opportunity to see how that part looks in different settings. This can save the time and cost of printing multiple, different color versions or laboriously hand painting various color options on different models.

The first iteration of this unique projection mapping system for 3D printing was shown at Infocomm 2013 and consisted of www.design-engineering.com

14-10-07 12:47 PM

The RSM2800 Magnetic Encoder counts turns, measures angles down to the last degree, and remembers shaft positions without power Don’t try this with other encoders: imagine your machine with the RSM2800 inside both lose power and are still turning without power; when power is restored, the RSM2800 reports the correct position including the counts that occurred with no power!

RSM2800 magnetic encoders provide the level of reliability and accuracy sought in demanding applications like: • Material Handling

• Agricultural Machines

• Forklifts

• Cable Extension Transducers

• Overhead Doors

• Medical Equipment

The RSM2800 is based on Novotechnik’s proprietary non-contact, multi-turn technology for absolute 5,760° (16 turns) measurement.

This new wear-free device combines advanced capabilities with mechanical simplicity in a very compact and sturdy housing to provide for longer life and lower cost than optical encoders.

RSM2800 Specifications:

✔ Absolute multi-turn ■ ✔ Up to 16 turns ■ ✔ Up to 0.1° resolution ■ ✔ Up to 0.1% ■ ✔ ■ ✔ ■ ✔ ■

Contact us for samples or for complete specs, visit www.novotechnik.com/rsm

✔ ■

independent linearity Outputs: 0.1 to 10V or 4 to 20 mA or 0.25 to 4.75V Housing OD=30 mm IP rating options: IP54 or IP67 No gears, no optics, no batteries

Novotechnik U.S., Inc. • 155 Northboro Road • Southborough, MA 01772 Tel: 508-485-2244 Fax: 508-485-2430

18-21-DES.indd 19

14-10-07 12:47 PM

20 RapidPrototyping an Audi R8 model in the interactive display. At Infocomm 2014, the system had a C7 Corvette model with the additional functionality to auto map the content, as well as manipulating the background details to show enlarged images of the mapped content on the back screen.

Also, various smaller parts, ranging from a dinosaur to the Angkor Wat temple, were 3D printed and then projected upon using lower quality projectors, but done in an automated environment where the object could be rotated or moved anywhere in the display area.

These unique projection-mapping solutions can be used at numerous stages of production, from the in-the-design phase, which helps determine the colors that suit the product, to the consumer level, where consumers can dynamically change the colors to configure the system they want to purchase.

So how does the Christie Interactive Design Studio work? First, you need to create the model of your part. Most companies already have the existing CAD details, so you can either print the part as is or, in the case of the C7 and Audi R8 examples, you can manipulate the model to provide ribbing inside and hollow out the shape to make it faster and more cost effective to print.

Hyphen recommends the stereolithography (SLA) process for this, as it provides the smoothest surface finish to projection map onto. If the object needs to be larger than the SLA build size, it

can be built in sections and joined together. Once the part is printed, it can be painted a perfectly matt charcoal gray color to ensure the best contrast in your projection mapped content.

Next, you move to the digital content and update it to have the colors and textures you want and create a GUI-based system to manipulate the choices. In the future, this could be an automated process.

The physical part is then placed into the design studio, in essence a “stage� for the printed part. In the examples above, we used proprietary automated alignment and mapping technology to create the extreme warping and blending required to fully cover the surface of the object.

Now that it is set up, you can replicate a photo-real, physical object that audiences can customize in real-time, while the background can also be selected using an intuitive centric interface.

Although this technology is still in the final design stage, soon it could be coming to a car dealership, model home display or department store display near you.

DE www.hyphenservices.com

Mark Barfoot is the Managing Director of Hyphen, a fullservice rapid prototyping and environmental testing center in Kitchener, Ontario.

A p p d m

O t c p

W d

Vi Š

7PLNT15928.indd | 2014 October

18-21-DES.indd 20

1

3/20/07 12:32:48 PM www.design-engineering.com

14-10-07 12:47 PM

Some say they’re FAST...

But do they have the SCALE to deliver?

At Proto Labs, we’re optimized to deliver quick-turn additive, machined and molded parts in as fast as one business day. Our three distinct services allow us to manufacture prototype and production parts for thousands of customers each day, many with dozens of designs that need to be simultaneously tested. Since 1999, we’ve shipped millions of parts to product designers and engineers around the world.

Our proprietary software and automated technology let us make parts for you faster than anyone else, but we back it up with large-scale manufacturing facilities on three continents that house hundreds of 3D printers, CNC machines and injection-molding presses.

Whether your project requires a single prototype or thousands of parts from 50 different designs, we have the capacity to meet your manufacturing needs every time.

2015 Cool Parts Calendar Request your free calendar at

go.protolabs.com/DE4D

Visa/Mastercard Accepted | ISO 9001:2008 Certified | ITAR Registered © 2014 Proto Labs, Inc. | protolabs.com | 877.479.3680

18-21-DES.indd 21

14-10-07 12:47 PM

22 Hardwire

Home MAKER Dremel’s sub-$1,000 3D Idea Builder takes complexity out of 3D printing at the cost of flexibility and versatility.

By Mike McLeod

I

n the bad old days of early laser printers, users often had to fiddle in the minutia of font file formats, raster image processors and even the intricacies of the PostScript printing language to get documents to output correctly. By the time laser printers became common in people’s homes, however, companies like Adobe, Apple and Canon had boiled the amount of arcane tech knowledge needed to operate these machines down to a driver install and pressing Ctrl-P. Today, 3D printers are taking a similar path. Many of the sub-$1,000 machines targeted at a consumer market (e.g. Solidoodle Press, PP3DP Up!Mini, Robo3D) work out of the box and generally don’t ask as much from would-be Makers as the early kit-built machines. Yet, as far as it has come, 3D printing is still a bit of a dark art that requires users to futz with build table calibration, extruder nozzle care and 3D geometry file formats not to mention enough mechanical design know-how to create parts that won’t fail mid-build.

Dremel, the makers of every tinker’s favorite rotary cutting tool, hopes to push the technology to the next level of adoption.

In September, the company introduced its 3D Idea Builder (3D20), a sub-$1,000 3D printer squarely targeted at users unfamiliar with the nitty-gritty of additive manufacturing.

“We have the same technical capabilities as all the current printers out there, but at the same time we’re trying to get more people using 3D printing,” says Eli Shane, lead engineer for the Dremel printer. “We really want to push the technology and make it more approachable and accessible, allowing users to get started printing before they get overwhelmed by all the technical details.”

Intended for home use, the UL certified 3D printer offers some decent specs for a consumer price-point system. It’s enclosed build space measures 9.0 x 5.9 x 5.5 inches (230mm x 150mm x 140mm) for a total build volume of 292 in3. While smaller than the MakerBot Replicator 2 (410 in3) or the Tinkerine Studios’ DittoPro (433 in3), the Dremel system is half the price ($999 SRP) of typical pro-sumer systems. Layer resolution is also comparable, varying between 300 microns (.3mm) at the low resolution and 100 micron (.1mm) at the high setting.

For ease-of-use, the system features a built-in SD card reader, integrated print software and a color touch screen to allow it to work without being hooked up to a computer. The system also comes with a build table leveling sheet and a nozzle clog tool to help users take care of common 3D printing problems.

Since the 3D20 is targeted at the consumer market, it sacOctober | 2014

22-23-DES.indd 22

rifices flexibility and choice for push-button simplicity. To help new users avoid a negative experience, the company has restricted or simplified some of the fine-tuning options common on similar printers.

