Designfax weekly eMagazine

Subscribe Today!

Archives

View Archives

Partners

Manufacturing Center
Product Spotlight

Modern Applications News
Metalworking Ideas For
Today's Job Shops

Tooling and Production
Strategies for large
metalworking plants

Ruggedized Nano servo drives for harsh environs

Copley Controls has released its R47 and R48 NanoPlus Micro Module servo drives. Designed for extreme environments and space-constrained applications, these rugged platforms operate from 9 to 180 VDC, delivering peak power up to 6.3 kW. Offering CANopen (R47) or EtherCAT (R48) communications, both feature STO SIL 3 safety and broad encoder support. Well suited for COTS military, nautical, aviation, oil refining, and vehicle-based systems.
Learn more.

Simplify AC motor control with the new OMRON M1 Inverter

The OMRON M1 Inverter simplifies machine design by unifying motion, safety, networking, and motor control into a single platform. Available in M1-STD, M1-ECT, and M1-EMP models, it controls IM and PM motors with high precision. Featuring SIL3 PLe STO safety and native EtherCAT, EtherNet/IP, or RS-485 communications, the M1 accelerates development within the Sysmac environment.
Learn more.

Flexible planetary gearheads: Quiet, extremely robust

FAULHABER GPT gearheads for miniature and micro motors deliver high power density, exceptional flexibility, and excellent cost efficiency. Designed for seamless integration with diverse motors and encoders, these compact planetary drives feature hardened stainless steel components that reliably withstand extreme torques and abrupt load changes. Offered in standard, low-noise, and high-torque variants, they ensure precise, durable performance across wide operating temperature ranges.
Learn more.

What is a low-waving linear motion guide?

If you are having a problem with your linear guides not always staying perfectly straight during use, it may be due to a phenomenon called waving -- a problem that is particularly critical in high-precision markets such as semiconductor and LCD equipment-related applications or machine tools. Thankfully, THK has an answer.
Read the full article.

NORD serves up sweet energy and cost savings for industrial bakeries

NORD DRIVE-SYSTEMS offers robust, highly configurable drive solutions designed to optimize efficiency, ensure hygiene, and reduce the TCO for automated bakery systems. From industrial-scale mixing and portioning to baking, cooling, and packaging, NORD's modular product portfolio delivers precise, reliable performance across every stage of production.
Read the full article. You may learn something even if you are not in the baking industry.

Key considerations for battery-powered motors

Battery-powered motor applications require careful design considerations to pair motor performance and power consumption profiles in concert with the correct battery type. This Power Electric article covers power requirements, performance considerations, and battery choices to assist you in selecting an efficient motor and a battery with the appropriate capacity. Good technical info.
Read the Power Electric technical article.

Driving next-gen pump and fan applications: Sinamics G210X

The Sinamics G210X is a new frequency converter for advanced pump, fan, and compressor applications, combining easy engineering with robust design. Integrated functions, seamless TIA Portal integration, and a web server reduce PLC effort to speed up commissioning, operation, and diagnostics. IP55 protection, 3C3 coating, and S2 system redundancy ensure reliable operation in demanding environments.
Learn more.

New Exlar food-grade actuator

Curtiss-Wright's Actuation Division has expanded its Exlar line with hygienic electric actuators using FDA-approved materials and finishes. Designed for food, beverage, packaging, and pharmaceutical automation, the new GTF unit enables economical USDA, 3-A, BISSC, and EHEDG certification. Its IP69K washdown option, inverted roller screw, and compact servo-driven design deliver reliable, high-performance motion for hygienic machinery.
Learn more.

New Texas conveyor system is 42 miles long!

SEW-EURODRIVE is helping power one of the most ambitious bulk material handling projects in North America through its contribution to the Dune Express conveyor system, a record-setting 42-mile single-flight conveyor across the Permian Basin.
Read the full article.

Compact servo drives for harsh environs

Built on Copley's proven NanoPlus platform, the compact, 1.2-oz R-Series Nano servo drives withstand extreme temperatures, vibration, shock, and humidity. Available in R47 (CANopen) and R48 (EtherCAT) models, they suit space-constrained, harsh environments such as mil/aero robotics and gimbals. This commercial off-the-shelf series provides a hardened option without defense-specific development lead times.
Learn more from Copley Controls.

Hybrid actuator with force up to 14,726 lb

Kyntronics' new all-electric HyCore hybrid actuator is a compact, low-cost alternative to traditional hydraulic, pneumatic, and electro-mechanical systems. Engineered for OEMs, it delivers up to 14,726 lb of force. The self-contained design eliminates leaks and wear, providing precise control, shock-load tolerance, and high efficiency. It simplifies integration and lowers operating costs for mobile equipment, packaging, assembly automation, and more.
Learn more.

SDP/SI motion products: Best sellers

SDP/SI's best sellers aren't just popular -- they're proven. These are the motion components their customers return to time and again for precision, reliability, and unbeatable value. From belts and pulleys to gears, bearings, and couplings, each product has earned its place through consistent performance in real-world applications.
Learn more and see the full products list.

Automated part grinding and finishing in one unit!

Grinding large fabrications is a classic dull, dirty, and dangerous task perfectly suited for automation, yet traditional setups require multiple costly robots. At Automate 2026, Güdel debuted a single-robot solution that utilizes two extra degrees of freedom to finish massive surfaces without complex part repositioning.
Read the full article.

