Appliance Design June 2011

June 2011

REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

24TH AN N UAL

INSIDE 14 Excellence In Design 27 Software 31 Smart Grid and IP

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See our ads on pages 9, 11 and 13

WHAT DO YOU CALL IT WHEN 10 INCREDIBLE INNOVATORS

ARE COMBINED INTO ONE? WE CALL IT

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CONTENTS JUNE 2011 volume 59, no. 6 REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

DEPARTMENTS 4 Editorial: Form and Function Get Awarded 6 Shipments/Forecasts 8 News Watch 40 Association Report: AHRI

27

31

41 Advertiser’s Index

FEATURES 24TH ANNUAL EXCELLENCE IN DESIGN AWARDS 14 Meet the winners of our annual Excellence in Design competition and who have proved their abilities through innovation, aesthetics, eco-friendliness as well as technologically intelligent designs. The best this year range from major appliances and medical/lab equipment to electronics, HVAC and small appliances.

MEET THE JUDGES

14

24 Jim Kaufman, Marco Perry and Kevin Shinn make the tough call on products for Excellence in Design.

appliance DESIGN ONLINE WEB EXTRAS WEB EXTRAS

Liquid Fuel Technology Enables Clean and Green Power Currently, combustion of bio-fuels in gas turbines is by burning these liquids as a spray, which can generate much higher emissions of pollutants. Now there is a “lean, premixed, prevaporized combustion technology from LPP Combustion, LLC. Engineering Metal Stampings and Springs for Manufacturability Since plastic parts cannot be changed without significant mold costs and very long lead times, stamped metal parts and springs frequently need to adjust to other parts’ restrictions. This makes prototyping a very important part of the design development process.

BLOGS Paul’s European Perspective Kevin Henry’s The Essential Kitchen AD’s Remix Blog

SOFTWARE 27 Welcome to flexible tech. There is now a lowcost and efficient process for transforming heavy 3-D CAD and model-based definition data into lightweight 3-D PDF manufacturing documents.

SMART GRID 31 It’s coming. As the smart grid grows and evolves, it makes sense to adopt Internet Protocol all the way to the edge of the sensor network. 36 Should OEMs care? Appliances need to be designed so that load shifting and load shedding can be handled. And IP-layered architecture is a tool.

E-NEWSLETTERS Sign up for appliance DESIGN’s monthly e-newsletters at www.applianceDESIGN.com/enews

www.applianceDESIGN.com 2 applianceDESIGN June 2011

COVER From left: Humanscale’s personal zone air purifier. Above, Railtones speakers from Encompass Lighting Group. At right, Miele G 5000 Futura dishwashers. Photos courtesy of the makers www.applianceDESIGN.com

EDITORIAL ®

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Award Focus: Form, Function

T

here are so many design competitions throughout the year. What sets the Excellence in Design Awards apart from many is the focus on product design and aesthetics, as well as usability, functionality and improvement above any other product like it on the market. Our panel of judging experts looks at appliances in a range of categories—everything from vending machines to parking machines, electronics, medical and laboratory equipment and white goods. This year’s 24th annual Excellence in Design (EID) award recipients are applauded not only for innovative product design and functionality, but a commitment to sustainability, user communication and advanced features unmatched by other products on the market. There is no set number of winners, or a winner in each and every product category. Products are judged individually based on their form and function—period. If there is no product in the category that makes the cut for an award, then a winner is not named. Our elite group of Gold recipients this year comes from three product categories: electronics; major appliances & HVAC; and medical, laboratory & test equipment. Comments from the judges on the Gold recipients included: “A clever and simple solution that seems so obvious, I wonder why I haven’t seen these before.” “Simple, elegant and timeless design! One dial plus 12 touch pads make it easy to understand and interact with.” “This design is very sleek and comforting; it looks technical but soft. The smaller footprint and mobility should make it a hit for

publishing staff Darrell Dal Pozzo Group Publisher

professionals that need to move it often. The ergonomic considerations of the hand piece are thoughtful and seem to be successful for various size users.” To see all of this year’s 24th annual Excellence in Design award recipients, turn to page XX. Also visit page XX for a look at this year’s judging panel. If you visit us online at www.appliancedesign.com and click on this month’s issue, you can see a slideshow of the award winners, expanded entry descriptions and more commentary from the judges. Information on the 2012 Excellence in Design awards competition will be available in November of this year. Eligible entries will be those products in distribution between January 1, 2011 and December 31, 2011. If you want to share your thoughts on the awards or have further questions, join our appliance DESIGN LinkedIn Group or e-mail me at sheinm@ bnpmedia.com. Also in this issue, is a focus on smart grid in the appliance industry. Our two articles on the subject this month focus on IP as a technology for manufacturers looking to get into smart grid functionality. IP is one of several technologies being discussed in the world of smart grid products. For more, visit our online Smart Grid Channel (http://www.appliancedesign. com/Articles/SmartGrid) to stay up to date on all the latest news and technologies in this category. 

Maggie McFadden Shein Editor

(847) 405-4066 [email protected]

Daryl Delano Economics Editor

(508) 746-7986 [email protected]

Paul Roggema Kevin Henry New Media Contributors

[email protected]

Lindsay Nagy Production Manager

(248) 244-6438 [email protected]

MaTT Britcher Art Director

(480) 334-0286 [email protected]

circulation Rita Foumia Corporate Strategy Director Christina Roth Audience Development Coordinator

(248) 786-1687 [email protected] (248) 244-6435 [email protected]

Alison Illes Multimedia Specialist

(248) 244-1730 [email protected]

Catherine M. Ronan Corporate Audience Audit Manager

[email protected]

(248) 244-8259

Kevin Collopy List Manager

(800) 223-2194 x684 [email protected]

Michael Costantino

(800) 223-2194 x748 [email protected]

marketing Michele Raska Marketing Coordinator

(248) 786-1694 [email protected]

Deana Weber Trade Show Coordinator

(248) 244-6249 [email protected]

editorial advisory board Bob Brown Vice President, Marketing & Sales, North America, Emerson Industrial Automation John Davis

Business Development Manager, Traulsen

Kevin Henry Joseph McGuire

Maggie McFadden Shein, Editor E-mail: [email protected] Twitter: @aplncdsgn

(847) 405-4044 [email protected]

Richard Watson

President, Group42 President, Association of Home Appliance Manufacturers (AHAM) Founding Partner, Essential

Stephen Yurek, JD President, Air-Conditioning, Heating and Refrigeration Institute (AHRI)

| HVAC | Majors | Water Processing | Housewares | Commercial Appliances | Vending | Medical | Lab | | Test & Measurement | Lawn & Garden | Electronics | Computers | Communications | Business Equipment | APPLIANCE DESIGN (ISSN 1552-5938) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: APPLIANCE DESIGN, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to APPLIANCE DESIGN, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected]

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June 2011

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SHIPMENTS Product

FORECASTS Mar-11

Mar-10

%Chg

3 Mo. 2011

3 Mo. 2010

%Chg

MAJOR APPLIANCES (Thousands of Units) TOTAL

7,900.40

7,124.40

10.90%

16,194.60

15,291.70

5.90%

Cooking-Total Electric Cooking-Total Electric Ranges Electric Ovens Surface Cooking Units Gas Cooking - Total Gas Ranges Gas Ovens Surface Cooking Units Microwave Ovens

1,786.70 499.7 392.7 69 38.1 305.2 265.7 5.3 34.3 981.8

1,610.10 450.8 359.5 57.7 33.6 278.9 244.2 3.9 30.8 880.5

11.00% 10.90% 9.20% 19.50% 13.40% 9.40% 8.80% 35.20% 11.20% 11.50%

4,072.80 1,104.70 859.9 151.4 93.4 659.1 569.1 11.6 78.4 2,309.00

3,955.20 1,078.20 847.6 147 83.6 656.2 570.1 11.2 75 2,220.70

3.00% 2.50% 1.50% 3.00% 11.70% 0.40% -0.20% 3.50% 4.50% 4.00%

Home Laundry - Total Automatic Washers Dryers-Total Electric Gas

1,737.40 976.2 761.2 612.4 148.8

1,617.60 893.1 724.5 599.9 124.5

7.40% 9.30% 5.10% 2.10% 19.50%

3,625.60 2,023.30 1,602.20 1,289.00 313.2

3,742.70 2,040.70 1,702.00 1,395.50 306.5

-3.10% -0.80% -5.90% -7.60% 2.20%

Kitchen Clean Up - Total Disposers Dishwashers-Total Built-In Portable Compactors

1,171.70 518.7 648.3 638.2 10 4.7

1,102.50 456.3 640.5 633.2 7.3 5.7

6.30% 13.70% 1.20% 0.80% 38.30% -18.60%

2,794.30 1,333.50 1,450.10 1,428.90 21.1 10.7

2,738.00 1,317.30 1,408.80 1,390.80 18.1 11.9

2.10% 1.20% 2.90% 2.70% 16.90% -10.10%

Food Preservation - Total Refrigerators Freezers - Total Chest Upright

1,142.90 934.7 208.3 127 81.3

1,113.60 910.7 202.9 124.8 78.1

2.60% 2.60% 2.60% 1.70% 4.10%

2,397.00 1,959.40 437.6 263.8 173.8

2,388.20 1,953.90 434.2 260.9 173.3

0.40% 0.30% 0.80% 1.10% 0.30%

Home Comfort - Total Room Air Conditioners Dehumidifiers

2,061.60 1,908.10 153.5

1,680.60 1,344.70 335.8

22.70% 41.90% -54.30%

3,305.00 2,956.70 348.2

2,467.70 1,916.50 551.2

33.90% 54.30% -36.80%

Note: Figures (in units) include shipments for the U.S. market whether imported or domestically produced. Export shipments are not included. Source: Association of Home Appliance Manufacturers (AHAM).