For example, the 3D20 only works with PLA filament (not ABS) and only Dremel-brand build material. Shane says ABS isn’t offered for a number of reasons. PLA is plant rather than petroleum-based and therefore is environmentally friendly and doesn’t give off the same “melting plastic” smell as ABS. In addition, ABS is a trickier build material that is more likely to curl or warp as it cools. This fact necessitates a heated build platform in similar machines, which would make the system more complex to operate and drive up the end price.

Beyond the limitation on build material, the printer itself doesn’t read STL files directly. Instead, it accepts the company’s propriety .3drem or .3dremel file formats, although the 3D20’s build software does read and convert standard STL and OBJ formats. Shane says the special format allows for the inclusion of build meta-data (e.g. model orientation, scale, position, etc.) in addition to simply the B-rep geometry data.

“For example, if you load multiple STL files into one build platform preview, you can save it as a build platform file [.3dremel] that works with our software,” he says. “That way, if you had manipulated the STL in any way, like scaling it, the next time you open the Dremel file, you don’t have to re-scale it.”

To alleviate the burden of learning 3D modeling, the printer will ship with a set of “Dremel-approved” files that have been tested to build correctly on the machine and the company also hosts an expanding catalog of 3D files on its web site.

Of course, the allure of a 3D printer is building parts you’ve designed yourself. In place of traditional CAD software, the company is partnering with Autodesk to make its 123D suite of design software available to Idea Builder owners. In addition, users can create files using TinkerCAD’s browser-based, primative-oriented modeler or the University of Toronto-developed 3D sculpting tool, MeshMixer, now owned by Autodesk.

While there are many similar consumer 3D printers available, Dremel’s printer has an edge in that it’s the first from a wellknown brand name and is available for pre-order from common retail chains, including Home Depot and Amazon. For the Canadian market, the system will also make its debut in select Canadian Tire locations and canadiantire.com by the end of 2014, the company says.

DE www.Dremel3D.com www.design-engineering.com

14-10-07 12:48 PM

© T a f

Strongest link.

Connect to your team instantly with the push of a button.

Samsung Galaxy Rugby™ LTE

Sonim XP5560 BOLT 2

Samsung GALAXY S5™

New TELUS Link™ service is the next evolution of Push To Talk for business.

■

Get superior US, Canadian and international coverage to connect individuals and groups

■

Use it on the most popular smartphones and rugged devices

■

Send data at the fastest speeds available on our 4G LTE network

Try TELUS Link service free for 30 days*. Visit telus.com/teluslink

©2014 TELUS Corporation. © 2014 Samsung Electronics Canada Inc. All rights reserved. Samsung is a registered trademark of Samsung Electronics Co., Ltd., used with permission. Screen images simulated. © 2014 by Sonim Technologies, Inc. All rights reserved. Sonim, Sonim Technologies, Inc., all Sonim logos are trademarks of Sonim Technologies, Inc. *The TELUS Link free trial is offered at no additional charge for the fi rst 30 days and can be added to a new or existing TELUS Link compatible device and rate plan. If you decide to keep TELUS Link and do not notify TELUS otherwise, normal charges will apply after 30 days. The 30-day trial applies only to the $15 feature add-on called TELUS Link 15. Add-on is subject to terms and conditions as outlined in the Customer Service Agreement. 14_00490

22-23-DES.indd 23

14-10-07 12:48 PM

24

CADBeat

Exhaustive SIMULATION Canadian exhaust system designer uses multiphysics simulation to reduce costly iterations.

By Matt Butson and Ning Cao, Active Exhaust Corp.

D

esigning exhaust systems is complicated by the number of different physical phenomena involved.

Designers must consider airflow inside the exhaust system and its impact on back pressure experienced by the engine. The flow of gas through the exhaust manifold produces vibrations and noise that the design must mitigate. The system’s temperature must be maintained to maximize exhaust after-treatment performance and to minimize impact on both the environment and adjacent vehicle components. Active Exhaust uses multiphysics simulation to reduce costly iterations by validating designs before testing.

Active Exhaust is a world-class provider of exhaust management systems for industrial engine and vehicle applications.

The company specializes in sound, emissions and thermal management solutions for mobile and stationary engine applications ranging from 5 HP to 700 HP. Headquarters in Toronto, the company’s facility houses R&D, product engineering and customer support, as well as its North American manufacturing center. It has a staff of approximately 275 employees along with two off-shore joint ventures in China and India, and warehouse locations in the United States. Active Exhaust caters its technologies to markets that include consumer and commercial lawn care equipment, construction and farming machinery, welders and generators, as well as all-terrain, recreation and utility vehicles.

ANSYS FEA results show deformation of this manifold headerpipe designed by Toronto-based Active Exhaust Corp.

Environmental Protection Agency and Department of Agriculture.

As a value-added service, Active Exhaust directly collaborates with various approving bodies to simplify the process for its customer base. As a result of uncertainty in design performance, all new exhaust systems have to undergo lab validation of criteria such as pressure drop, horsepower, torque, thermals, vibrations, acoustics, emissions, cleanliness, particulates and leak testing.

This process relied heavily on physical testing to validate design performance. Active Exhaust’s extensive test facility has provided the final validation before products are shipped to customers. The million-dollar test facility includes five eddy current dynamometers with capacity of up to 10,000 rpm, 400 Nm and 160 kW. When the engines are instrumented,

Design Validation by Testing In the past, the company utilized 2D design tools that were developed internally based on existing tube and muffler elements. The design engineer approximated the design performance using these tools, but the accuracy, documentation and scope of design-ready geometries were limited.

Engine manufacturers must adhere to stringent regulations Simulation, such as this temperature distribution of gas inside an exhaust diffuser, allows including those set forth by the U.S. Active Exhaust to virtually validate designs, and thereby reduce costly physical testing.

October | 2014

24-27-DES.indd 24

www.design-engineering.com

14-10-07 1:27 PM

You can buy pipe...

You can buy valves...

You can buy fittings...

or, you can buy the IPEX system.

The IPEX Advantage

Leader in Thermoplastic Piping Systems

The advantage is obvious. Every plastic Pipe, Valve and Fitting you need for any Industrial project; available from a single, reliable Canadian source.

IPEX Inc. designs and manufactures one of the world’s most diverse lines of integrated thermoplastic piping systems. All engineered from the ground up to handle the full range of today’s Industrial, Mechanical, Municipal and Electrical applications.

Only IPEX offers a complete system of Pipe, Valves and Fittings engineered and manufactured to strict quality, performance and dimensional standards.

Available in Industrial PVC, CPVC, ABS and Natural and Pigmented Polypropylene – for Process Piping, Double Containment, High-Purity, Acid Waste and Compressed Air applications, as well as a full range of specialty systems and products.

A Canadian pioneer with more than 50 years’ experience in plastic piping systems combined with progressive manufacturing technologies, efficient distribution centres and coast-to-coast customer support. When you choose IPEX, you can be confident that all your piping materials are backed by one company.

Industrial Piping Systems Double Containment

w w w. i p e x i n c . c o m

24-27-DES.indd 25

High-Purity

|

Acid Waste

Compressed Air

T oll Free: 1-866-473-9462

Actuated Valves

Tough Products for Tough Environments ®

Pipes and fittings are manufactured by IPEX Inc. Valves are manufactured for IPEX Inc. by FIP S.p.A.

14-10-07 1:27 PM

26 CADBeat these state-of-the-art data acquisition systems collect flow, pressure, noise, acceleration, temperature and other measurements at frequencies to distinguish exhaust pulsations with high resolution.

Recently, however, the company entered markets with engines so large that they exceed the capacity of internal dynamometers.

