Click this link if you cannot read the issue below: Designfax - Tech for OEM Design Engineers
September 17, 2019Volume 15 Issue 35


Image - Universal Robots Doubles Production Capacity in CNC Machining Operations
Universal Robots Doubles Production Capacity in CNC Machining Operations
Watch how Chicago machine shop Fusion OEM increased productivity by adding four Universal Robots, equipped with Robotiq's UR+ certified Hand-E, Force Copilot, and Insights, over the span of a year. Running a job with this setup doubles production throughput and is four times cheaper than operating manually.
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In this issue of Designfax

  • DOD: Next-gen air dominance will rely on data sharing
  • OnRobot converter kit unifies cobot tool connections
  • 'Blackest black' material ever discovered -- by mistake
  • First hybrid Lamborghini uses supercapacitor for boost
  • Mike Likes: At Smalley, customized parts are standard
  • Injection Molding: 9 tips for designing multipart assemblies
  • High-traction robot goes underground
  • Low-profile rotary positioner with high-force torque motor
  • No-wear flat magnetic angle sensors
  • igus ball transfer units ease move of high loads
  • High-speed image sensor for AI, drones, robotics
  • Can electrical resistance be used to predict shielding effectiveness?
  • Standard and custom process heaters -- fast delivery
  • Videos+: Technologies and inspiration in action
    • Jay Leno's Garage uses On Demand Manufacturing
    • History: Caterpillar first tractor with tracks
    • Design Tips: Top ways to save on CNC machining
  • Most Popular Last Issue
    • First all-electric Porsche: Taycan
    • Army cold spray tech repairs tank gun mounts
    • World's smallest autonomous racing drone
  • New Products
    • Electrical, Mechanical, Motion
    Cover Image: Fastest Lamborghini of all time: Sián hybrid

News

Researchers produce synthetic Hall effect to achieve one-way radio transmission

Simulation technique can predict microstructures of alloy materials used in jet engines -- before they are made

BAE Systems demonstrates first integration of unmanned surface vessel with a U.K. Royal Navy warship

Wow. Upgraded NIST quantum logic clock won't gain or lose one second in 33 billion years



Image - Best-kept secret in the circuit breaker industry
Best-kept secret in the circuit breaker industry
When STELPRO, a Quebec-based manufacturer of integrated heating solutions for the HVAC industry, asked partners all along its supply chain to identify cost-saving opportunities, installing NOARK miniature circuit breakers in panels on all their equipment was one solution that provided long-term quality and savings (typically 30 to 50 percent in price). NOARK's five-year warranty was a huge added bonus.
Read the full article.

Feature articles
DOD: Next-generation air dominance will rely on data sharing -- not new aircraft
For about two decades, the Air Force has fielded both the F-22 Raptor and the F-35 Lightning II -- both billed as technical marvels. But what's next for the Air Force?
Read the full article.
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Intelligent control algorithms running a high-speed mechanical XY linear stage to quickly scan and align photonics components.


Image - New OnRobot converter kit unifies cobot tool connections
New OnRobot converter kit unifies cobot tool connections
In a bid to make robotic applications faster and easier to implement, OnRobot has created a unified mechanical and electrical interface for any OnRobot end-of-arm tooling (EoAT). The innovation dramatically simplifies automation. The Digital I/O Converter Kit allows OnRobot end-of-arm tools to work with a full range of leading collaborative and light industrial robot brands including Universal Robots, KUKA, FANUC, Doosan, Techman, Yaskawa, Mitsubishi, Kawasaki, and Nachi. Use one tool easily on two different cobots, or even use two tools in one cycle.
Read the full article.

Image - 'Blackest black' material ever discovered -- by mistake
'Blackest black' material ever discovered -- by mistake
Engineers at MIT have cooked up a material that is 10 times blacker than anything that has previously been reported -- even Vantablack (from Surrey NanoSystems) that has been featured in Designfax several times. The material is made from vertically aligned carbon nanotubes the team grew on a surface of chlorine-etched aluminum foil. The foil captures more than 99.995 percent of any incoming light.
Read the full article.

Image - Air Operated Conveyors
Air Operated Conveyors
EXAIR's Line Vac connects to standard hose or tube to create a powerful conveyor. The design features large throat diameters for maximum throughput capability. A small amount of compressed air is injected through directed nozzles to produce a vacuum on one end and high output flows on the other. Multiple styles available.
Learn more.