HVAC - Shipment figures for unitary air conditioners, heat pumps, furnaces, and water heaters can be found at www.ahrinet.org.

36>*6:;=HYPHISL:WLLK*VU[YVSZ -VY-HUZ)SV^LYZ/\TPKPÄLYZ:[V]LZ/LH[LYZ >OVSL/V\ZL=LU[PSH[VYZ9HUNL/VVKZ3HTWZ DIAL-A-TEMP Plug-In 2.5 Amps-120VAC.

Qtr: 1 2 3 4

2010 15291.7 18309.3 14169.4 13729.6

2011 16194.6 18987.2 15175.4 14635.8

2012 17312.0 20354.2 15949.4 15279.7

For 2011, a 5.7% increase to 64.993 million units For 2012, a 6.0% increase to 68.895 million units Data Source: AHAM Forecast Source: Delano Data Insights

DIGITAL TELEVISIONS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 5497.2 6708.9 7955.3 15652.9

2011 5920.5 7326.1 8305.3 16216.4

2012 6181.0 7487.3 8396.7 17124.5

For 2011, a 5.5% increase to 37.768 million units For 2012, a 3.8% increase to 39.189 million units Data Source: CEA Forecast Source: Delano Data Insights

MICROWAVE OVENS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 2220.7 2355.9 2370.5 2387.3

2011 2309.0 2461.9 2448.7 2504.3

2012 2376.0 2560.4 2573.6 2642.0

For 2011, a 4.2% increase to 9.724 million units For 2012, a 4.4% increase to 10.152 million units Data Source: AHAM Forecast Source: Delano Data Insights

RESIDENTIAL ELECTRIC WATER HEATERS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 1006.3 984.1 864.0 882.2

2011 955.0 994.9 887.4 919.2

2012 992.3 1039.7 930.8 958.7

For 2011, a 0.5% increase to 3.756 million units For 2012, a 4.4% increase to 3.922 million units Data Source: AHRI Forecast Source: Delano Data Insights

KBWC-Wall Box Mount 2.5, 5.0, 6.0, 8.0, 10.0, 12.0 & 15.0 Amp models, 120 & 240VAC, 50/60Hz.

KBMC-Panel Mount 2.5, 3.0 & 4.0 Amp models, 120 & 240VAC, 50/60Hz.

Designed for Shaded Pole, AC/DC and Permanent Split Capacitor (PSC) Motors. Send for complete literature. If it’s not in our catalog, let KB engineers design a custom control for your application.

2),SLJ[YVUPJZ0UJ

MAJOR HOME APPLIANCES – Shipments (Thousands of Units)

 5> [O:[YLL[‹*VYHS:WYPUNZ-3  ‹-H_! ‹6\[ZPKL-3 ^^^RILSLJ[YVUPJZJVT‹,THPS!PUMV'RILSLJ[YVUPJZJVT

DISHWASHERS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 1408.8 1508.4 1355.7 1437.5

2011 1450.1 1547.6 1445.2 1519.4

2012 1506.7 1615.7 1547.8 1601.5

For 2011, a 4.4% increase to 5.962 million units For 2012, a 5.2% increase to 6.272 million units Data Source: AHAM Forecast Source: Delano Data Insights

ROOM AIR CONDITIONERS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 1916.5 3621.5 612.8 267.6

2011 2956.7 3820.7 516.6 148.5

2012 2856.2 3988.8 556.4 164.9

For 2011, a 16.0% increase to 7.442 million units For 2012, a 1.7% increase to 7.566 million units Data Source: AHAM Forecast Source: Delano Data Insights Note: Forecasts begin in Q2/2011

6 applianceDESIGN June 2011

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NEWS WATCH

NEWS WATCH

EPA Kicks Off 2011 Energy Star National Building Competition he U.S. Environmental Protection Agency’s (EPA) Energy Star program launched the 2011 National Building Competition: Battle of the Buildings. Teams from 245 buildings around the country are going head-to-head to improve energy efficiency and determine who can reduce their energy use the most. Nearly five million commercial buildings in the United States are responsible for approximately 20 percent of both the nation’s energy use and greenhouse gas emissions at a cost of more than $100 billion annually. Through energy efficiency improvements, competitors are working to save energy, reduce harmful greenhouse gas emissions and protect

T

Mobile hotspot devices displayed at the 2011 International Consumer Electronics Show are among applications energizing W-Fi, including the evolution of low power embedded approaches. Photo courtesy PRNewsFoto/Verizon Wireless

WILL LOW POWER EMBEDDED WI-FI ECLIPSE ZIGBEE?

“The opportunity for low power embedded Wi-Fi is substantial and eclipses that of ZigBee, given the existing infrastructure that Wi-Fi-based networks can leverage and the lack of generalized demand for complex

8 applianceDESIGN

June 2011

the health of Americans. “I am excited to see so many companies joining our Battle of the Buildings competition and finding new ways to improve their energy efficiency,” says EPA Administrator Lisa Jackson. “We’re harnessing our nation’s innovative capacity to save money on electric bills, create a cleaner environment and protect the health of American families.” The competition includes 26 different types of commercial buildings, such as retail stores, schools, hotels, and museums, some of which are more than 100 years old. Competitors will be able to exchange ideas and strategies through various social media applications, including a live Twitter feed and a Facebook forum. Information about all competitors, including photos and facts about each, are featured on the competition website in addition to tips and links to consumer-friendly information about saving energy where Americans work, live, play, and learn. More at www.energystar.gov/BattleOfTheBuildings 

mesh networking among the majority of wireless sensor network (WSN) applications,” says Kirsten West, principal analyst with WTRS, the Mountain View, Calif., research firm. “If proponents of this WSN technology can stimulate the Wi-Fi Alliance to place attention on the WSN sector, with sufficient marketing focus, it is quite likely that low power embedded Wi-Fi will gain a strong and significant portion of the overall WSN market.” Applications include smart metering, home area network, and building automation, among others. More information at www.wtrs.net/lpewifi.htm

ONE BILLION EMBEDDED WIRELESS NETWORKING DEVICES AND COUNTING

Shipments of electronic products with embedded wireless local area network-

ing technology (WLAN) will surpass one billion units for the first time ever in 2011 and then rise to more than two billion in 2015, as ubiquitous connectivity increasingly becomes a standard feature, IHS iSuppli research indicates. Shipments of consumer electronics, computer, communications, home and automotive products with builtin WLAN capability will amount to 1.2 billion units in 2011, up 35.8 percent from 880.4 billion units in 2010. In 2015, shipments will nearly double from the 2011 level to reach 2.2 billion. This year, 19.7 percent of suitable devices shipped worldwide will have some form of embedded WLAN, up from 15.6 percent in 2010. By 2015, that percentage will rise to 28.1 percent. The penetration of embedded WLAN has risen dramatically in recent years, expanding from just one percent of these devices in 2002. www.applianceDESIGN.com

NEWS WATCH

Photo – AD0611Newswatch3 Robot Today’s robot gladiators, tomorrow’s appliance design engineers? Says Ron Overton, CEO of Mooresville, Ind.-based Overton Industries and a member of the NTMA board of directors, “The U.S. remains the world’s largest manufacturing economy, and the manufacturing sector is experiencing tremendous growth as the economy recovers.”

ROBOT BATTLES WILL AID APPLIANCE DESIGN

Sparks flew and metal crunched at the 2011 National Robotics Leagues (NRL) Championships last month at the Vincennes University Aviation Technology Center in Indianapolis. The National Tooling and Machining Association

(NTMA) created the NRL, a robot combat competition, to introduce a new generation of Americans to manufacturing and to help change misperceptions about manufacturing and attract students to high-paying technical careers. The program partners teams of middle school, high school, and post-secondary school students with local NTMA manufacturers who work together to build machines designed to do battle and test ingenuity in a Plexiglas arena. Robots are hot. North American robotics companies enjoyed their best opening quarter since 2007, according to the Robotic Industries Association, the industry’s trade group. A total of 4,021 robots valued at $263.5 million were ordered by North American manufacturing companies through March, an increase of 31% in units and 27% in dollars. Robots with smart sensors, video, and communications capability now play a greater role in hospital and healthcare appliances.

GENERAL ELECTRIC ADJUSTS MANUFACTURING PROCESS TO REDUCE GREENHOUSE GAS EMISSIONS

The company’s appliances and lighting division has adopted cyclopentane at GE’s Decatur, Ala., manufacturing plant. The foam-blowing agent produces 99 percent less greenhouse gas emissions than HFC 134a, the chemical it replaces, according to the firm, which equates to more than 400,000 metric tons of emissions avoided at the facility. The benefit of using cyclopentane is twofold, GE says. Cyclopentane, a foamblowing agent that propels insulation into the doors and cases of refrigerators, also boosts the energy efficiency of the foam. GE estimates that shifting to cyclopentane will generate 25 new jobs. The Decatur manufacturing facility is the focus of a $59 million investment by GE. The site will house its Center of Excellence for top-freezer refrigerators. By 2014, GE expects to offer the highest

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June 2011 9

NEWS WATCH

PEOPLE NEWS AHAM HONORS APPLIANCE INDUSTRY LEADERS The Association of Home Appliance Manufacturers (AHAM) has honored three industry leaders for contributions and leadership to the home appliance industry and to the association during AHAM’s annual member meeting in early May in Washington, D.C. The Home Appliance Industry Leadership Award was presented to Vincent Anderson, project technical leader of government programs at Whirlpool Corporation. Anderson was recognized with the industry’s top award for his substantial volunteer efforts over the past decade, particularly for technical support on issues such as the multi-product consensus energy standards agreement, AHAM’s refrigerator/freezer test standards and the development of AHAM verification programs. AHAM awarded the Michael C. Thompson Public Policy Award to a recipient who demonstrates extraordinary effort and accomplishment in the area of public policy: Kevin Messner, AHAM’s vice president of government relations. He led the industry’s public policy efforts for the past three years, instrumental in AHAM’s successful advocacy of public policy positions for the home appliance industry. The AHAM Distinguished Service Award, which recognizes significant contributions by virtue of longevity and quality of service to AHAM and the home appliance industry, was presented to Steven Nackers, design engineer at Sub-Zero, Inc. who has been involved in AHAM’s Smart Grid Task Force. Nackers is the lead author of AHAM’s evaluation of communication protocols for smart grid technology, titled “Assessment of Communication Standards for Smart Appliances.” AHAM also awarded Kelley Kline of GE Appliances & Lighting and Brad Brush of Lasko Products with the Emerging Leader Award.