Third-party testing would have been required, driving costs to uncompetitive levels. The additional costs related to building prototypes and the outside manpower required to perform analyses made it too expensive to continue designing these larger systems employing the physical testing method.

Active Exhaust recognized several other limitations in their test-based design process. Whenever a design did not meet requirements, the team had to react quickly to redesign, rebuild the prototype, and repeat the tests at considerable expense.

Additional design iterations took substantial amounts of time, running the risk of delaying product introduction. The measurements that were captured by physical testing were constrained by the physical limitations of sensor technology: Information generated by the tests was often insufficient to diagnose the root cause of a problem. For example, physical testing is unable to detect flow recirculation, which can significantly increase exhaust pressure drop.

Further, the high cost of testing meant that the team had only limited opportunities to evaluate design alternatives that might optimize performance and cost.

Simulation-Based Design Process Active Exhaust considered a number of different simulation options. With fluid flow crucial to the design, the company first focused on computational fluid dynamics (CFD) solutions.

Engineers found several software packages that met the company’s needs, but ANSYS software was distinguished by its ability to solve the additional physics involved in the design, including mechanical, thermal and acoustics.

Active Exhaust selected ANSYS CFD-Flo for fluids simulation along with ANSYS Mechanical, which provides structural, thermal and acoustics capabilities. These and other ANSYS tools reside within the ANSYS Workbench environment, providing bidirectional data transfer with CAD systems, a common user interface and integration between the different physics, among other capabilities.

Simulation now is at the heart of the design process at Active Exhaust. The first step typically is to open a file containing the CAD geometry that has been created in PTC Creo software.

Active Exhaust then extracts the fluid volume from the solid model and adds boundary conditions to it, such as the mass flow rate at the exhaust inlet, exhaust outlet pressure and other parameters arising from the engine operating conditions.

ANSYS CFD is then used to perform a flow simulation October | 2014

24-27-DES.indd 26

through the exhaust system. This simulation calculates the exhaust system pressure drop and resulting back pressure at the inlet. Since the flow is now being simulated in the actual exhaust geometry, the results usually correlate quite closely with physical measurements.

The CFD software provides diagnostic capabilities far beyond what is obtainable from test results, including velocity and pressure at every point in the flow path. For example, an engineer running a flow simulation of a new exhaust system might see a recirculation zone in the flow path. Aware that recirculation generally increases the system pressure drop, he would then make changes to the geometry of the CFD model, such as reducing any obstruction or excess curvature in the main flow path.

The engineer would then rerun the simulation to see if the change eliminated the recirculation zone. If not, the engineer would continue modifying the model geometry until the recirculation zone was eliminated. This process often leads to a significant reduction in back pressure. The benefit of using the analysis software is that, as the geometry changes, the mesh, setup and solution are automatically updated, saving time in the development process.

In conjunction with using CFD simulation, Active Exhaust engineers apply ANSYS Mechanical to analyze the exhaust system from thermal, structural and acoustics perspectives. The integration between ANSYS CFD and ANSYS structural mechanics software makes it easy to transfer the internal temperatures calculated using CFD to ANSYS Mechanical, where they become inputs for a thermal analysis that determines the temperatures on the exterior of the exhaust system and identifies the stresses generated by thermal expansion.

Flow field streamlines and temperature distribution inside a venturi-type aspirator.

ANSYS Mechanical is also used to validate the structural integrity of the exhaust system by inputting power spectral density data from the vehicle. Using these inputs to drive a random vibration simulation determines frequency response and stress distribution. The dynamic analysis also determines modal frequencies of the exhaust system. If the modal frequencies have the potential to be activated by the engine, engineers make design changes.

The next step in simulation at Active Exhaust is to predict the acoustic performance of exhaust systems prior to the prototype phase. This is determined using ANSYS structural mechanics features that utilize the output from modal analysis www.design-engineering.com

14-10-07 1:27 PM

CADBeat data to calculate attenuation and absorption of pressure waves (sound) by the muffler.

Based on this data, the software simulates the transmission loss across the frequency spectrum and calculates noise emission levels. Active Exhaust has been able to utilize its library of raw engine acoustics as a source impedance to help characterize insertion loss values, a widely compared value in the industry.

The most important advantage in moving to a design process based on simulation is that Active Exhaust now almost always gets the design right the first time. Every new design is still exhaustively tested, but up front simulation ensures that the first prototype meets the customer’s requirements in nearly every case. Simulation also provides much more diagnostic information, making it possible for engineers to quickly identify the root cause of problems and to make substantial improvements in performance.

www.design-engineering.com

24-27-DES.indd 27

27

Flow field streamlines and temperature distribution inside a muffler displaying streamlines and temperature contours.

The company’s customers benefit from higher performance and shorter lead times. Active Exhaust absorbs most design costs with the intent of earning them back when the exhaust system moves into production. Active Exhaust has won several major contracts that can be directly attributed to the new design methods.

DE www.activeexhaust.com

Matt Butson is the Engineering Services Manager and Ning Cao is the Product Design Engineer at Active Exhaust Corp. in Toronto.

October | 2014

14-10-07 1:27 PM

28 CoverStory

A 500 kW flywheel being lowered into the vault at Temporal Power’s manufacturing facility to undergo testing.

On the

FLY

Temporal Power’s flywheel design is putting the Mississauga-based firm on the global energy management map.

By Treena Hein October | 2014

28-31-DES.indd 28

S

ometimes what seems like bad luck can turn out to be a life-changing catalyst – the thing that sets us on a course we never could have imagined.

That’s been the extraordinary experience of Jeff Veltri. A non-work-related injury in young adulthood ended his five-year stint as a pipe fitter and sent him back to school, into Ryerson University’s mechanical engineering program. He was employed for a while and then started his own firm, working over the next ten years on industrial, biomedical and military projects. “I’ve always been an inventor and a tinkerer, taking things apart to see how they worked,” Veltri says. “But I’ve always had the goal of being able to both create and manufacture a product.”

The realization of this goal started without Jeff realizing it – in 2008, when the government of Ontario was introducing time-of-use electricity rates. It prompted him to look at how power could be purchased during non-peak billing times and www.design-engineering.com

14-10-07 12:55 PM

CoverStory 29 then used whenever it was needed in his home office-shop. In his research, he was drawn to the flywheel.

“Any conventional energy storage device, like a battery, degrades a little each time you charge it and discharge it, but a device that is purely mechanical like a flywheel is immune to that, if the design is proper,” Veltri explains. “A flywheel can also deliver 100% of its capacity.”

As Veltri mused about flywheel use for his own business, he realized it could be commercialized for grid use. “So, I designed a small prototype and took it to the OPA (Ontario Power Authority) to show it off.” The device had an analog power meter with a disc that spun one way when the machine was charging and the other way when it was discharging, which gave a good visual demonstration.

To move forward, the next step was obtaining an $300,000 OPA Technology Development Fund grant, but applying would involve business model expertise. “I hired Cam Carver, and he was very enthusiastic,” Veltri explains. “He suggested partnering and creating a new business, and we formed Temporal Power in 2010 [Veltri is President and CTO, and Carver is CEO]. The management of grids was changing and Cam realized the concept would be of great value to the IESO (Independent Electricity System Operator of Ontario) in terms of frequency regulation.”

The company did secure the OPA grant, which allowed the tech to be scaled up to bench size, a 1 kW model, and then to what they now offer commercially: a 50kWh, 250kW or 500kW module that can be arrayed to multi-MW scale. Along the way, Sustainable Development Technology Canada and Hydro One provided assistance, and Lockheed Martin verified the design. Carver and Veltri also secured an investment of $500,000 from MaRS Discovery District, and $6 million from a Toronto-based venture fund, allowing the company to move to a facility in Mississauga.

