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July 05, 2017Volume 13 Issue 25


Image - Achieve Maximum Flexibility with Electroformed Bellows Couplings
Achieve Maximum Flexibility with Electroformed Bellows Couplings
Electrodeposited bellows technology offers the best combination of flexibility and strength among coupling technologies. Servometer® flexible shaft bellows couplings offer seamless construction with maximum flexibility, and handle angular misalignment up to 31° and parallel misalignments up to .076". Servometer bellows couplings exhibit low-windup due to the bellows’ radial rigidity, and low side thrust due to its lateral flexibility.
Request a free sample.

In this issue of Designfax

  • Long-range sniper system is the BOSS
  • Air spray: Stunning military aircraft paint jobs
  • Wheels: Camaro ZL1 tries for 200 mph
  • Next Big Thing: Liquid metal 3D-printing system
  • Wheels: Ford GT supercar's digital display
  • Wings: Siemens electric airplane motor setting records
  • Stepper or servo motor -- Which should it be?
  • Extreme Engineering: Fuel trim on SpaceX rocket launch
  • Engineer's Toolbox: Bike design gets HyperSizer treatment
  • Brushless motors -- What’s the difference?
  • Top Mike Likes: Latest thermal imaging for smartphones
  • Top Product: Did you know you can tint chrome?
  • Top Training: Become a robot programmer in 87 minutes!
  • Top Product: Carbon composite bellows springs
  • Engineer's Toolbox: How to choose the right relay
  • Videos+: Technologies and inspiration in action
    • Great Concepts: Expanding-wheelbase skid steer
    • Pushing the limits of motorcycle design
    • Disney engineers tackle wireless power transfer
    • Feel the Burn -- Combustion Simulation Video
    • Boeing's 777 automated factory of the future
  • New Products
    • Electrical, Mechanical, Motion, Special: Software
    Cover Image: Most Popular Stories -- Ford GT display system

News

Scientists identify chemical causes of lithium-ion battery 'capacity fade'

Researchers find computer code that Volkswagen used to cheat emissions tests

World's most powerful jet engine is being turned into 65-MW power plant

NASA releases software catalog, gives public no-cost access to technologies for earthly applications

Totally new spacesuit unveiled for Boeing Starliner astronauts



Image - New Piezo Motor with Integrated Optical Encoder
New Piezo Motor with Integrated Optical Encoder
MICROMO launches the new Piezo LEGS® Linear 6N motor, also called the Piezo LL06. This new motor is the next generation of the classic Piezo LEGS® LL10 with the same piezo ceramic actuators at its core as the popular predecessor, LL10 with some major redesign work. The LL06 features an integrated high-resolution optical encoder, plus a slimmer design and options for guides that steer the drive rod.
Click here to learn more.

Feature articles
Long-range sniper system is the BOSS

What does it take for an Army sniper to accurately hit a person-size target at extreme ranges? The Army thinks it may have the answer to this challenge in a new integrated fire control sighting system for military sniper weapons called the Ballistically Optimized Sniper Scope (BOSS).
Read the full article.
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Get your pocket-sized Material Selector quick-reference guide.


Image - Air spray: The comeback of stunning military aircraft paint jobs
Air spray: The comeback of stunning military aircraft paint jobs
Eight Oregon Air National Guard members received a call to arms. Their wing commander handed them an assignment, stressing high priority. They worked 33 consecutive days, some pulling night shifts. Their orders: Paint a Boeing-built F-15 Eagle jet fighter in a manner that would elevate base morale at Kingsley Field in Klamath Falls, OR, and commemorate the Air National Guard’s 75th anniversary across the state. By Dan Raley
Read the full article.

Image - Wheels: <br>Camaro ZL1 tries for 200 mph on German test oval
Wheels:
Camaro ZL1 tries for 200 mph on German test oval

It's official. The Camaro ZL1 Coupe has a top speed of 198 mph (318 km/h). Chevrolet tested the max velocity of the ZL1 (with 10-speed automatic) on the High Speed Oval at Germany's Automotive Testing Papenburg GmBH proving ground. What makes this the fastest Camaro ever?
Read the full article.

Image - Next Big Thing: <br>Father-son team create liquid metal 3D-printing system
Next Big Thing:
Father-son team create liquid metal 3D-printing system

A breakthrough idea five years ago by former University at Buffalo student Zack Vader, then 19, has created a machine that prints 3D objects using melted aluminum. The nozzle design, which uses a pulsed magnetic field, is key. Printing objects in steel is in the works.
Read the full article.