NEWLY ELECTED BOARD MEMBERS AT AHAM ANNUAL MEETING The Association of Home Appliance Manufacturers (AHAM) has elected new members to its Board of Directors at its annual May member meeting in Washington, DC. David Becker, vice president, strategy, Viking Range Corporation and Drew Fiorenza, vice president, North America/Australia Sales and Marketing and New Business Development, Remington Products have been elected to the Board of Directors. Re-elected members of the board are John Arganbright, vice president, sales and marketing, Panasonic Home Appliances Company; Board Chair Mark Bissell, chairman and CEO, Bissell Inc.; and Tom Vining, vice president, engineering, Electrolux Home Products NA. Continuing members of the board include Franz Bosshard, CEO Emeritus, BSH Home Appliances Corporation; second vice chair Thomas Catania, vice president, government relations, Whirlpool Corporation; Donald Hoeschen, vice president, sales, National Presto Industries, Inc.; Earl Jones, senior counsel - regulatory compliance, GE Appliances & Lighting; Edward V. McAssey, III, chief operating officer, Lasko Products, Inc.; Alvise Ricoveri, managing director, DeLonghi America, Inc.; Jerry Ryder, chairman, InSinkErator Division, Emerson Appliance Solutions; first vice chair Robert Scaglione, chief marketing officer, Sharp Electronics Corporation; treasurer Paul Sikir, vice president of design engineering, Sub-Zero, Inc.; John Taylor, vice president, government relations and communications, LG Electronics USA; and Joseph McGuire, AHAM president.

10 applianceDESIGN

June 2011

percentage of U.S.-made refrigerators among full-line appliance manufacturers.

GE makes energy efficiency news following a history of innovations. It helped harness electricity for two main household essentials: light bulbs and toast. The first U.S. patent for an electric toaster was made in 1909 by General Electric for an appliance surrounded by a wire cage to hold the bread. This model, the D-12, is considered the first commercially successful toaster in U.S. history. Photo by Michael McKovesk for the Grain Foods Foundation

FRAM microcontrollers from TI reduce the industry’s best active power by up to 50 percent when executing code from FRAM, operating at 100uA/MHz in active mode and 3 uA in real-time clock mode. Photo courtesy of Texas Instruments.

IT’S MCU GOING EMBEDDED FRAM

Ushering in a new era of reliable data logging and RF communication capabilities, Texas Instruments last month announced ultra-lowpower ferroelectric random access memory (FRAM) 16-bit microcontrollers. The MSP430FR57xx FRAM series ensures data can be written more than 100 times faster and uses as little as 250 times less power than flash- and EEPROM-based microcontrollers. Additionally, the on-chip FRAM allows data retention in all power modes, supports more than 100 trillion write cycles, and delivers a new dimension of flexibility by allowing developers to partition data and programming memory with changes in software. The FR57xx series eliminates existing power consumption and write endurance barriers, enabling developers to make the world smarter with more cost-efficient data logging, remote sensing and wireless www.applianceDESIGN.com

NEWS WATCH update capabilities in new products that do more and last longer.

The result is our new built-in cooking suite, a line of cooking products that meets the needs, aspirations and lifestyles of today’s modern cooks.”

CIAO AS ITALY’S BERTAZZONI UNVEILS NEW BUILT-IN COOKING PRODUCTS TO U.S. MARKET

It’s a 129 year-old family-owned Italian manufacturer and it has launched a new built-in oven, cooktop and ventilation line. The move underlines the appeal of design with appliances. “For over five generations, Bertazzoni has been guided by the principles of imaginative styling and advanced technology to offer products that last a lifetime,” says Paolo Bertazzoni, CEO and principal of Bertazzoni s.p.a. “In keeping with this credo, we realized that the user experience of built-in cooking products had remained unchanged for several decades. With this in mind, our team of engineers and designers set out to develop a collection of built-in cooking products aimed at improving the user experience.

The citywide scanning of Cambridge, Mass., had to be done at night in wintertime in order to see the effects of heated air escaping from buildings. Photo courtesy of Long Phan.

A PICTURE IS WORTH A THOUSAND WATTS

Created in collaboration with Milan designer Stefano Giovannoni, the Bertazzoni designs combine metropolitan flair and technical virtuosity.

An MIT system boasts a comprehensive view of energy inefficiency of a home or a commercial building kind of like a Google Street View with a streamlined process allowing for scans of large groups of buildings — or even entire cities. The project uses a vehicle with automated cameras that take thermal infrared images of every building as it moves

Strength and Cost

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June 2011 11

NEWS WATCH along. Researcher Long Phan and research scientist Jonathan Jesneck, working with Professor Sanjay Sarma, developed the system, which they have used over the last few months to scan the entire city of Cambridge, Mass., and an army installation, Fort Drum in New York. The team: MIT’s Department of Mechanical Engineering Field Intelligence Laboratory. The concept is to quickly identify the buildings that are most inefficient, by detecting the heat escaping through walls, roofs, doors and windows in a way that allows detailed, quantitative comparisons of the rate of heat loss. That will make it possible to target remediation efforts at the worst buildings, thereby getting the most out of any efficiency-improvement spending.

COOL IDEA! SUPPORTS TOMORROW’S INNOVATORS

Proto Labs, a manufacturer of CNC machined and injection-molded parts,

has a Cool Idea! Award for designers to bring innovative products to life. It provides $100,000 worth of prototyping and short-run production services to award recipients. “We know there’s a Cool Idea at the foundation of every innovation,” says CEO Brad Cleveland, whose program helps designers take ideas to its first-run production with Firstcut CNC machining or Protomold injection-molding. Visit www.protolabs.com/coolidea.

GOOGLE’S ANDROID@HOME AIMS AT RESIDENTIAL MANAGEMENT

If you think Google is big enough, think again. Just week ago, Joe Britt, head of the Android@Home team, in a Los Angeles Times interview, said, “We’d like to think of your entire home as an accessory, or better yet as a network of accessories, and think of Android as the operating system for your home.” It is expected that Android software for this application

will include an entirely new communications protocol to compete against ZigBee (including RF4CE for A/V control) and Z-Wave. Uniquely it will have bandwidth to also transmit audio and video. One sweet spot, shared by appliance designers, homeowners and businesses is energy management and monitoring. On the home side, it is forecast that 13 percent of U.S. households will have energy management networking by 2015, according to research firm Parks Associates. There will be greater interest by businesses. One-third of consumers in broadband households find remote control of lights, appliances and thermostats via Web-enabled devices very appealing. Nearly 50 percent find email/text notification of smoke, fire, water, or gas leaks very appealing. Companies such as ADT, Best Buy, GE, Intel, and Verizon have entered the market from several different entry points; all have the marketing clout to educate. 

SMART GRID SPEEDS UP According to BCC Research, the U.S. market for smart grid technologies, worth $15.3 billion in 2008, is expected to increase to $37.4 billion in 2014, for a compound annual growth rate (CAGR) of 16.6 percent. Distributed energy generation and storage technologies generated $10.1 billion in 2008 and an estimated $11.3 billion in 2009. This segment should reach $20.1 billion in 2014, for a CAGR of 12.2 percent. Sensing, measurement and control technologies were worth almost $4 billion in 2008 and reached an estimated $4.4 billion in 2009. This should increase at a CAGR of 26 percent to reach $14 billion in 2014. The century-old U.S. electrical grid consists of more than 9,200 electric generating units with more than 1,000,000 MW of generating capacity connected to more than 300,000 miles of transmission lines. Smart grid describes a set of related technologies, rather than specific technology with a generally agreed on specification. These technologies fall into diverse areas.

Two-way integrated communications: allow for real-time control, information and data exchange to optimize system reliability, asset utilization, and security. Sensing and measurement: evaluate congestion and grid stability, congestion and grid stability, monitor equipment health, detect energy theft, and support control strategies support.

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Utilities, for the most part, are driving smart grid advances. Florida Power & Light, for example, now has an online virtual energyefficiency tour for visitors to explore a typical Florida home roomby-room to learn facts and helpful tips about how to save energy around the house. Photo courtesy PRNewsFoto/Florida Power & Light Company

Advanced components: flexible alternating current transmission system devices, high voltage direct current, first and second generation superconducting wire, high temperature superconducting cable, distributed energy generation and storage devices, composite conductors, and “intelligent” appliances. Advanced control that enables rapid diagnosis of and precise solutions to specific grid disruptions or outages. Improved interfaces and decision support that reduce complexity so that operators and managers have tools to effectively and efficiently operate a grid with increasing numbers of variables.

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NEWS WATCH

MEETINGS June ELECTRONIC SECURITY EXPO ESX June 6-10, Charlotte, N.C. Website: www.esxweb.com/ MIDWEST DESIGN-2-PART SHOW June 14-15, Covington, Ky. Website: www.d2p.com PACKEX June 21-23, Toronto, Ontario, Canada Website: www.packextoronto.com ASHRAE ANNUAL MEETING June 25-29, Montreal, Quebec, Canada Website: ashraem.confex.com/ashraem/s11/cfp.cgi

July CHINA INTERNATIONAL CONSUMER ELECTRONICS SHOW (SINOCES) 2011 July 7-10, Qingdao, China Website: www.sinoces.com SPI’S FLEXIBLE VINYL PRODUCTS 22ND ANNUAL CONFERENCE July 10-13, Burlington, Vt. Website: www.plasticsindustry.org

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I Twenty-fourth Annual EID Winners

Sustainable

Innovation The recipients of the 2011 Excellence in Design Awards demonstrate a greater focus on sustainability and communication with the user than ever before.