They are now at 30,000-sq.-ft. with 24 full-time employees, including eight engineers.

“It’s been a period of great excitement mixed with some terror,” Veltri chuckles. “It’s great to have all the support and confidence of investors, and my very patient wife over the years, but the pressure is there. My hair went from brown to mostly grey trying to stay on budget, dealing with engineering challenges…but it’s been the time of my life.”

A simple flywheel design In simplest terms, a flywheel is a mechanical battery that stores kinetic energy in a rotating mass. When charging, the motor uses power from the grid to accelerate the rotor to high speeds.

Variable frequency drives feed the motor to convert electrical energy to rotational kinetic energy. On discharge, the flywheel slows and its inertial load drives the motor as a generator, adding power back to the grid.

Through their ability to efficiently balance energy and control energy frequency (at the standard 60 hz) by rapidly absorbing or generating power, Temporal Power flywheels improve power quality and lower costs. Veltri notes that problems with not being able to regulate grid voltage and frequency quickly helped cause the massive eastern North America power outage in 2003. www.design-engineering.com

28-31-DES.indd 29

Temporal Power tech is also obviously very handy in integrating variable power generated from renewable sources like wind into the grid. The size and patented design of these flywheels allows them to hold massive amounts of energy many hundred times greater than conventional (relatively tiny) flywheels. The life cycle of the tech is 20 years with minimal maintenance and full recyclability, Veltri says.

The rotating mass is steel, weighing in at 4,000 kg with a top speed of 12,000 rpm. Veltri notes that while carbon fibre has been used in smaller flywheels, it is not feasible in this case as there are few companies who could make such a large rotor with it; carbon fibre is brittle and detecting flaws in it is difficult.

“Steel has been around for hundreds of years, and it’s a material that’s easily-obtained, relatively inexpensive and offers excellent defect testing,” he explains. “We have the machining done locally, and as much of everything else that we can within Canada as well.”

The flywheel spins in a vacuum to eliminate wind resistance, and the permanent magnet at the top forms a closed magnetic circuit that lifts the entire mass off the mechanical bearings, allowing them to do radial and axial positioning but under a very light load. The friction losses are therefore very low, less than 1 KW, and the bearings are expected to last a long time.

One of the two main engineering challenges was rotor dynamics. “At first glance, there is only one moving part, but with such

F RE E CATA LOG & B ROC H U R E

WASHERS & STAMPINGS

Call 1-888-WASHERS

1-888-927-4377 • sales@bokers.com 612-729-9365 • FAX 612-729-8910

WWW.BOKERS.COM/DE October | 2014

14-10-07 12:55 PM

30 CoverStory

exterior view

a large mass spinning this fast, resonance was a big issue,” Veltri explains.

“Any spinning object will resonate at certain speeds and directions depending on the geometry, and we used rotor analysis software to tell us theoretically how things should be shaped, but you still have to do prototypes. The models are excellent, but the characteristics change – things shake – because other things within the entire system come into play.”

Precision balancing of the rotor was the other main challenge. “We’d outsourced this but had to bring it inhouse as no one had machinery that could do the job, balancing a 4,000 kg part within a few grams,” Veltri explains. “We had to customize the equipment to achieve the required tolerances, which are ISO G0.4 to G1.0.”

Temporal Power flywheels are being used, so far, by a company called NRStor in their contract with the IESO for frequency stability, and another proposal is in the works. They are also hard at work at a wind energy facility in Tillsonburg for Hydro One. “There is a lot of talk about energy storage, storing it now to

cross-sectional view

use later, but where energy storage has the most value in our eyes is in high-speed precision voltage and frequency regulation,” Veltri says. “This saves money, allows green energy to be integrated into the grid and can save island nations enormously in diesel fuel costs. We hope to have our technology used on islands in the near future.”

DE www.temporalpower.com

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 October | 2014

28-31-DES.indd 30

800.469.6275 www.design-engineering.com

14-10-07 12:55 PM

Yo Yo We

You want expertise.

You are looking for innovation.

We are the specialists in your industry.

WE ARE THE ENGINEERS OF PRODUCTIVITY.

Security Simplicity Efficiency Competency www.festo.ca

28-31-DES.indd 31

14-10-07 12:55 PM

32

MotionControl

Safe by DESIGN Assuring machine safeguarding compliance requires a team approach.

By Tony Rigoni, Beckhoff Automation

T

oday, customers face greater challenges when figuring out the proper way to safeguard their machines while meeting the various safety requirements. Not only do they need to determine what safety standards to adhere to (e.g. ISO 13849-1, EN 954, ANSI B11.19, RIA 15.06, PMMI B155.1, Semi S2, NFP 79, etc.) but also determine the proper way to conduct risk assessments and safety risk mitigation.

At the end of the day, customers just want to make sure their machines are running safely and that their employees are protected. So, what is the best approach for a customer to take, ensuring they not only meet the proper safety requirements, but also safeguard their machines in an appropriate and productive way? Here are a few suggestions on how to get there: Develop an internal panel to discuss machine safety: Many users already have an Environmental Health and Safety manager but, in a lot of cases, EH&S personnel aren’t well-versed in the intricacies of machine controls. By developing in-house teams October | 2014

32-33-DES.indd 32

of control engineers, maintenance workers and production to work alongside EH&S, companies can review the best approach for them to ensure proper machine safety. This approach only works if end-users have qualified personnel who can handle the task and develop the necessary internal resources. Admittedly, it can take a long time to develop and acquire the internal knowledge needed here.

Turn to outside help: Many customers today have outside consulting companies come in and take care of their risk assessments and machine safeguarding. While this approach is by far the easiest for a customer to take, it also usually is costly and leaves you with little internal safety knowledge.

This approach might be best applicable if you are trying to safeguard one machine quickly. However, another potential risk is that many outside consultants are safety experts, but have little knowledge of machine controls; this could result in an overall solution that isn’t as productive as it should be.

Turn to the OEMs: End-users today are increasingly seeking help from OEMs to implement and deliver safe machines. This has been the standard practice in European markets and we are www.design-engineering.com

14-10-07 1:00 PM

MotionControl starting to see the same trend develop in North America. Of course, nobody knows a machine better than the OEM, so they can decide what the best standards and practices to follow are. Many OEMs are jumping onto this trend by offering turnkey, safeguarded machines compliant to the relevant standards.

So what is the best approach? Just like there are several safety standards, there are also several effective ways to integrate safety into your machines.

By using products such as TwinSAFE I/O terminals from Beckhoff Automation, for example, it allows the OEMs to tie safety directly into their existing controls network, reducing development time and hardware costs.

Common safety functions—such as e-stops, light curtains, safety doors, floor mats, etc.—are easily connected via distributed I/O terminals that act as safety PLCs, as well as safety inputs and outputs. This safety technology ties seamlessly with standard I/O ter-

33

Safety products, like Beckhoff Automation’s TwinSAFE I/O terminals, allows OEMs to tie safety into their existing controls network.

minals and standard controllers on the same network (EtherCAT) and are programmed using the same software environment as the machine controls (TwinCAT).

It’s critical to partner with a knowledgeable safety expert who not only understands safety, but also machine controls. If there is one “best answer,” it would be for companies to take action and prepare their organization to become complaint with the applicable safety standards. This is not only to protect employees, but to ensure corporate responsibility for any manufacturing company.

DE www.beckhoffautomation.com

Tony Rigoni is a Regional Sales Manager and Safety Specialist with Beckhoff Automation.