Image - First hybrid Lamborghini is fastest car ever for brand, uses supercapacitor for boost to 819 hp
First hybrid Lamborghini is fastest car ever for brand, uses supercapacitor for boost to 819 hp
Lamborghini unveiled its latest super sports car at the Frankfurt Motor Show in Germany Sept. 10, and wow, is it full of firsts. The Sián FKP 37 is the luxe Italian automaker's first hybrid supercar, fastest ever for the brand, and the first to use a supercapacitor (instead of Li-ion batteries) to boost its extra e-motor to a whopping 819 hp. There are lots of other impressive tech touches to boot. It's even got wings.
Read the full article.

Image - Mike Likes: <br>At Smalley, customized parts are standard
Mike Likes:
At Smalley, customized parts are standard

The uniqueness of applications often demands a ring or spring to conform to application-specific requirements. Smalley can manufacture custom Wave Springs and Retaining Rings quickly and economically to meet your specific application requirements. Their No-Tooling-Cost™ process provides an economical alternative to produce a custom retaining ring or wave spring to meet your exact specifications. Customs can be produced from .157" to 120" diameters in carbon steel, stainless steel, or other readily available exotic alloys.
Learn more.

Image - Injection Molding: 9 tips for designing multipart assemblies
Injection Molding: 9 tips for designing multipart assemblies
Finding creative solutions to multipart assemblies can be tricky, but fortunately there are many different ways to approach product designs that involve multiple components. To keep things cost effective and efficient, simplify your design, don't make what you can buy off the shelf, explore all of your manufacturing options, and understand the rules of each part of the process. But like most design challenges, it's not as easy as it sounds. Great info from Protolabs.
Read the full article.

Image - High-traction robot goes underground
High-traction robot goes underground
Recent developments in motion control and engineering make it possible to inspect and perform maintenance in compact sewers from the inside. The underground sewer robot is equipped with a swiveling camera and an air-powered milling machine driven by FAULHABER miniature DC motors from FAULHABER MICROMO.
Read the full article.

Image - Low-profile rotary positioner with high-force torque motor is mountable on 6-axis hexapod
Low-profile rotary positioner with high-force torque motor is mountable on 6-axis hexapod
Nanopositioning leader PI has expanded its PIMag series of high-dynamics linear and rotary positioning systems with a new high-performance rotation stage. The low-profile (1.1-in.) V-610 is equipped with a high-force 3-phase torque motor with direct incremental encoder for position feedback and closed-loop operation. Direct drive torque motors do not require gears and mechanical components, eliminating friction in the drive train. Despite its compact size, the ironless motor provides a peak torque of 1.2 Nm (10.6 in.-lbf). Ironless motors provide smoother running with better velocity control due to the lack of cogging effects caused by permanent magnets. Can be combined with PI's H-811 hexapod 6DOF parallel positioner, adding unlimited rotation to this compact 6-axis alignment system.
Learn more.

Image - No-wear flat magnetic angle sensors
No-wear flat magnetic angle sensors
Novotechnik U.S. has just introduced the Vert-X 05E Series of magnetic rotary position sensors with compact, flat housing. Interfaces include analog, SPI, and incremental. The series is available in single and redundant versions. The sensors are touchless magnetic angle sensors with a permanent magnet that can be secured to an application's rotating shaft, so there is no direct mechanical linkage between the shaft and the measuring system -- and therefore no wear. Key specifications for Vert-X 05E include 5-mm profile, 0 to 360° measurement range, repeatability of 0.1° or better, and maximum hysteresis of 0.1°. Sample rate is up to 5 kHz, and its active measurement region extends to within 6 mm from edge of housing.
Learn more.

Image - igus ball transfer units ease move of high loads
igus ball transfer units ease move of high loads
igus has introduced new ball transfer units that allow lubrication-free and smooth transport with a dramatic increase in load-bearing capacity. Ball tables are used if delicate or heavy goods are to be transported in different directions. The ball transfer units from igus are manufactured with the high-performance plastic xirodur B180, which absorbs loads up to 500 N (112 lb). The ball transfer units are lubrication and maintenance free. They also include stainless steel balls inside the roller to allow for smooth running. Based in Germany, igus runs its North American operations out of Providence, RI.
Learn more.