F

or this year’s 24th annual Excellence in Design competition, our judges spent a lot of time focusing on the design and functionality of each entry. There was some stiff competition, but the winning recipients this year demonstrated designs across all categories that focused on simplicity and strong functionality for the end-user, while optimizing and increasing product capabilities. Add to that a focus on energy savings, recyclability and sustainability, and we have a group of products this year that represents the best of what is available in the marketplace. This year’s Gold recipients represent true innovation, and include: a speaker system that integrates into an existing light fixture without any wire installation; a dishwasher that capitalizes on capacity and minimizes noise; an oven that brings defrosting, steaming, baking, slow cooking and reheating to the residential kitchen; and a medical device that

maximizes energy savings while treating superficial vascular conditions with minimal lateral damage. All entries fit into one of eight categories with a chance to win a Gold, Silver or Bronze award. As always, winners are not evenly distributed across categories and there is no predetermined number of awards established. The focus of the competition is to recognize the most excellent product designs— regardless of how many entries a category receives. Find more information about our independent panel of judges on page XX. Next year’s competition will be announced in November of this year. Information on the 2012 EID competition will be available at www.appliancedesign.com/EID. For more information, contact Maggie M. Shein, editor, at [email protected].  Editor’s Note: For more information on this year’s competition, including judge’s comments and a slideshow of the recipients, visit www.applianceDESIGN.com and click on “Issue.”

Electronics GOLD Railtones (model RTSPKTO1) by Encompass Lighting Group, Skokie, Ill., and design firm Beyond Design Inc. Chicago. This speaker system is mounted to and powered by a low-voltage track lighting system. The speakers are mounted to the rail just as any low voltage lighting fixture. The transmitter can be connected to any audio device, and provides audio without any wire installation. Speakers are compatible with a portable MP3 player, smartphone, stereo or computer. The speakers have a three-zone capability where they can be controlled individually with the use of a remote control. The open architecture system allows for an infinite number of speakers within a certain range—depending on the number and material of walls in the space. 14 applianceDESIGN

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I Twenty-fourth Annual EID GOLD Awards GOLD G O LD D 2011

Major Appliances & HVAC GOLD G 5000 Futura Series Dishwashers by Miele Inc., Princeton, N.J. These dishwashers expand on the technology developed from the company’s previous G 2002 series. Highlights of this appliance include a cutlery tray, baskets, lighting system, quiet operation, ultralow water and energy consumption and intuitive functionality. The 3-D cutlery tray offers flexibility with the largest possible capacity, which is height-adjustable and contains sliding inserts to accommodate large items such as ladles and whisks. BrilliantLight technology uses LEDs on the interior to improve loading and unloading. A further convenience is the low noise level called “extra quiet,” where the dishwasher is hardly audible. AutoOpen drying opens the door to allow air to escape and circulate, producing efficient drying results.

Major Appliances & HVAC GOLD Thermador Steam & Convection Oven (model MES301HS) by Thermador Home Appliances, Huntington Beach, Calif. This oven defrosts, steams, proofs, bakes, slow cooks and reheats food in the residential kitchen. The three distinct cooking options—steam, convection or a combination of the two—reduces the risk of over-cooking, over-boiling or drying out of food. It includes 40 automatic food programs, nine advanced cooking modes and a series of advanced features geared toward cooking enthusiasts. The oven was designed to complement the company’s existing line of professional kitchen appliances, and can be installed as a standalone oven or integrated with other appliances such as wall ovens and warming drawers. Additionally, design elements such as an interchangeable oven handle and stainless steel trip kit make the product compatible with the company’s other appliances.

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I Twenty-fourth Annual EID GOLD Awards GOLD G O LD D 2011

Medical, Laboratory & Test Equipment GOLD Cutera Excel V by Cutera Inc., Brisbane, Calif., and design firm Zoe Design Associates, San Francisco. This vascular laser is used in cosmetic dermatology to treat unwanted veins, brown and red sun damage and vascular birthmarks. The product has a multi-kilowatt 532nm laser output and the adjustable laser treats superficial vascular conditions with minimal lateral damage—leading to less down time after treatments and better epidermal protection. The vascular laser has no disposables, a small footprint, and features such as variable contact cooling, real-time calibration, zoom spot size adjustability, and a warm-up time of less than one minute.

I Twenty-fourth Annual EID SILVER Awards SILVER 2011

Business Machines SILVER Black & Decker Hanging Crosscut 6-Sheet Paper Shredder by Homedics Inc., Commerce Township, Mich., and design firm TEAMS Design, Chicago. This wall-mounted paper shredder includes a messaging center with magnetic white board. The slim line product is designed to hang on a wall, or reside on a desk or floor using the included stand. The multi-function product can be adjusted to any comfortable height for the user when mounted on the wall. In addition to the unique wall-mount capability, the product includes the white board, mesh organization pocket to hold envelopes or notes, a bin full sensor and protective safety shield. The shredder can crosscut up to six sheets of paper and also shreds credit cards and staples—all with a noise level of 68 db.

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I Twenty-fourth Annual EID SILVER Awards SILVER 2011

Electronics SILVER VGo by VGo Communications Inc., Nashua, N.H., and design firm Helix Design Inc., Manchester, N.H. The company calls this video teleconferencing device an active-presence revolution. The user, who could be in the next building or on the other side of the globe, is independent of the people in the remote location. Controlling the unit from a PC or laptop, the user is able to interact in a valuable and effective way by broadcasting his actual presence into the remote site, without the cost of money and time in traveling there. The product operates through a standard Wi-Fi network and no additional or proprietary infrastructure is needed. The design was scaled appropriately for conversing with people who are seated, standing or walking, and because of the Wi-Fi connectivity, the product is very portable.

Lighting SILVER The Element 790 by Humanscale, New York. This task light uses 7 watts of power to produce light output equivalent to 90 watts of incandescent lighting. The light uses a single, powerful, multi-chip LED to cast a wide footprint of illumination. An intuitive dimmer control provides seven levels of adjustable light output for energy savings and user control.

Major Appliances/HVAC SILVER KitchenAid Commercial-Style Dual Fuel Range (model KDRU783VSS) by Whirlpool Corp., Benton Harbor, Mich. The 48-inch, dual-fuel, double oven range features a fully reconfigurable, touch screen LCD display that offers users advanced cooking features such as dual-fan convection with steamassist cooking. Other innovations include 20K BTU Ultra Power dual-stacked cook top burners, easy-to-clean Even-Heat chromed griddle and Satinglide full extension roller oven racks.

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I Twenty-fourth Annual EID SILVER Awards SILVER 2011

Major Appliances & HVAC SILVER KitchenAid Dishwasher (model KUDE60HXSS) by Whirlpool Corp., Benton Harbor, Mich. This dishwasher features a chrome latch handle on the front of the door, constructed of die cast metal. In addition, a capacitive touch user interface provides a responsive and easy-to-clean user experience. One other feature which distinguishes this product is the professional grade ball bearing glides on the upper rack, which provide a silky smooth motion. A Proscrub feature aims to eliminate tough-to-clean soil through a dedicated water manifold with 36 water jets that spray the water directly onto dishes. The door is balanced so that it will stay in any position that the user desires. Operational sound level is 43 dBA.

Major Appliances & HVAC SILVER NEXT Hybrid High Efficiency Gas Water Heater by A. O. Smith, Ashland City, Tenn. This water heater has a tankless engine and a small buffer tank, delivering the benefits of both technologies in one product. The product handles peak periods and provides homeowners the performance they expect from a tankless model, with more efficiency. The buffer tank serves as a secondary heat exchanger to extract additional heat and transfer it to the water. This unit is 90% thermal efficient, whereas a standard tankless model is 82% and conventional storage models are 78%. The water heater qualifies for state and local incentives as well as a Federal tax credit.

Major Appliances/HVAC SILVER SilKEN (model B80101) by Kenyon Custom, Clinton, Conn. This induction cooking system is applicable to a range of markets, including residential, marine, recreational vehicle, hospitality, institutional, military and academic housing, and offers 90% energy efficiency compared to gas stoves and radiant cook tops. The recessed lip and silicone mats provide pot stability for user safety, especially important in mobile installations. In addition, the mats contain accidental boil overs and spillovers for easy clean up and can be removed for cleaning in the sink or dishwasher. Acting as an insulator, the appliance surface remains cool to the touch as the silicone mat prevents transfer of heat back to the cooking zone. 18 applianceDESIGN

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I Twenty-fourth Annual EID SILVER Awards SILVER 2011

Medical, Laboratory & Test Equipment SILVER DentalVibe Comfort System Unit by BING Innovations, Boca Raton, Fla., and design firm Bresslergroup, Philadelphia. This cordless, handheld device is designed to reduce the pain and fear associated with dental injection for adults and children. This vibrating, lighted retractor helps the dentist retract tissue to physically and visually access an injection site, while reducing a patient’s pain and anxiety. Through a proprietary microprocessorcontrolled VibraPulse technology, the device provides counter-stimulation by delivering a pulsed, percussive vibration with enhanced amplitude to block the painful stimuli of injections. The LED light highlights the injection area to ensure precision, avoid accidental needle sticks and greatly enhance operator visibility.