Image - Wheels: <br>It's all about change -- Ford GT supercar's digital display is dashboard of tomorrow
Wheels:
It's all about change -- Ford GT supercar's digital display is dashboard of tomorrow

Like the glass cockpit in airplanes and race cars, the all-new Ford GT features an all-digital instrument display in the car's dashboard that quickly and easily presents information to the driver based on five special driving modes.
Read the full article.

Image - Wings: <br>Siemens electric airplane motor setting records left and right, up and down
Wings:
Siemens electric airplane motor setting records left and right, up and down

Electric motor technologies in aircraft are making steady development progress -- and setting records along the way. Case in point is the Extra 330LE aerobatic plane, powered by a propulsion system from Siemens, which set several records recently. Weighing just 110 lb, the system supplies a constant electric output of 260 kW, which is five times more than comparable propulsion systems. It features a unique weight-to-performance ratio of 5 kW/kg.
Read the full article.

Image - Stepper or servo motor -- Which should it be?
Stepper or servo motor -- Which should it be?
Bring out the full capacity of your machines through the most efficient mechatronic design. Hurley Gill, Senior Applications/Systems at Kollmorgen, outlines servo and stepper motor baseline capabilities for selection criteria like torque, speed, accuracy, and repeatability. Technical advantages and disadvantages are discussed, helping machine designers select the best motor-drive system for their application.
Click here to read: Servo or Stepper: Which Should It Be?
Kollmorgen designs and manufactures innovative motion control systems, including servo and stepper motors, drives, amplifiers, gearheads, and actuators.

Image - Extreme Engineering: <br>Fuel trim on SpaceX rocket launch
Extreme Engineering:
Fuel trim on SpaceX rocket launch

One way for private space company SpaceX to control costs for launch vehicles like the Falcon 9 is by optimizing fuel burned during launch to minimize waste. The SpaceX team ensures top performance with the help of a special fuel-trim valve, powered by robust, reliable, off-the-shelf servo motors from MICROMO (the FAULHABER Group).
Read the full article.

Image - Engineer's Toolbox: <br>Lightweight bike design gets HyperSizer optimization treatment
Engineer's Toolbox:
Lightweight bike design gets HyperSizer optimization treatment

Collier’s NASA-spinoff HyperSizer software has been widely used in military and commercial aircraft and space-agency programs over the past 20 years. Now the company has released a user-friendly "Express" version of its workhorse tool with the aim of supporting the growing number of other industries that are adopting composite materials to make lighter, stronger, more durable products. Wait until you see what it can do with lightweight composite bike design.
Read the full article.

Image - Brushless motors -- What’s the difference?
Brushless motors -- What’s the difference?
Brushless motors are used in an extensive variety of OEM applications, from pick-and-place equipment and robotic joints to GPS-based automated vehicle steering and pumps/fans/blowers. Do you know the difference between a brushless DC motor, brushless servo motor, and brushless torque motor? Learn more about these motors, when they’re used, and how to choose the right one for your application.
Read the article now -- Brushless Motors: What’s the big difference?
Allied Motion Technologies designs and manufactures precision specialty motion control components and systems.

Image - Top Mike Likes: <br>Latest thermal imaging for smartphones
Top Mike Likes:
Latest thermal imaging for smartphones

The third-generation FLIR ONE provides a powerful, introductory-level thermal camera that attaches to iOS or Android devices. Featuring the new OneFit adjustable-height connector, including a USB-C version for Android, the latest FLIR ONE easily attaches to more smartphones without needing to remove your phone case. As the most affordable FLIR ONE to date at $199.99, this unit is the perfect camera to introduce people to the benefits of thermal imaging. Also comes in a PRO version for $399.99.
Click here to learn more.

Image - Top Product: Did you know you can tint chrome?
Top Product: Did you know you can tint chrome?
Push the boundaries of design. SRG Global, a leading manufacturer of chrome-plated and painted plastic parts for the automotive, commercial truck, and household appliance industries, has introduced its G-Coat tint-over-chrome process solution. The G-Coat process delivers distinct metallic surface finishes for both exterior and interior applications and regularly improves paint adhesion to any chrome-plated plastic part. It offers nearly unlimited custom color options, including a high-optical-density deep black finish not achievable by other technologies. The process also provides enhanced corrosion protection and fingerprint resistance and meets multiple automotive OEM performance standards for basecoat and clear-coat paint systems.
Click here to learn more.