Rockford RBS ball screws and nuts now available

Automation-Direct now offers US-manufactured RBS ball screws and nuts for precise linear motion in OEM and maintenance applications. Achieving over 90% efficiency, they feature low friction, high accuracy, and minimal wear. Available in various diameters, lengths, and leads, these precision-matched components handle axial loads with minimal backlash, providing a dependable solution that reduces maintenance and extends operational life. Great prices too.
Learn more.

Next-gen conveyor transports 3,000-kg payloads

Building on its established portfolio of twin-strand conveyors that are currently used in a variety of industry verticals, Bosch Rexroth is introducing the TS 7plus transfer system, which is the world's first freely configurable, fully electric conveyance solution to workpieces weighing up to 3,000 kg. TS 7plus transports material via conveyor rollers on freely configurable modular sections with lift/transverse, rotary, and positioning units, as well as stop gates. Great for automotive, battery, aerospace/defense, and more.
Learn more.

Army lab converting JP-8 fuel to hydrogen for portable electric power

By Joyce P. Brayboy, U.S. Army Research Laboratory

What if Soldiers could convert Jet Propellant 8 to clean hydrogen fuel for fuel cell applications anywhere and anytime they need it?

A small team of scientists at the U.S. Army Research Laboratory are collaborating with counterparts at the Communications-Electronics and the Tank Automotive Research, Development and Engineering Centers (TARDEC) to develop technology for lightweight, portable prototype systems that would convert Jet Propellant 8, commonly referred to as JP-8, to hydrogen on the spot.

"There is a growing demand for portable electrical power for both commercial and military applications," says Dr. Deryn Chu, fuel cell team leader. "Our challenge is, 'How can we remove the many impurities in JP-8 so it can be effective in a fuel cell?'"

Dr. Dat Tran, U.S. Army Research Laboratory electro-chemistry, shows two samples of materials that combine to extract sulfur from JP8, or Jet Propellant 8, that is a fuel widely used in the Army. [Photo credit: Joyce P. Brayboy]

 

 

 

 

JP-8 is widely used by the U.S. Army as a fuel for powering aircraft, engines of tactical ground vehicles, and electrical generators. It comes with a set of problems like the logistics resupply chain it requires and the high cost associated with force protection of convoys, Chu says.

The Pentagon's most-used jet fuel costs roughly $15 per gallon, but "... the cost multiplies to hundreds of dollars by the time you move it to and around operational locations," Chu says.

For the Army "... the smallest gain in efficiency is important. But fuel cells -- when the concept is fully developed -- may yield huge gains, potentially doubling the efficiency of diesel generators," he says.

The chance for a game-changing technology is why fuel reformation is one of three high-risk, high-reward projects that the laboratory is pushing toward in search of operational energy solutions for the battlefield. The other two are called "Smart Battlefield Energy on-Demand" and "Long-Lived Power."

Researchers already knew the value of fuel cells for increasing efficiency, as that kind of approach has been explored since the 1960s. They also knew of ways to convert the high energy density of hydrocarbons into hydrogen for fuel cells like the process that Bloom Energy and others use on the commercial market, says Dr. Zachary Dunbar, a team member who is exploring palladium membrane technology, using a rare metallic element as part of a purification system.

The challenge is developing a practical fuel reformation process for better energy conversion that would have to be portable, quick, and easy to use, he says.

Last year, Army Research Laboratory's research reached a milestone when they figured out a way to reduce the production costs associated with fuel reformation by using palladium membranes to purify hyrogen-rich reformate, Dunbar says.

In their work, scientists developed a new supported palladium membrane composite structure for purification technology to produce high-purity hydrogen from a feedstock of hydrocarbon fuel. Before this discovery, designing affordable, leak-free, and high-flux membranes was much more difficult, he says.

A large palladium membrane, like the one shown here, uses less than $1 worth of palladium metal, due to the ultrathin deposition processes used for its fabrication in the Army Research Laboratory Clean Room. [Photo credit: U.S. Army Research Laboratory]

 

 

 

 

"While it is a significant milestone, the research is in its early stages. Fuel reforming is a complex problem that we don't expect to solve quickly," Dunbar says.

The team tests materials that may reduce the sulfur concentration in JP-8. Dr. Dat Tran has tested at least 300 different combinations of materials during the last four years he has been investigating with the team, he says.

"JP-8 is a complicated and dirty fuel. The sulfur is a huge problem, because it can hurt the fuel cells," Tran says. "Sulfur has many different compounds that behave differently. The compounds in sulfur make it hard to find an agreeable material."

JP-8 is a logistical fuel for the Department of Defense under its one-fuel policy. It is a unique problem for the Army. Industry is focused on natural gas, Chu says.

The U.S. Army Research, Development and Engineering Command's Communications-Electronics center Command, Power and Integration experts demonstrate a novel power unit for other defense experts in the industry. [Photo courtesy: CERDEC]

 

 

 

 

The U.S. Army Research, Development and Engineering Command's Communications-Electronics Center, Command, Power and Integration (CERDEC CP&I) experts are integral to the research because they transition mobile power systems from the lab to the field, says Dr. Terry Dubois, fuel reforming and combustion engineer at CERDEC.

Everything from man-worn to multikilowatt systems comes through CERDEC, he says.

CERDEC CP&I enables the quick transition of optimum capabilities to the warfighter in support of ongoing operations.

Army units often wind up in places overseas with no infrastructure and limited supplies. The Army needs to explore and develop high-efficient fuel cell systems to reduce logistical supply. Scientists continue to grapple with the question of the best way to rid JP-8 of its organic sulfur compounds after it is in theater, Chu says.

Published October 2013

Rate this article