Medical, Laboratory & Test Equipment SILVER Lifeline View AED by Defibtech, Guilford, Conn. This automated external defibrillator has three modes of instruction: audio, text and video, designed to make it easy for anyone from first responders to untrained bystanders to provide defibrillation quickly, easily and reliably in any setting. The full-color, full-motion interactive video display shows step-by-step, real-time instructions for preparing the patient, performing CPR and rescue breathing, and performing external defibrillation. Animated video images show the user how to perform each step. The interactive display also allows users to view the status of the unit, including battery pack life and expiration date of the pads, view perform maintenance, and access additional instructions.

Medical, Laboratory & Test Equipment SILVER PacBio RS by Pacific Biosciences of California Inc., Menlo Park, Calif., and design firm Zoe Design Associates, San Francisco. This 3rd-generation DNA sequencing instrument can analyze biochemical reactions in real time. The system captures and analyzes vast arrays of sequencing data, and incorporates large volumes of precision components including lasers, robotics, environmental controllers and computers. Design innovations include isolating vibrations that disrupt the nanometerscale performance of precision optics; mitigating heat and contaminant damage to samples; and ensuring transportability for diverse lab environments. The system allows scientists in medicine, agriculture and biofuels to study diseases, drug responses, and environmental factors faster and with more accuracy. www.applianceDESIGN.com

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I Twenty-fourth Annual EID SILVER Awards SILVER 2011

Small Appliances SILVER 12-Inch Dual-Bevel Glide Miter Saw by Robert Bosch Corp., Mount Prospect, Ill., and design firm TEAMS Design, Chicago. This dual-bevel glide miter saw eliminates rails in favor of mechanical arms that extend the reach of the blade by folding out and back. This results in saving up to 12 inches of workspace versus a traditional sliding compound miter saw, and also enables the saw to be operated with almost no clearance behind it. Without sliding rails, the saw sits flush against wall, and upfront controls eliminate the need to reach behind the saw to make adjustments.

Small Appliances SILVER Black & Decker iShred by Homedics Inc., Commerce Township, Mich., and design firm TEAMS Design, Chicago. This paper shredder has a vertically oriented paper feed, allowing for a slim, conical form and efficient bin capacity. This design also increases safety by limiting direct access to the shredder’s blades. The shreds instead fall into a naturally even conical pile, filling the bin more efficiently, than traditional shredders that often create triangular pile of shreds in rectangular shredder bins.

Small Appliances SILVER CM5 Series Countertop Coffee System by Miele Inc., Princeton, N.J. This coffee system is a fully functional whole bean espresso machine in a compact, countertop layout. An angled, two-line text display is part of an easy-to-use interface letting the user know when to replenish the water or beans, empty the waste container or other maintenance aspects, aiding in the longevity of the machine. The unit is tested for 50,000 cups of coffee or roughly 20 years of use. Optimal temperature, strength, consistency and flavor can all be chosen and even frothed drinks can be created with the frothing system and insulated, stainless steel milk flask. The appliance was designed with extensive use of sound insulation yield a quiet, pleasant operating tone. 20 applianceDESIGN

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I Twenty-fourth Annual EID BRONZE Awards BRONZE B R O NZE 2011

Business Machines BRONZE The blueSLR for Nikon Advanced DSLR by Xequals, Manotick, Ontario, Canada, and design firm Design 1st, Ottawa, Ontario, Canada. This Bluetooth device is a camera accessory that can be controlled remotely by a compatible iOS device. Users connect the device to a Nikon camera and download the free companion blueSLR App from the App Store to an Apple device. An iPad, iPod Touch or iPhone can then remotely control the camera’s shutter and geocode from up to 300 feet away. Instead of offering various iterations of one product for different camera models, the design allows for changing of the adapter on the accessory to mate with the appropriate connection type on the camera.

Major Appliances & HVAC BRONZE Broan 744SFL and NuTone 744SFLNT Humidity Sensing Recessed Fan/Light by Broan-NuTone LLC, Hartford, Wisc. The Energy Star qualified humidity sensing recessed fan/lights feature SensAire technology to help ensure moisture is effectively exhausted at the source. The outside looks like a recessed light, and inside is a humidity sensing switch that triggers a concealed, quiet ventilation fan. The switch turns on when it senses a quick jump in humidity and turns off once the job is done. The product is U.L. listed for use over bathtubs and showers when connected to a GFCI protected branch circuit without the use of an additional glass lens to protect it. This model not only senses a preset relative humidity level, but additionally senses a change in humidity over a short period of time—making it an accurate and efficient way of determining when a shower has been turned on and ventilation is needed.

Major Appliances & HVAC BRONZE Cirrex Solar Thermal Water Heating System by A. O. Smith, Ashland City, Tenn. Available in 80- and 120-gallon models, this water heating system has solar energy factors of up to 10.1 and is eligible for a federal tax credit of 30% of the total installation cost without a cap. The product is designed to provide up to 70% of a home’s water heating needs directly from the sun, unlike photovoltaic systems with high upfront costs and lower efficiency. This water heating solution integrates all component parts needed for a comprehensive solar water heating solution—without additional component parts to purchase.

Major Appliances & HVAC BRONZE Hyperion Air Handler by Trane, Piscataway, N.J. This air handler is constructed more like a refrigerator than a typical air handler, with insulation between double-walls of its Air-Tite II cabinet. This insulation prevents condensation that may cause damage to the air handler itself or a consumer’s home. In addition to eliminating sweating, the cabinet also eliminates the loose fibers from fiberglass insulation that may enter the airstream with other air handlers. The product is fully modular and is smaller, smarter and more flexible than other air handlers on the market—making a one-person installation possible. www.applianceDESIGN.com

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I Twenty-fourth Annual EID BRONZE Awards BRONZE B R O NZE 2011

Major Appliances & HVAC BRONZE Rheem/Ruud SPIDERfire – GHE100 Series Commercial Water Heater by Rheem Manufacturing, Atlanta.

With up to 95% thermal efficiency, this high-efficiency, fully condensing commercial water heater can dramatically reduce fuel cost. The heat exchanger system consists of a series of connected, elongated tubes immersed in the tank through which heat transfers to the water. Combustion gases, generated by the burner at the unit’s top, are blown down the large main flue in the center of the unit and nearly traverse the full length of the unit two more times, extracting as much heat as possible. Hot spots are eliminated with a wet-based design, which suspends the flue’s first two legs in water, rather than connecting them to the tank bottom. This also keeps heat from escaping the bottom.

Major Appliances & HVAC BRONZE The Smart System by Lochinvar Corp., Lebanon, Tenn. The user interface on this heating boiler system provides greater level of control than ever before, offering installers and facility managers access to all of the information they need to set-up, troubleshoot and monitor all equipment functions. The system is equipped with several features, including a larger display screen, color coding functionality and soft keys for quick and easy use, as well as two selectable cascade options to allow the user to fine-tune the sequencing of multiple-unit installations. A cascading sequencer allows for up to eight boilers or water heaters to be installed, with two cascade options.

Medical, Laboratory & Test Equipment BRONZE Circulating Water Bath (model PP07R-20) by PolyScience, Niles, Ill., and design firm Cesaroni Design Associates Inc., Glenview, Ill. This circulating water bath is a refrigerating and heating temperature control unit used in laboratory applications. The unit stores liquid and samples in the reservoir, while its pump circulates water throughout—delivering consistent temperatures for long durations. The LCD touchscreen guides the operator through setup and operation. Temperatures can be monitored from anywhere in the laboratory with a pivoting control head. The unit employs ergonomic features such as convenient handles and a lid docking system. The compact design of the control head occupies a minimum of reservoir space to provide more room for liquid and samples.

Outdoor & Leisure Appliances BRONZE The xR3ci Seated Elliptical by Octane Fitness, Brooklyn Park, Minn., and design firm Cesaroni Design Associates Inc., Glenview, Ill. This seated elliptical machine was designed to deliver a home fitness system in a compact footprint. With multiple height and tilt positions, the unit accommodates users from 5 to 6 1/2 feet tall. An ergonomically designed mesh-back seat and oversized pedals offer flexible foot position and ensure correct posture. The console informs the user of intensity, duration and number of intervals according to fitness level and objectives. The elliptical motion offers the user the option of pedaling forward or backward. 22 applianceDESIGN

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I Twenty-fourth Annual EID BRONZE Awards BRONZE B R O NZE 2011

Small Appliances BRONZE Mr. Coffee Optimal Brew Thermal Coffeemaker by Jarden Consumer Solutions, Rye, N.Y., and design firm TEAMS Design, Chicago. This coffeemaker was designed to brew faster and hotter than the average coffeemaker on the market. Even hours after shutting the unit off, coffee stays hot, because of the heating and insulation design. Water quickly heats in a boiling chamber; a heating plate has been eliminated in order to save energy and prevent coffee from overheating, imparting an unappealing burnt flavor. Instead, a double-walled, vacuum-insulated, stainless steel thermal carafe insulates the coffee. A removable water reservoir allows the user to fill the unit without moving the entire coffeemaker or cooling down the carafe.

Small Appliances BRONZE Oster Designer Series Blender by Jarden Corp., Rye, N.Y., and design firm Essential, Boston. The blender family utilizes an all metal drive, unique to the price segment. This feature is based on the interfacing drive mechanism being metal (instead of plastic) and results in a durable, long-lasting blender. The motors used are either a six speed or eight speed reversible 475 or 600 watt motor, point star blending blade and pre-programmed controls. The products also incorporate a thermally shock tested universal, six-cup, square, glass jar. The handle on the jar can be placed in four orientations on the base—designed so that a left or right handed user can pick the jar up easily. The surfaces, as well as the core blender blade assembly and jar were designed for easy cleaning.

Small Appliances BRONZE TheO by Cloud Nine, West Yorkshire, United Kingdom, and design firm Absolute Product Design Limited, Cornwood, Devon, United Kingdom. This heated hair roller system differentiates itself with the speed of operation. Each roller can be heated to 130 degrees in under four seconds. The rollers are light weight and have a Velcro wrap enabling them to be held into the hair without the need for additional clips. Instead of using thermal conductivity to transfer heat from hot rods or plates to the rollers, this product uses induction heating to quickly and efficiently heat. Also, heating from the core out means the rollers are initially cool to the touch.