Image - Top Training: Become a robot programmer in only 87 minutes!
Top Training: Become a robot programmer in only 87 minutes!
Learning how to set up and program a collaborative robot -- or cobot -- no longer depends on real-life access to a robot or a training class. Now everybody with a desire to learn the concepts of cobots can log in to the Universal Robots Academy and get the introduction necessary to master basic programming skills. Become a master of the cobots! (That's a pretty sweet title.)
Click here to learn more.

Image - Top Product: Carbon composite bellows springs for lightweighting and more
Top Product: Carbon composite bellows springs for lightweighting and more
The Carbon Composite Bellows Spring (CCBS) from MW Industries is a system of carbon fiber elements that combine to work as a high-performance, lightweight, and design-flexible compression spring meant to replace conventional coil springs or metallic Belleville disc springs. It offers value through unique dynamic characteristics and unparalleled in-the-field design flexibility. A functional spring is made from several individual elements, paired in sets and joined to make a stack. The spring rate of the stack is determined by the number of elements, the base rate of each element, and their series or parallel orientation in the stack. Applications include motorsports, aerospace, outdoor recreation, general industry, and high-performance activities.
Click here to learn more.

Image - Engineer's Toolbox: <br>How to choose the right relay
Engineer's Toolbox:
How to choose the right relay

Relays come in a variety of form factors, styles, and technologies. Depending on your application, only one relay type may be suitable. In other cases, multiple relay types may be appropriate. By understanding the strengths and weaknesses of the different relays, you should be able to pick the one that is best suited for the job at hand. National Instruments lays out the options.
Read the full article.

Videos+: Technologies and inspiration in action
Great Concepts: Next-gen expanding-wheelbase skid steer
It's all about leverage! A company called Extend Manufacturing has created an ingenious proof-of-principle expanding-wheelbase skid steer machine called the Pro-Handler that solves many of the problems faced when using these types of loaders/fork lifts, including handling heavier loads and not tipping over. The reach on the prototype has also been lengthened with an extendable boom, so there are pluses all around for this concept's design. The extensions are done hydraulically with four extra cylinders and telescoping tubes with frictionless pads. Check out all the details on Extend Manufacturing's Fundable page, and watch the video to see it to believe it.
View the video.

Video Image
Pushing the limits of motorcycle design and manufacturing
Matt Chambers, founder and CEO of Confederate Motors, talks about the impact that 3D Systems' Quickparts rapid parts and prototypes service has on his design-and-build business. With the exception of some engine components, wiring, wheels, tires, and lighting, 3D Systems makes every part of the super-boss P51 Combat Fighter motorcycle, saving a tremendous amount of time and hassle for Confederate Motors by being able to consolidate part production with one primary vendor.
View the video.

Video Image
Disney engineers tackle wireless power transfer
Wireless power delivery has the potential to seamlessly power our electrical devices as easily as data is transmitted through the air. Existing solutions, however, are limited to near-contact distances and don't provide the geometric freedom to enable automatic and un-aided charging. Disney engineers introduce quasistatic cavity resonance (QSCR), which can enable purpose-built structures, such as cabinets, rooms, and warehouses, to generate quasistatic magnetic fields to safely deliver kilowatts of power to mobile receivers contained nearly anywhere within. Although we all probably won't live in aluminum-clad rooms, the potential is here for a real next-gen breakthrough.
View the main demonstration video.
Learn a little more about the engineering set-up details.

Video Image
Feel the Burn -- Combustion Simulation Video
Combustion is a complex process which can only be handled by high-performing Computational Fluid Dynamics (CFD) software such as FloEFD. Watch this 5-minute video to learn how to:
  • Optimize mixing of burning fuels and oxidizers
  • Determine flame shape, patterns, as well as temperatures
  • Minimize emissions to ensure the design meets stringent regulatory standards
View the video.

Video Image
Boeing's factory of the future: 777 automated assembly
Take a peek behind the scenes of Boeing's factory of the future. Fuselage Automated Upright Build (FAUB) is a partnership of automation and manual work to assemble the forward and aft sections of the 777 fuselage. Teams load and set the panels, then the robots are moved in to help install thousands of fasteners to connect the sections. Mechanics are able to move the robots and massive parts around on automated guided vehicles (AGVs).
View the video.

Video Image

New products

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