ZERO BACKLASH UNIVERSAL JOINTS

GTC Falcon Mini-Joints feature Zero-Backlash and all stainless steel construction. Suitable for instrumentation and control systems. Mini-Joint universal joints available as single, double & telescoping versions. Bore sizes of .031” to 1” / 1mm to 30mm.

Also now available:

NEW Mini-Joint Ball Splines, featuring Zero-Backlash.

Also available: Precision Mini-Joint Couplings for angular, parallel & axial misalgnment, with operating speeds to 30,000 RPM U-Joint and Shaft Coupling inquiries, as we design our product to YOUR application.

Tel: (508) 746-0200, 888-309-0646 Fax: (508) 746-6494 E-mail: sales@gtcfalcon.com URL: www.gtcfalcon.com

www.design-engineering.com

32-33-DES.indd 33

October | 2014

14-10-07 1:00 PM

SE

34

3D Scanning

Tracking the Path to SUCCESS

C

M

Y

CM

MY

CY

Quebec’s Soucy Track leverages Creaform 3D scanning technology to boost accuracy of the company’s custom-built farming machinery rubber track systems.

F

ounded in 1967, Soucy International Inc. is a Quebec company that has developed state-of-the-art expertise in designing and manufacturing parts and accessories for the agricultural, industrial, military and recreational markets. Its “Soucy Track” line of products is a world leader when it comes to rubber track systems for farming machinery. These tracks are meant to replace wheels on tractors and any other kind of vehicle, to improve their traction and flotation, as well as make the ride more comfortable for the driver.

When coming up with Soucy Track, the company’s first intention was to create a system that could easily be fitted on the vehicles, without having to modify them, an idea that is still the key driver of the design process. To maintain the integrity of the vehicle, and to find a perfect fit, Soucy created a manufacturing process where the track system seamlessly adapts to the axles of any vehicle.

In straightforward terms, this means Soucy doesn’t work with digital files or 2D plans of the agricultural machinery.

Instead, Soucy scans the vehicle “as built” to make sure the tracks comply with it. Most vehicles are measured in the factory, but the company doesn’t hesitate to go to a dealership or even to travel overseas to scan vehicles that are not distributed in October | 2014

34-37-DES.indd 34

CMY

K

North America. Its measurement technologies therefore need to be portable and, more specifically, easily transportable.

Arm Wrestle Until 2010, Soucy used a FARO measuring arm. This probing arm produced measurements that were accurate enough. However, the device was time consuming and required many resources. As a result, the company would only measure the parts of the tractor where the track system needed to be secured.

Furthermore, technicians needed to make so many manual measurements, that they often forgot to keep track of important data. In short, these limitations were causing problems when the track system was mounted.

To solve this situation, Soucy Track’s Director of Engineering, André Léger, started looking for a 3D technology that could replace the probing measurements. The company was looking for a solution that could also measure the axles as well as all the nearby components of the machinery, without forgetting any other part that could potentially interfere or be used to attach the track system. In 2010, Mr. Léger discovered Creaform, another Québécois company, and got interested in the potential of its HandySCAN 3D contactless 3D scanning technology. www.design-engineering.com

14-10-07 1:33 PM

SEW-DesingEnginer-8x11Aug-2014.pdf 1 8/14/2014 11:16:13 AM

C

M

Y

CM

MY

CY

CMY

K

34-37-DES.indd 35

14-10-07 1:33 PM

36 3D Scanning 3D scanning When compared to a conventional measuring arm, the handheld, selfpositioned Handyscan 3D offers several benefits. Foremost, the scanner records 25,000 measurements every second, with an accuracy of up to 40 microns, which enables users to work considerably faster, with an increased precision and a much higher volume of data. Moreover, the HandySCAN 3D doesn’t require any kind of specific setup, making the measurement process even simpler.

Its ease-of-use also inf luenced Soucy. The technology would be simple to integrate within its existing manufacturing process, by simply providing a short training session to its employees without the need to hire a specialist. Another of the HandySCAN 3D’s strong point was its mobility, permitting the technician to measure every corner of the axle and its components, even the sections that would have been impossible to reach with the measuring arm.

Soucy decided to purchase a HandySCAN 3D scanner to replace its measuring arm, which obviously led to some changes in the measuring process. With the FARO arm, the digital model was built directly into Solid Edge, with a point cloud. By using the HandySCAN 3D, Soucy added an additional step, since the data must be post-treated with the Rapidform XOR software before being used.

“It’s difficult to really establish the benefits of the scanner when comparing to the measuring arm, because it’s like comparing apples with oranges,” Léger says. “Since we’ve been using our HandySCAN 3D, we collect a lot more data, and we’ve significantly increased our level of exactness. Even if this technology pays for itself in the long term, we must not only consider that aspect… In fact, this technology brings us to a whole new level, and enables us to go further in our designs.”

To tell the truth, the process is now taking three to four times longer than it did before. An inconvenience? Quite the opposite, the company says, which has only seen positive results. The high data accuracy of the STL files generated by the hand-held scanner resulted in such a superior level of quality that its 3D models are now truly world-class, perfectly reproducing the vehicle’s structure. This had been impossible to achieve with a probing arm. Thanks to Creaform’s technology, Soucy has solved the interference problems between the machinery and the track system directly into the design phase.

“The technology is very impressive,” says Léger. “Since we’ve been using the Creaform scanner, our early-stage process may take longer, mainly because now we collect a lot more information on the tractor structure than we did with the FARO arm.

But now, we work with complete models, which prevents mistakes later on and thus reduces our development schedule while allowOctober | 2014

34-37-DES.indd 36

S

LO

Th

wi

bo

ch

Above: Creaform’s HandySCAN 3D scanner allows Quebec-based Soucy Track to create detailed models of not only wheel mount assembly (middle) but also the entire tractor (bottom) to provide a precise fit for the company’s custom-built rubber track systems.

ing us to optimize our designs.”

“Like any other new process or technology, it’s important to provide plenty of training, and to be persistent,” he concludes.

“But we can now confidently say that the scanner is 100% integrated to our company.”

DE www.soucy-group.com www.creaform3d.com

This article was provided by Creaform www.design-engineering.com

Al ©

14-10-07 1:33 PM AD-184-14

Speed + Strength LOCTITE 4090 – Hybrid Adhesive ®

™

NEW

This innovative adhesive combines the speed of an instant adhesive with the strength of a structural adhesive. LOCTITE® 4090™ delivers both performance & versatility to solve your design & assembly challenges.

• Strength of a structural adhesive • Speed of an instant adhesive • High impact & vibration resistance • Temperature resistance up to 300°F • Gap filling up to 0.2“ • Suitable for a variety of substrates, including metals, most plastics & rubbers

For additional information, or to request a product evaluation, call 1.855.436.5354, or visit www.henkelna.com/4090

All marks used are trademarks and/or registered trademarks of Henkel and its affiliates in the U.S. and elsewhere. ® = registered in the U.S. Patent and Trademark Office. ©2014 Henkel Corporation. All rights reserved. 13073. AD-184-14 (08/14).