Small Appliances BRONZE Personal Zone Air Purifier by Humanscale, New York. This air purifier creates a clean air zone around users to ensure that they are breathing nothing but the cleanest possible air. By focusing on just the air being breathed instead of all the air in a room, the system delivers cleaner air with less energy and fewer ongoing costs. Patented technology uses a tightly coiled paper filter that offers large surface area for particle capture. Other operating features include breeze-free, ozone-free and virtually silent operation. The unit consumes 22 watts of energy while producing a CADR of 125—all with a recyclable paper filter.  www.applianceDESIGN.com

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MEETTHEJUDGES JIM KAUFMAN is principal of Kaufman & Co., a Colorado design consultancy and is professor emeritus of the Ohio State University. In 2008, he finished a semester as visiting professor at Massey University in Wellington, New Zealand and continues to be affiliated with the university’s research efforts and consults on curriculum and leadership matters. Kaufman recently concluded his term as a national officer, secretary/ treasurer of the Industrial Designers Society of America (IDSA) and service on its Board of Directors 2009-10. He was National Education Chair for IDSA and served on the Board of Directors 2001-02, was IDSA Special Awards Chairman 2007, an original trustee of IDSA Design Foundation, Mid-Ohio Chapter Chairman, Mid-East Regional Conference Chairman & Education Representative, and was the University of Cincinnati’s Merit Award Winner 1969. Kaufman is a National Schools of Art and Design evaluator and former accreditation commissioner. He has M.F.A and M.A. degrees from the University of Notre Dame, and a B.S.I.D. from the University of Cincinnati.

MARCO PERRY is a founder of Pensa, a Brooklyn, N.Y.-based consultancy firm that focuses on product strategy, design, development and invention. Perry has more than 15 years experience designing and engineering everything from diapers to lab equipment to vending machines. His work has earned several awards, including from IIDEX/Neocon Gold, BusinessWeek/IDEA, Spark Award, Chicago Anthenaeum Good Design, appliance DESIGN and a Medical Design Excellence Award. He has a B.S. in mechanical engineering from Lehigh University and a masters of industrial design from Pratt Institute. Perry is currently the Northeast District vice president of the Industrial Designers Society of America.

KEVIN SHINN is the global industrial design manager at Dow Corning Corp. He joined Dow Corning in 2007 to lead the transformation of the company toward design. Shinn has helped create a new design culture within Dow Corning, leveraging the company’s technical and scientific background to create proven experiences and solutions. Prior to his current position, he was the head of industrial design for Rubbermaid Home Products and has an extensive background in consumer, toy and automotive products. Shinn is currently the Industrial Designers Society of America Mid-East District vice president and sits on the Board of Directors for the organization. He is an alum of the College for Creative Studies, from where he holds a degree in industrial design.

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4,469@<7.9(+, Connolly Bove attorneys understand the technological advances of the 21st century and how they relate to IP and your ever-changing business needs.

It’s like we’re in your head. www.cblh.com

DESIGN MART This appliance DESIGN Design Mart section brings you information on new products and services available through print and online. To receive more information about the the products and services in this section, visit appliance DESIGN online at www.applianceDESIGN.com.

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SOFTWARE With the help of 3rd party software applications, engineers can create fit-for-purpose, lightweight, 3-D PDF manufacturing documents available to an extended enterprise. Image: Anark Corp.

Who Needs 2-D Drawings?

F

ew people would argue that the revolution in drafting—from 2-D to 3-D product definition—has yielded incredible benefits for manufacturers. Digital drafting tools and 3-D modeling enable accelerated time to market, reduce development costs, and yield higher-quality products, even as products have become smaller, more complicated and more difficult to manufacture. To varying degrees, it has been possible since the mid-80s to create a “digital product definition” that encompasses critical aspects of a design. More recently, through the use of dimensioning and tolerancing tools found in modern CAD packages and the ability for these tools to create 2-D drawings, manufacturers have been able to define and capture all aspects of a product’s design characteristics—in essence, creating a total product definition.

Opportunities CAD-generated 2-D drawings have been an effective medium for communicating a design’s product definition, but it has been obvious for several years that: 2-D drawings restate much of the information that is already captured in a 3-D model that can be ambiguous as to the designers original intent; are prone to quality errors; and are expensive to generate and regenerate when www.applianceDESIGN.com

the design changes. In a quest to eliminate unnecessary 2-D drawings, many manufacturers have turned to model-based definition (MBD) practices, which seek to add all of the important product definition data typically found in a 2-D drawing, back into the original 3-D model. Special manufacturing notes, definition of block tolerances, special material treatments, and structural considerations are all examples of 2-D drawing data that are being added to the 3-D model. Eliminating redundant design steps and expensive, non-value added activities may be driven by quality initiatives, however, eliminating these factors as expenses may ultimately serve as a differentiator between successful and unsuccessful OEMs.

Problems While it has been possible for some time to define all aspects of a product through the use of CAD modeling tools, annotations, etc., effective reuse of 3-D CAD and embedded 3-D MBD data for downstream manufacturing process has been elusive for the following reasons: 1. OEMs and prime contractors use different 3-D CAD authoring tools (like CATIA, UG/NX or Pro/E) that store their parts and assembly designs in proprietary CAD formats. This requires

Modern 3-D CAD applications can create rich, 3-D, total product definitions, and software applications can now expose this data to downstream operations—eliminating the need for redundant, ambiguous and expensive 2-D drawings. by chris garcia and paul perreault Chris Garcia is senior vice president business development, and Paul Perreault is senior product marketing manager at Anark Corp., Boulder, Colo. applianceDESIGN

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SOFTWARE

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5.

6.

downstream manufacturing organizations to purchase and become experts in each of the native CAD software systems in order to make effective use of the 3-D designs and MBD information. OEMs and prime contractors assign MBD information to parts and assemblies (such as dimensions, tolerances, surface finish symbols and manufacturing attributes) using different techniques and nomenclature (schemas). The lack of a standard schema makes interacting with and interpreting MBD data difficult, inconsistent and hard to find within the native 3-D part or assembly. 3-D CAD assemblies are usually too heavy and too complex for normal downstream manufacturing operations, which then require labor intensive manual simplification in the native CAD system to make the 3-D data fit for purpose. It should be no surprise that 3-D CAD systems are great for creating complex parts and assemblies, but are often poor at simplifying these parts and assemblies to make them usable for a given manufacturing, inspection or assembly operation. Activities like this can drive PLM black belts insane: Is the simplified model a configuration of the original model? What revision? Requiring people to use a native CAD application to view MBD data such as part tolerance, imposes a significant learning curve to learn the software. In addition, MBD is usually too detailed and too hard to find or interpret for typical manufacturing and inspection operations. The abundance of data makes it hard to isolate critical part dimensions and tolerances from the hundreds, if not thousands, of tolerances embedded within the 3-D parts or assemblies. CAD and PLM software vendors have been hesitant to aggressively embrace open standards or to promote open access to their 3-D CAD and MBD formats for fear of losing a lock on the customers’ CAD data. Preventing CAD and MBD data from being accurately represented in non-native formats is driven by fear of customers switching to other 3-D CAD vendors or losing market share to best-of-breed 3-D software technologies provided by other 3rd party developers. CAD and PLM software vendors promote their complete line of downstream manufacturing PLM software tools based upon the ability to accurately rep-

28 applianceDESIGN June 2011

resent their own native 3-D CAD and MBD formats within same-brand applications. These systems do not typically offer best-of-breed technology. And, if they do, they typically do not work well with CAD and MBD formats from other vendors. This lack of interoperability typically forces the customer to maintain a plethora of different products for each CAD format. People that work in heterogeneous CAD environments readily agree that maintaining two proprietary CAD formats within a single project or operation is worse than dealing with a single proprietary CAD format. Most large companies use multiple CAD and PLM products, and suffer with sub-optimal design to manufacturing practices as a result.

A Perfect Storm Despite these hurdles, strategic planning by Adobe, long hours spent in standards committees, hard lobbying by customers to PLM vendors and other recent developments, have all converged to create a “perfect storm” that will finally allow manufacturers to create and share rich product manufacturing data without requiring end users to purchase expensive and proprietary CAD applications to support every format they receive. Among the benefits are:  Widely accepted, potable, secure data container and viewing platform (Adobe PDF platform);  Open standards for model-based definition (JT, STEP, PRC);  Well-disciplined standard modeling practices; and  Easy-to-use, cost-effective, best-ofbreed, off-the-shelf software provided by independent and aggressive 3rd party software vendors. Adobe’s PDF format has evolved and matured since its introduction in 1993 and gained the ability to embed true 3-D CAD geometry in version 8.1 with the introduction of the PRC format. The beauty of the PDF format is that it can encapsulate just about any type of media and structured data into an electronic document that can be opened on most PCs around the world using a free Adobe Reader. In fact, the PDF format is ideal for downstream manufacturing processes because a single PDF document can contain a combination of 3-D geometry, dimensions and tolerances, manufacturing notes, process steps, 2-D

pictures and animation—all the information required to completely and effectively capture the manufacturing, inspection or assembly processes. Equally important, Adobe has created a vibrant ecosystem around the PDF platform (a published ISO standard) to facilitate document distribution and collaboration.