Image - High-speed image sensor for AI, drones, robotics
High-speed image sensor for AI, drones, robotics
ON Semiconductor has introduced the ARX3A0 digital image sensor with 0.3 Mega-Pixel (MP) resolution in a 1:1 aspect ratio. With up to 360 frames per second (fps) capture rate, it can perform like a global shutter in many conditions but with the size, performance, and responsivity benefits of being a Back-Side Illuminated (BSI) rolling shutter sensor. With its small size, square format, ultra-low-power requirement, and high frame rate, the ARX3A0 is particularly suitable for emerging Machine Vision, Artificial Intelligence, IOT, drones, robotics, and AR/VR applications, as well as small supplemental security cameras.
Learn more.

Image - Can electrical resistance be used to predict shielding effectiveness?
Can electrical resistance be used to predict shielding effectiveness?
Conductive elastomer EMI shielding gaskets use metallic particles to create a conductive path and shield enclosures from electromagnetic radiation. Gaskets with silver particles, which are very conductive, often outperform gaskets with graphite particles. However, this is not always the case. A common misconception is that a measurement of DC resistivity can directly predict shielding effectiveness. Ben Nudelman, market development engineer at Parker, explains why.
Read this informative Parker Hannifin blog.

Image - Standard and custom process heaters -- fast delivery
Standard and custom process heaters -- fast delivery
Durex builds standard as well as custom heaters for a host of applications and industries, including power plants, oil and gas, chemical and petrochemical, pharmaceutical, plastics, packaging, heat treating, cleaning and plating, aerospace, semiconductor processing, and food service equipment. The Cary, IL, company now offers screw plug, flange immersion, and circulation heaters with fast-turn shipping capabilities. Durex uses product platforms to provide standard "catalog" type designs as well as customized designs in the same fast turnaround window. Plug heaters ship in 3 to 5 days. Flange heaters ship in 5 to 7 days. Circulation heaters in 9 to 12 days. No upcharge for customized units or "non-standard" configurations.
Learn more.

Most popular last issue

Image - First all-electric Porsches: Taycan Turbo and Turbo S
First all-electric Porsches: Taycan Turbo and Turbo S
Move over, Tesla. The big kids are coming out to play. The world premiere of the first all-electric Porsches happened on Sept. 4, and the Taycan Turbo and Turbo S are, well, electrifying. The Turbo S (which doesn't have a turbocharger at all!) will do 0 to 60 in under 3 sec. There are lots of high-end features, with a focus on fast charging and sustainability too.
Read the full article.

Image - Army develops cold spray technology to repair Bradley tank gun mounts
Army develops cold spray technology to repair Bradley tank gun mounts
Repairing a 40-ton armored vehicle is a lot harder than having your car fixed at a neighborhood auto repair shop. Tactical armored vehicles require specialized repair procedures, which are very costly. But what if repairing routine wear and tear on an Army vehicle was inexpensive and as easy as fixing your car?
Read the full article.

Image - World's smallest autonomous racing drone proves to be a design challenge
World's smallest autonomous racing drone proves to be a design challenge
Scientists at Delft University of Technology in the Netherlands have created the world's smallest autonomous racing drone. The main challenge in making the 10-cm drone was using only a single, small camera and a highly restricted amount of processing. The main innovation was the design of robust, yet extremely efficient algorithms for motion prediction and computer vision.
Read the full article.

Videos+: Technologies and inspiration in action
Jay Leno's Garage uses On Demand Manufacturing
A reverse-engineering workflow using Faro scanners, Geomagic software, and SLA-printed investment casting patterns through On Demand Manufacturing from 3D Systems helped Jay Leno and his team get this hundred-year-old Owen Magnetic electric car back up and running efficiently and cost effectively.
View the video.

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History: Caterpillar first steam tractor with tracks
Learn about how big-machine juggernaut Caterpillar got its start when Benjamin Holt decided it was time to test his prototype steam-powered, track-type tractor on Thanksgiving Day in 1904. Lee Fosburgh, Caterpillar's corporate archives manager, tells the story of "the machine that changed everything." A really interesting take on reinventing the wheel. Bonus: Also learn how Caterpillar got its name.
View the video.

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Design Tips: Top ways to save on CNC machining
Xometry CNC Applications Engineer Tim Bowman pulls from over 25 years of CNC machining experience to compile his top recommendations on how to reduce the cost of CNC machined components. Learn his best tips on making your CNC machined parts more cost effective. Straightforward and effective.
View the video.
Read more Xometry CNC design guide tips.

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New products

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