AD-184-14 4090 AD 37 Design Engineering.indd 1 34-37-DES.indd

14-08-271:33 10:09 14-10-07 PMAM

38

IdeaGenerator Automation Controller WAGO introduced its PFC200, a real-time Linux-based controller that features multiple fieldbus ports, a 600 MHz ARM Cortex A8 processor and an integrated web server that supports WAGO’s Web Visu mobile application. In addition, the PFC200 features 256 MB of on-board storage plus 32 GB removable. Supporting multiple protocols, the controller 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 further simplified with the WAGO-I/O-PRO programming and visualization software tool, the company says. www.wago.us

HMI CARLO GAVAZZI launched its CGHMI Series of HMIs. Available in four sizes (4.3, 7, 10 or 15 inches), the LED backlit HMIs come in one of up to three different housing bezels: plastic, aluminum or wash down resistant stainless steel (IP66K). The series features ARM processors, 128MB ROM, 128/256MB RAM and WinCE 6.0 operating system. All models also offer an SD slot and Ethernet port and connectivity via Profibus-DP, ProfiNet, DeviceNet, EtherNet/ IP, CANopen, EtherCAT and CC-Link. Models also come with CG Design Studio software, with the option for CG Design Studio Plus (featuring Symbol Factory and its 4,000+ HD symbols) www.carlogavazzi.com

On-Machine Ethernet Switch Rockwell Automation launched its AllenBradley ArmorStratix 5700, an onmachine Ethernet switch with IP67 protection. The Layer 2 managed switch can be mounted directly onto a machine or application. Using the Cisco IOS network infrastructure software, the switch manages the transfer of production data to enterprise-level databases and information systems. The ArmorStratix 5700 offers Quality of Service (QoS) and automated monitoring, as well as 8, 16 and 24 fixed-port configurations. Each base model also comes with M12 Ethernet connectors, SD flash card, dual-power inputs and a panel-mounted design. An expanded ArmorStratix 5700 switch offering includes 10 and 18 fixed-port configurations, with 2 gigabit ports, hardware-based IEEE 1588, hardware alarms and up to eight Power over Ethernet (PoE) ports. www.rockwellautomation.com October | 2014

38-43-DES.indd 38

EtherCAT Box Beckhoff released its EQxxxx EtherCAT Box I/O series in V2A stainless steel housings that are rated at protection class IP 69K and qualified for the extended temperature range of -25 to +60°C. Through an integrated EtherCAT interface, the self-contained modules can be connected directly to an EtherCAT network without an additional coupler box. The performance of the EtherCAT industrial Ethernet system, with communication speeds in the microsecond range, is maintained into each module. Each box is a EtherCAT device and an EtherCAT slave, which can be connected directly to any other EtherCAT device via a standard Ethernet cable with 100BASE-TX. www.beckhoff.com

Motors & Drives Mini Drive WEG Electric introduced its CFW100 Mini Drive, a single-phase variable speed drive designed to handle 150% overload for 60 seconds at 50°C ambient temperature rating. Approximately the size of a typical panel contactor, the tiny VFD has power ranges of 1/4HP, 1/3HP, 3/4HP and 1HP at 230 VAC with single-phase in and 1.5A, 2.6A and 4.2A three-phase output current. It also features a built-in HMI, built-in PLC, DIN rail mounting, detachable fan and plug-in modules for communication and I/O options. The CFW100 is also manufactured with conformal coated circuit boards classified as 3C2 per IEC specification 60721-3-3. www.weg.net

Torque Motor ETEL introduced its best selling torque motor, its TMB motor series, to the North American market. The series comes in 50 standard model sizes with different windings to provide performance based on torque, current and speed requirements.

The company says TMB motors can achieve a peak torque of up to 31,200 Nm and speeds of up to 4,500 rpm. It can also be equipped with the company’s IMTHP thermal module for temperature monitoring. Compatible with most CNC controllers, the motor series has no backlash and requires zero maintenance, the company says. www.etelusa.com www.design-engineering.com

14-10-07 1:07 PM

IdeaGenerator 39 Stepper Motor and Driver Oriental Motor introduced its CVK Series, standardized 24V DC input driver combined with high torque stepper motors. The series features two motor types with three basic step angles:1.8°, 0.72° or 0.36°. The 1.8° motor type offers the highest torque in the low speed range. The 0.72° motor type is designed for the mid- to upperspeed range and the 0.36° provides positional accuracy compared to 1.8° and 0.9° stepper motors. The CVK Series is available in five frame sizes: 20 mm (0.79 in.) to 60 mm (2.36 in.). For customers requiring a driver only, the CVD driver is also available with a range of adjustable current settings. www.orientalmotor.com

Power Transmission Disc Coupling Baldor announced that all its disc couplings now meet ATEX certification, a European Union directive that defines essential health and safety requirements for equipment used in potentially explosive atmospheres.

The couplings meet all ATEX requirements for mining applications and other applications with combustible dust and gas atmospheres. Each Baldor-Dodge disc coupling has the following ATEX ratings: I M2 c Sizes 94 to 310 with an ambient range of -30˚C to +65˚C; II 2 GD c 135˚C (T4) Sizes 94 to 310 with an ambient range of -30˚C to +65˚C; and II 2 GD c 100˚C (T5) Sizes 94 to 210 with an ambient range of -30˚C to +50˚C www.baldor.com

Pipe Mount Clamps Stafford Manufacturing released its Staff-Lok Hinged Shaft Collars designed for pipe mounts and pipe hangers. The collars feature a hinge with a conformal cam lever for clamping and a knurled nut for adjusting the clamping preset. They also include a mounting flat with a countersunk hole and attachment screw for securely mounting pipe and tube requiring frequent or fast changes. The collars come in eight pipe sizes from 1/4 to 2 inches and 12 shaft sizes from 1/2- to 2-1/2-inch I.D. www.staffordmfg.com

Black Oxide Bearings SKF unveiled a line of black oxide bearings with a protective surface layer for wind turbines. The black oxidation surface treatment — applied to a bearing’s rings and/or rollers — involves up to 15 different immersion steps to create a thin, black surface layer to upgrade performance for a range of bearing types and sizes (up to 2.2m in diameter and up to 1,000 kg per individual bearing component). Suitable bearing types for the coating include tapered roller bearings, cylindrical roller bearings, spherical roller bearings and CARB toroidal roller bearings, among others. www.skfusa.com

www.design-engineering.com

38-43-DES.indd 39

October | 2014

14-10-07 1:07 PM

38-43-DES.indd 40

14-10-07 1:07 PM

IdeaGenerator 41

DieQua offers more gearboxes

Flow Control Air Nozzle EXAIR introduced its 1-inch High Power Stainless Steel Flat Super Air Nozzle. The CE compliant component produces a flat 1-inch (25mm) wide airstream with a blowing force of 16 ounces (462g) when mounted 12” (305mm) from the target. In addition, its Type 316 stainless steel construction makes it suitable for corrosive, high temperature, food, pharmaceutical and chemical environments. Air consumption is 17.5 SCFM (495 SLPM) at 80 PSIG. Force and flow can be adjusted by installing different shim thicknesses. The nozzle meets OSHA dead end pressure standard CFR 1910.242(b).

Sound level measures 82 dBA which meets OSHA noise exposure standard 29 CFR 1910.95(a). www.exair.com

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

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

Check Valves SFC KOENIG announced that it has added check valves to its line of sealing and flow control products.

The valves feature a ball-style, one-piece, self-contained design and can be used to maintain system pressure and prevent backflow. The components are available in both forward-flow and reverse-flow models in a range of standard size diameters, cracking pressures and flow rates. According to the company, the components don’t require thread machining, don’t generate debris and prevent contamination during installation. Their metal-to-metal seal design requires no additional sealants or threads. SFC KOENIG parts offer field failure rates less than 0.5 PPM (parts per million), the company says. www.sfckoenig.com

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

Sensors

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

Linear Encoders HEIDENHAIN Corporation released its absolute LC 185 and LC 485 sealed linear encoders as a complete family, including options for common encoder interfaces such as EnDat 2.2, Fanuc, DRIVE-CLiQ and Mitsubishi.