Importance of Open Standards Since the early 80s, a plethora of CAD tools have been developed to meet product development and manufacturing requirements. However, as is often the case in large, distributed manufacturing and supply chains, organizations are often faced with difficult interoperability issues stemming from multiple CAD tools from multiple CAD vendors—with data locked away in multiple incompatible CAD formats. Several open and standards-driven data exchange formats and numerous CAD translation solutions have been painstakingly developed and refined over the years to capitalize on the move toward capturing the complete product definition and 3-D MBD initiatives. Because of recent breakthroughs in the standard definition of MBD based data sets, it is now possible to faithfully, and with unparalleled quality, to translate dimensions, tolerances and other manufacturing annotations into the STEP AP203-E2, JT and PRC open standard formats. In addition to the advent of 3-D CAD modeling software tools, it is impossible to overstate the importance of defining and implementing standard CAD modeling practices for modeling tools used within manufacturing organizations. Implementing standard practices for defining product views, placement of dimensions and tolerances and schemas (standard methods for defining related product MBD data), drives consistency up and down the supply chain, and enables manufacturing application development based upon fixed product definitions that were defined early in the design process. The Army Research Lab, in conjunction with several of its contractors, has made great strides in defining a standard modeling practices for the United States Army. The document encompasses best practices, schema definition, and ASME Y14.41 standards for digital product definition and data practices. These 3-D CAD modeling www.applianceDESIGN.com

SOFTWARE and MBD techniques are encompassed within a standard data schema that can be implemented by anyone designing products for the U.S. Army. By implementing standard practices and data schemas, it will be possible to create a total product definition that combines 3-D design and manufacturing information— in essence, all the information required to completely define how military equipment should be manufactured, repaired and maintained. Once embedded into rich 3-D PDF documents, the data will be accessible to any Army facility or supplier in the world, using Adobe Reader.

Cost-Effective COTS Software Through the use of commercial off the shelf (COTS) software provided by 3rd party software companies, engineers can deploy an effective, low-cost and efficient process for transforming heavy 3-D CAD and MBD data into lightweight, standard 3-D PDF manufacturing documents which can be used for such things as: 3-D Inspection Instructions

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 3-D Tooling Instructions  3-D Request for Quote Documents  3-D Digital Work Instructions  3-D Technical Data Packages Once documents are created, they can be easily deployed inside the enterprise, and outside the firewall to partners and suppliers for little or no cost using Adobe Reader. Adobe has constructed a compelling feature-set and ecosystem around the PDF platform, which allows just about anyone to share, comment, review and view PDF documents. Documents also can be encrypted, password protected and distributed through standard e-mail. Modern 3-D CAD applications can now create rich, 3-D total product definitions, and software applications can now expose this data to downstream operations, eliminating the need for redundant, ambiguous and expensive 2-D drawings. However, only recently has it been possible to cost-effectively share high-quality total product definitions across an extended enterprise—thanks to a widely deployed, viewing platform such as Adobe Reader; MBD oriented data-exchange stan-

dards like STEP AP203-E2; disciplined modeling techniques and standard MBD practices like those developed by the Army Research Lab; and easily deployable, offthe-shelf, 3rd party software applications that can automatically create fit-for-purpose, lightweight, 3-D PDF manufacturing documents. The Acrobat 9 SDK offers 3-D developers the ability to tightly integrate the 3-D models, contained in 3-D annotations, in a PDF with the surrounding 2-D document. JavaScript in the PDF as well as the plugin API can be used to control animation, visibility, color of meshes and a wide variety of other aspects of the 3-D model right from the main PDF document. In addition , if a developer already has a U3D or PRC file, the Acrobat SDK can be used to add a 3-D model to the PDF using custom tools rather than the Acrobat 3-D tool.  For more information, visit: www.anark.com

applianceDESIGN

June 2011 29

SMART GRID: FOCUS ON IP email WWW phone... SMTP HTTP RTP... TCP UDP...

IP

The Smart Grid is Coming… The Th T h Smart Grid is Coming

ethernet PPP... CSMA async sonet... copper fiber radio...

S

mart grid technology is here, so how can manufacturers be sure their appliances are ready to participate? There are many different parts of “smart grid,” which includes all aspects of the power grid: generation (power plants), transmission (power lines, substations) and distribution (electric meters, and in-home devices), with a focus on enabling cost savings by monitoring and managing power consumption. The area that most affects appliances is automated demand response (ADR) and, for this, the focus is on the home area network (HAN). The HAN is defined as the network of devices within the home including HVAC, thermostat, energy management systems, inhome power displays, electric water heaters, pool pumps, plug-in hybrid electric vehicles (PHEV) and other appliances. With smart grid, all of these devices will be interconnected to the electric meter and utilities via either wireless or wired networks. Some of the wireless technologies that are being developed into products today include Wi-Fi (or 802.11), ZigBee (or 802.15.4) and Z-Wave. For connecting devices via a wired interface, the predominant direction is to use power line carrier (PLC) – which means the network runs over the same wires that prowww.applianceDESIGN.com

IP is often called the “hour glass” of Internet design, meaning that it supports many types of applications and can run on many types of underlying media.

vide power to the appliance. Some of the technologies vying for HAN use in appliances include HomePlug, G.Hn and P1901.2. The one common theme through all of these various technologies is that they are either currently using or are moving to adopt the use of the Internet Protocol (IP).

Choosing IP can

The Internet

the need for protocol

The current Internet is running out of available/usable numeric Internet addresses—not domain names such as www.example.com, but rather numeric addresses into which domain names have to be translated. Recently, the repository for available addresses (IANA) handed out the last blocks of IP version 4 (IPv4) addresses to the Regional Internet Registries. This does not mean the Internet will stop working. This means that new devices, such as the 150 million electric meters in the United States or the millions of smart grid-ready appliances, will need to use the newer version of Internet Protocol, IP version 6 ( IPv6). IPv6 has a nearly limitless address space. In fact there are enough addresses available to assign 667 trillion addresses per square millimeter of the Earth’s surface. IPv6 also

provide a scalable solution for appliance connectivity without translation and an external gateway.

by geoff mulligan Geoff Mulligan is chairman of the IP for Smart Objects (IPSO) Alliance and is Vint Cerf, Google. applianceDESIGN

June 2011 31

SMART GRID: FOCUS ON IP Open Standard

Cost

Data Rate

IP Support

802.11 (WiFi)

Yes

Medium

1-52 Mbps

Yes

802.15.4 (Zigbee)

Yes

Low

250 Kbps

Yes

Zwave

No

Low

100Kbps

Soon

PLC

Likely

Variable

10Kbps – 10Mbps

Yes

Proprietary

No

Variable

Variable

Unknown

provides other needed improvements such as stricter security, simplified packet format and Stateless Address Auto-configuration. The latter allows an appliance to automatically connect to the network without specialized DHCP servers or manual configuration. The simplified header means that the packet can be compressed so that it can be efficiently transmitted wirelessly or over low-speed PLC.

Using IP IP—once thought only practical for servers and PC type devices—is finding its way into the smallest computing devices and providing huge benefits. By using IP as the communications protocol, product designers can be relieved from having to invent new protocols or build gateways to interconnect

32 applianceDESIGN June 2011

proprietary protocols. IP provides a scalable and well understood networking architecture that advances interoperability and flexibility. It is often called the “narrow waist” or “hour glass” of the Internet design meaning that it supports many types of applications and can run on many types of underlying media. A plethora of tools, code and auxiliary protocols are already available for IP; there is no need to re-invent the wheel. On the other hand, adopting ad-hoc or proprietary protocols may require new techniques, tools and software, potentially increasing the length, risk and cost of implementation as well as decreasing interoperability. For years, IP was dismissed as being too bulky to run on small, low-cost 8- and 16-bit microcontrollers and requiring too much overhead for low-speed, low-power net-

Some of the technologies vying for HAN use in appliances include HomePlug, G.Hn and P1901.2. The one common theme through all of these various technologies is that they are either currently using or are moving to adopt the use of the Internet Protocol (IP).

works. Today there are nearly a dozen independent implementations of embedded IP stacks that run on microcontrollers costing less than $2 with code sizes under 16K and RAM requirements under 4K. Some of these implementations are available under open source terms and others are commercial products. While many of these stacks are implemented on top of the IEEE 802.15.4 lowpower radio standard, one of the notable advantages to using an IP-based solution is that the design is no longer constrained to a single radio or single physical medium. Using IP allows the selection of the most appropriate media for the design: RF, PLC or both. IP provides the necessary interoperability without the need for gateways, which add cost, complexity and security vulnerabilities.

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SMART GRID: FOCUS ON IP IP Advantages A significant advantage of using an IP based protocol for sensors and embedded devices is the ability to create and maintain end-to-end security. If the sensor network is built using a proprietary or nonIP-based protocol, the protocol translation gateway that is required to interconnect the sensor network to the Internet will break the endto-end integrity and security of the data transport, introducing unnecessary vulnerability into the design. Some of the goals of the smart grid currently being discussed include: Improve grid power management Enable remote monitoring and management of in-home devices Enhance consumer energy awareness Enable energy information sharing

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34 applianceDESIGN June 2011

These goals have been or are being hampered partly because of the differences in the protocols and application programming interfaces used in different meters and the mechanisms used to communicate with and through the meter. Adopting the use of IP—a known, scalable and available protocol— can allow appliance manufacturers to focus. The inclusion of IP into appliances should not increase the cost and, in many cases, will actually reduce the cost of providing device connectivity to the smart grid. In many cases, code size is smaller, availability from multiple vendors is greater, and support tools and knowledge are better than other technologies. All of this reduces risk and increases the return on investment, in addition to increasing the likelihood of interoperability with other systems and appliances. Choosing IP may provide a scalable, future-proof solution for appliance connectivity without the need for protocol translation and external gateways. As the Internet expands to connect devices across the globe, and the need for better energy and environmental monitoring

increases, manufacturers can better serve customers by adopting IP all the way to the edge of the sensor network. IP is ready and available to meet the needs of new devices and networks.