The LC 185 also features dual sealing lips. The resolution of the LC 185 and the LC 485 is 5nm with an accuracy grade of 3µm. The LC 485 features an improved design that allows the upgrade of slim-line linear encoders from incremental to absolute without drilling or tapping new mounting holes. www.heidenhain.us

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

Industrial Amplifier HBM, Inc. released its PX460 industrial measurement amplifier that measures raw and filtered torque, frequency, pulse, speed and angle of rotation. It can acquire up to four channels of data from torque transducers simultaneously with an analog bandwidth of up to 6 kHz. In addition to powering the torque transducer directly, the PX460 can also acquire encoder signals of up to 2 MHz. The amplifier interfaces with most reaction arm-based dynamometers. Using an on-board, position-based CASMA filter, the PX460 smoothes torque measurements so that they can be fed directly into a dynamometer or machine control system using real-time fieldbuses or by using an analog output. www.hbm.com www.design-engineering.com

38-43-DES.indd 41

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!

October | 2014

14-10-07 1:07 PM

NEWEST WEAPON FOR THERMAL MANAGEMENT Master Bond EP30AO is a thermally conductive, electrically insulative epoxy used for potting, bonding, sealing and coating. Featuring low viscosity, superior dimensional stability and high physical strength, EP30AO cures at room temperature. This high performance compound is widely used where electrical insulation and environmental protection are required and heat transfer must be maintained.

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.

Master Bond www.masterbond.com/tds/ep79fl Tel: 1.201.343.8983 • Email: info@masterbond.com

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

DUST COLLECTORS NEW - FULL LINE LITERATURE GUIDE

ARC POWER CATALOG “B217”

This impressive NEW guide outlines dozens of N.R. Murphy dust collectors, installations, capacities, styles and models. A must for any reference library. N.R. Murphy Limited has been in business over 70 years and has thousands of satisfied customers. “Dust Collectors are all we do; so get it done right the first time. Just Ask the Experts.”

BRECOflex CO., L.L.C., offers state-of-the art polyurethane timing belts with patented “ARC” tooth design. This revolutionary continuous engagement tooth form produces the smoothest running and quietest timing belt available. Typical applications include medical imaging, camera motion control and precision extrusion pulling or where the most advanced belting technology is required.

N.R. Murphy Limited www.nrmurphy.com Tel: 1.519.621.6210 • Email: 4nodust@nrmurphyltd.com

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

DRYLIN® W - FOR ALMOST UNLIMITED DESIGN FREEDOM

MORE FOR LESS – 1.8°, 0.9° OR SPUR GEARED STEPPER MOTORS

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

With up to 1.7 times more torque at new lower prices, the PKP Series 1.8° or 0.9° offers over 400 new high-torque bipolar stepper motors.

Designer advantages of utilizing more torque are; less heat is generated, lower vibration and downsizing of the motor. Available in bipolar windings, encoders or Spur gearhead, all with quick shipping.

Oriental Motor www.orientalmotor.com/PKP/ Tel: 1.800.468.3982 • Email: sales@orientalmotor.com

To advertise your solution in this section call Taebah Khan at 416.510.5230 October | 2014

38-43-DES.indd 42

www.design-engineering.com

14-10-07 1:07 PM

IdeaGenerator 43 Current Transducer NK Technologies announced that its ATH Series current transducers now accommodate 120VAC power supplies. ATH current transducers are also available in solidcore or split-core 24V models. ATH current transducers are compatible with most automation systems and are designed for monitoring burst-fired, timeproportional control of heating systems. The systems provide an output signal directly proportional to the RMS amperage and are accurate even though there are periods of time when the heating circuit is intentionally off, using no power. Their design enables the sensor to remain installed over the conductor while the heating circuit is powered or when it is being serviced, regardless of what may be connected to the output terminals and even when there is nothing connected. www.nktechnologies.com

Safety Relay Pilz Automation released its safety relay PNOZ s50 that can control two powerful brakes simultaneously without the use of contacts. The relay is designed to control holding brakes or safety brakes in the 24/48 Volt DC range on vertical axes up to PL e of EN ISO 13849-1 or SIL CL 3 of EN/IEC 62061. The relay has an output current of 3.5 amps, with peak currents of 6.5 ampere. The PNOZ s50 also offers fast shutdown of the power circuits or a slow shutdown for low-noise switching of the brakes. Four safety-related and two standard inputs are available to activate the functions. www.pilz.com/en-CA

Torque Sensor SensorData Technologies introduced its Model T261 Series, a family of rotary transformer coupled torque sensors. Units are available in standard rated capacities of 5K, 10K and 20K rpm. Rated speed of the series is 10K RPM, with nonlinearity and hysteresis specifications of Âą0.05% of rated output. Non-repeatability is Âą0.02% of rated output.

Series sensors are constructed of SAE 4340 alloy steel with satin nickel finish. The series also features an onboard shunt circuit for ease of remote calibration. As a rotary transformer torque sensor, the SensorData T261 Series requires the use of stand-alone AC strain gage signal conditioning electronics. www.sensordata.com www.design-engineering.com

38-43-DES.indd 43

October | 2014

14-10-07 1:07 PM

Low Cost Vacuum Generators For Lifting, Clamping, Mounting, Vessel Evacuation and “Pick and Place”!

E-Vac® Vacuum Generators are compressed air powered vacuum pumps that provide instantaneous response and are most commonly used for pick and place operations.

These single stage vacuum pumps are a low cost venturi available in a variety of sizes and flows along with a selection of vacuum cups suitable for a wide range of applications.

• • • •

Compact, portable Instantaneous vacuum up to 27"Hg Easy to mount at point of use Engineered for high efficiency to minimize compressed air usage

Adjustable E-Vac® Vacuum Generator

In-Line E-Vac® Vacuum Generator

Adjustable E-Vac vacuum generators permit easy adjustment by simply loosening the locknut and turning the exhaust to increase or decrease

In-Line E-Vac vacuum generators are cylindrical and compact. They can be threaded directly onto a compressed air line or held in place with a mounting clip.

the level of vacuum and vacuum flow.

Four models available. Ideal for porous

Fourteen models for porous and non-porous applications are available.

and non-porous applications.

Vacuum Cups, Mufflers Fittings, Tubing, & More WATCH THE VIDEO! www.exair.com/53/48053.htm

Scan for quick video access

EXAIR can provide the accessories you need to build your vacuum system.

If you would like to discuss an application, contact an Application Engineer at

www.exair.com/53/480.htm Manufacturing Intelligent Compressed Air® Products Since 1983 11510 Goldcoast Drive • Cincinnati, Ohio • 45249-1621 • (800) 903-9247 fax: (513) 671-3363 • E-mail: techelp@exair.com • www.exair.com

44-48-DES.indd 44

@EXAIR

14-10-07 1:28 PM

s

m

CanadianInnovator

45

From CAD to CUTTER Canadian-made ExactFlat CAD module for SolidWorks and Rhino removes the guesswork from 3D textile design.

By Mike McLeod

I

n traditional solid modeling, 3D geometry is assumed to represent parts made from a rigid material like metal or plastic. As a result, little if any consideration is paid to how the part may deform or warp during manufacture. Even with sheet metal design, turning 3D shapes into flat patterns need only consider the small material deformation introduced by forming stresses.

But what happens when a 3D design calls for a leather, cloth or a textile-like composite covering? Simply flattening the various panels that compose a car seat, for example, doesn’t account for the stretchiness of the material, the loads placed on the seams and a slew of other variables that can make the difference between a snug fit and a warped, wrinkled mess. Traditionally, such design has been a drawn-out manual process fraught with complication at not only initial design but also the manufacturing and project costing stages as well.

For more than a decade, Toronto-based CAD software company Tri-D Technologies has been developing ExactFlat, a 3D to 2D conversion module for SolidWorks and Rhino 3D specifically tailored for non-developable surfaces—those that require stretching, compressing or other deformations to be accurately flattened.

“Soft good modeling is an orphaned CAD category,” says Eaton Donald, CEO of Tri-D Technologies. “If you look at what has happened with solid mechanical modeling, the integration of CAD design and CAM has driven efficiencies across the board.

In the soft goods space, that isn’t the case. While the design is done in 3D, the material used to make them are typically rolled goods, so you have to somehow get from 3D to 2D. Until now, there hasn’t been technology that has accounted for the unique characteristics of industrial fabrics and textiles.”

While flattening is core to its function, thinking of ExactFlat as simply a flattening plug-in is like calling a Swiss Army Knife just a handy pocket screwdriver. In fact, Donald says the module incorporates every major function needed for soft goods manufacturers to go from CAD to cutter in a purely digital workflow.

For example, ExactFlat maintains a database of various textiles and their engineering properties plus an internally developed FEA solver that simulates how those fabrics behave under load.

The software then allows users to optimize 2D patterns so that the finished 3D textile covering will not only fit properly but bear up under stress.

“In the fabric world, unlike with sheet metal, distortion happens in both the x and y axis and you can form fabric in ways you can’t form metals,” Donald explains. “Our solver simulates the springiness of the material and how it will distort. Calculations like this are extremely difficult but, through theoretical and applied work, our solver performs at the high degree of confidence www.design-engineering.com

44-48-DES.indd 45

Toronto-based Tri-D Technologies’ ExactFlat module transforms 3D textiles, designed in SolidWorks and Rhino, into 2D patterns.

Once flattened, the 2D panels are optimized for fit and further refined to integrate details such as seam off-sets and alignment notches.

that customers need.”

Once pattern shapes have been optimized, ExactFlat then allows users to add features and PMI data, such as seam off-sets, alignment notches, reinforcement placement and grain-line directions. The next step involves nesting, the process of tightly packing the various 2D shapes to minimize material waste.

“Within the nesting component, you can project costs, which can be critical,” Donald says. “For example, during Black Friday in the U.S., Levi’s sells so many jeans that if their nesting is off by one inch, it costs them an extra quarter million dollars. So packing that nest down tightly is money to the bottom line.”

Beyond nesting, ExactFlat also provides project documentation October | 2014

14-10-07 1:28 PM

46 CanadianInnovator

ExactFlat’s associative nesting algorithm efficiently packs flattened 2D patterns to speed production and reduce material costs.

“Although our business is growing by four times each quarter, adoption of our product is low compared to the large CAD companies,” Donald says. “However, we have companies that have cut their design and turn-around times between 70 to 90 percent and material costs by 20 to 30 percent within months adopting our technology. The rest of the market will start to lose if they don’t adopt these type of practices, so we are very excited about it.” DE www.exactflat.com

Advertisers Index

October | 2014

44-48-DES.indd 46

Advertiser

Website

Automation Direct

www.automationdirect.com

Baldor Electric Company

www.baldor.com

Page 7 48

Beckhoff Automation

www.beckhoff.ca

11

Boker’s Inc.

www.bokers.com/de

29

Clippard Instruments Laboratory Inc.

www.clippard.com

Columbia Marking Tools

www.marking-machines.net

9 30

Daemar Inc.

www.daemar.com

Designfusion

www.designfusion.ca

40

Diequa Corporation

www.diequa.com

41

Exair Corporation

www.exair.com

44

Festo Canada, Inc.

www.festo.ca

31

GTC Falcon, Inc.

www.gtcfalcon.com

33

Henkel Adhesive Technologies

www.loctite.com

37

igus Inc.

www.igus.com

IPEX Management Inc.

www.ipexinc.com

Motion Industries - Eaton

www.eaton.com

NORD Drive Systems

www.nord.com

Novotechnik US, Inc.

www.novotechnik.com

19

Proto Labs, Inc.

www.protolabs.com

21

Rosta Inc.

www.rostainc.com

20

Roto Precision Inc. - Smalley

www.rotoprecision.ca

27

Roto Precision Inc. - NB Linear

www.rotoprecision.ca

12

Rotor Clip Company, Inc.

www.rotorclip.com

43

Schaeffler Canada Inc.

www.ina.com

SEW Eurodrive Canada

www.sew-eurodrive.ca

35

Tecom Inc.

www.crbearing.com

46

TELUS Corp.

www.telus.com/teluslink

23

UBM Canon: Design & Manufacturing

www.dm-montreal.com

47

Unitronics Inc.

www.unitronics.com

39

Yaskawa Electric Corp.

www.yaskawa.com

14-15

3 25 13 16-17

4

2

www.design-engineering.com

14-10-07 1:28 PM

28549_CN_DM14

and overall costing estimation. In addition to total material and nesting expenditure, Donald says ExactFlat will incorporate access to a continually updated database of the labor costs associated with individual manufacturing processes.

“We’ve done a great job with material and hardware costs,” he says. “The next wave will be nailing the labor component by attaching manufacturing operations like sew, flip and turn as well as machining such as double and single needle sewing, inserting grommets or zippers, etc. What we want to do is offer instant, accurate costing so that manufacturers will know, up front, whether a job will be profitable.”

Given Tri-D’s uniquely comprehensive software in a segment of the design industry largely untouched by traditional 3D MCAD to date, it’s not surprising that ExactFlat has gaining positive attention lately. In February, at SolidWorks World 2014, ExactFlat was awarded silver in TenLink’s Best of Show competition by a 15-man panel of CAD journalism’s heavyweights, including Brian McElyea, Ralph Grabowski and Roopinder Tara.

Closer to home, Tri-D Technologies also received a $500,000 small-business loan in July through the Southern Ontario Fund for Investment in Innovation to help the company scale up its sales and marketing campaign and further develop its software’s capabilities. Like many others in the CAD industry, Donald says ExactFlat next move will be to incorporate cloud technology to provide fast and precise manufacturing costs.

Designed to Make a Difference

Including:

EXPOSITION:

November 19–20, 2014

Palais des congrès de Montréal Montréal, Québec

This is the place to: See the latest versions of the products you need and the services you can use Hear free technology talks to keep you up to date Meet people who are making things happen in your industry Expand your knowledge with educational seminars

“As always, the show was informative…I was also impressed with the mix of cutting edge innovations, along with the traditional but still very necessary industries such as fasteners, springs, and bearings.”

28549_CN_DM14

—Jonathan Allen, Physicist, RF Electronics Consulting

44-48-DES.indd 47

CONNECT WITH OUR DESIGN COMMUNITY:

Get Your Badge Today!

DM-Montreal.com 14-10-07 1:28 PM

A New Line of Motors

Fit to Wear Our Name Whether you pump it, compress it, blow it or convey it, the new line of Baldor GPM motors are the perfect choice for safe area, general purpose applications. With ratings of 250 – 1500 Hp, Baldor GPM motors are easy to order and are suitable for use with adjustable speed drives. Plus, many of the motors you need are available from stock or with the shortest lead time in the industry.

Since 1920, our goal has been to design and build the highest quality, most reliable industrial motors in the world. And, 94 years later our commitment remains the same so that you can rest assured Baldor GPM motors not only fit your needs but are fit to wear our name. baldor.com

479-646-4711

• Fastest Delivery in the Industry • Unmatched Quality • Superior Reliability • Designed for Safe Operation • American Made Since 1920

©2014 Baldor Electric Company

44-48-DES.indd 48

14-10-07 1:28 PM