IPv4 and 6 Internet Protocol version 6 (IPv6), to succeed IPv4, operates by transferring data in small packets that are independently routed across networks. Each data packet contains two numeric addresses that are the packet’s origin and destination devices. Since 1981, IPv4 has been the publicly used version of the Internet Protocol. IPv6 allows for vastly more numerical addresses, but switching from IPv4 to IPv6 is challenging. 6to4 is an Internet transition mechanism for migrating from IPv4 to IPv6, a system that allows IPv6 packets to be transmitted over an IPv4 network. The IPSO Alliance promotes IP for smart object communications. Smart objects are small computers with a sensor or actuator and a communication device, embedded in objects such as thermometers, car engines, light switches, appliances, and machinery for applications such as home automation, building automation, smart cities, structural health management systems, smart grid and energy management. At ipso-alliance.org

Three-tier IP Gateways There is architecture for internetworking between home automation networks and a TCP/IP based wide area network, such as the Internet. The architecture abstracts the functionality of any home network into a driver layer (tier one), and provides a common access layer (tier two) from any TCP/IP network application (tier three) to a local home automation network. Clients and application programs may transparently access services and resources on the home network and appliances connected to the home network may access resources and services on the TCP/ IP network.  For more information, visit: www.ipso-alliance.org www.applianceDESIGN.com

STAY CONNECTED with appliance DESIGN, wherever you are! Now it’s easier than ever to stay connected to the BEST source of the latest news and information. Find us on Twitter, LinkedIn and Facebook. FOLLOW APPLIANCE DESIGN ON TWITTER http://twitter.com/aplncDSGN Find us on Twitter @aplncDSGN. Get great article headlines, communicate with our staff and share your opinion with us. JOIN THE APPLIANCE DESIGN LINKEDIN GROUP http://www.appliancedesign.com/connect Join design and engineering teams in the global, commercial, and medical appliance/durable goods industry at appliance Design’s LinkedIn Group. Read and participate in industry news, trends, educational opportunities, jobs and discussions.

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SMART GRID: FOCUS ON IP

Why Should OEMs Care About Smart Grid? It is a matter of load shifting and load shedding for appliances.

S

mart Grid is not a concept built by electricians for electricians. The challenge behind smart grid is to master energy from production to consumption and its transport in the electric grid. It is in this consumption area where appliance manufacturers have an important and unique role to play. But first, let’s review the different components of the smart grid:

1. Energy Production

by patrick wetterwald Patrick Wetterwald is the founder of the IP for Smart Objects (IPSO) Alliance and past president. 36 applianceDESIGN June 2011

The sources of energy are now not only the big power plants (nuclear, gas or hydraulic), but anyone. Energy can be produced with solar panels, micro combined heat and power (CHP) or windmills, and can be used or injected back into the electric grid. Renewable energy will become more important in the near future. For example, Germany wants to be 100% based on renewable sources of energy by 2050. The injection of this energy at the extreme low end of the distribution grid is introducing a level of instability never

seen in this domain. In order to properly manage such instability, energy needs to be measure and closely controlled. Numerous connected sensors and actuators will need to be deployed via an IP communication network to deal with this challenge.

2. Energy Transportation and Distribution Energy transportation and distribution are basically the grid, which transports the electricity over high, medium and low voltage lines. Some countries are more advanced in the management of the transport and distribution of electricity than others. Already, different levels of mechanism have been implemented to recover from faults and to automatically reconfigure the distribution grid. Distribution companies have defined a grid topology that permits isolating and restoring electricity transmission, even in case of permanent failures of some lines. Also in this domain, extensive use of new IP sensors www.applianceDESIGN.com

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SMART GRID: FOCUS ON IP and actuators enables (or enhances) this automation.

3. Energy Consumption One of the main challenges, currently, is the few times where this consumption reaches its peak. In order to absorb these peaks of demand, utilities have to build specific power plants, which are used only for these instances. This is very costly and usually these power plants are not optimized for CO2 emission, but more for their ability to start producing electricity very quickly. The smart grid is bringing together two concepts: the ability to adapt the production to the demand, and the ability to shift (load shifting) or shed (load shedding) the demand in energy. The deployment of smart meters by the utilities is a first step toward the automatic measurement of energy consumption, but the granularity is not small enough for efficient demand response applications.

Current Appliances Appliances need to be designed so that

load shifting and load shedding can be accomplished. In the absence of communicating appliances, the only way to enable these two functions is via the use of electric smart plugs, which allow switching on or off of a device. Some smart plugs also can measure the electric power consumed. Not all appliances can be managed this way, however, and that is the real problem. Modern appliances must include local energy efficiency intelligence. When optimizing energy efficiency of a product, the device itself is able to reduce and adapt the consumption without negatively impacting the functionality. For example, with a swimming pool pump, a consumer could easily reduce the number of hours per day or shift the time that a pump is working without degrading the quality of water. Additionally, the pump could decrease the speed pump engine to reduce consumption. With home heating, the optimum way to reduce energy consumption is to reduce the temperature of the house by 1 or 2 degrees during peak hours. With washing machines, motor speed, water temperature and cycle duration all can be modified to optimize energy consumption. Modern appliances need to be connected

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www.towermfg.com 38 applianceDESIGN June 2011

with two-way communication path mechanisms in order to: get energy information from producers/retailers about tariff and peak hours; send out energy consumption forecasting for the next cycle, next coming hours or days; and to send out load shedding/ shifting capacity.

Where is the Communication Path? Currently, there is no standard or there are too many standards developed by commercial companies attempting to preserve their small and fragmented market shares—making many appliances unable to support new services and tariff changes that utilities are planning. The solution is not too complicated. A layered, future proof architecture is needed and Internet Protocol (IP) can bring OEMs this architecture. What else do you really need? A network reachability or an addressing scheme. IPv6 offers sufficient address space, routing and auto configuration mechanism. An identification mechanism separated from the addressing scheme. This is an area where progress is still required. Should one use an RFID-based solution, the MAC address (there are some issues on the uniqueness), or the well-known “serial number” per industry segment? A tested security and privacy framework. With more than 30 years of Internet hardware and software security solutions, end to end IP security has been developed and extensively tested. An OEM just needs to ensure that the right mechanism suitable for the application is being implemented. This IP-layered architecture also brings the capability to choose the best physical link for deployment. Power line communication (PLC), low-power radio (such as 802.15.4) or Wi-Fi radio are logical choices to connect home appliances. The key to the success of energy efficient appliances and applications is the use of open standards, and IPv6 architecture is one way forward.  For more information, visit: www.ipso-alliance.org www.applianceDESIGN.com

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40 applianceDESIGN

erhaps it is trying to get all the rulemakings out of the way before its budget gets cut or maybe it’s just that things got a little out of hand and it’s catch-up time. Either way, the Department of Energy (DOE) is picking and choosing from a veritable smorgasbord of efficiency-related rulemakings in early 2011. At the time this article was published, rulemakings were underway for walkin refrigerators and freezers; commercial refrigeration equipment; commercial icemakers; residential central air conditioners, heat pumps and furnaces; furnace fans; and standby power (direct heating, residential A/C, and residential furnaces). These rulemakings are in various stages of development and are intended to establish federal test procedures and minimum energy efficiency standards. In the case of central air conditioners, heat pumps and furnaces, we expect DOE to publish in the Federal Register a direct final rule before this article is actually published, proposing to adopt the consensus agreement reached between AHRI and several advocacy groups establishing regional energy efficiency standards for those products. Such a move would be a sharp departure from common practice, but if it occurs, a direct final rule (as opposed to the much more common Notice of Proposed Rulemaking) takes care of the court-ordered deadline for completion of this rule. In point of fact, however, one negative comment on the direct final rule will start the whole process over again—presumably not something the DOE wants, but certainly something that gets the Department of Energy out from under a tight deadline. At the same time, DOE has significantly strengthened its certification, compliance and enforcement requirements for federally covered equipment. In March 2011, DOE published a final rule expanding those requirements to all covered residential and commercial products. Under the rule, manufacturers of commercial air conditioning, heating, water heating and commercial refrigeration equipment currently regulated by DOE will be required to certify that their products meet the minimum federal standards through submission of a certification report. AHRI has been working with DOE officials on several problematic aspects of this rule since its publica-

P

tion in the Federal Register, including the definition of “basic model” and “basic model group,” the short time frame given for compliance, and the Alternative Energy Determination Method (AEDM) contained in the rule. AHRI estimates that if not adequately addressed, these issues would dramatically increase the number of tests required for compliance and would result in approximately $2 billion in initial additional costs for AHRI member companies. After meeting with DOE officials on several occasions, AHRI is pleased with the progress made in two of these areas: Compliance Deadline Extension and AEDM/ARM Alteration. On April 15 of this year, DOE issued a Notice of Proposed Rulemaking (NOPR) seeking comment on a proposed 18-month extension of the compliance deadline originally scheduled for July 5. AHRI is supportive of such an extension, and will provide comments to that effect as soon as the NOPR is published in the Federal Register. Shortly thereafter, DOE published in the Federal Register a notice requesting information regarding the current procedures being used to calculate or estimate efficiency ratings for DOE-covered products and to better understand how DOE’s current AEDM and Alternative Rating Method (ARM) procedures are being applied. AHRI is working on providing industry comments to the DOE on this subject. Following review of the comments received, the Department plans to issue a NOPR that will examine how, and if, the AEDM option final rule should be altered. AHRI will continue to work with DOE on changing the definition of “basic model” contained in the rule, as the Department’s definition is different from current definitions under which the HVACR and water heating industry operates and will make compliance difficult. AHRI appreciates the Department’s willingness to work with the organization and we are hopeful agreement can be reached that will enable member companies to comply with these DOE regulations in a timely and economical manner. It is issues such as these that make membership in a trade association particularly beneficial, and we are happy to be in a position to be of service to members and the HVACR and water heating industry as a whole. 

June 2011

www.applianceDESIGN.com

By Francis Dietz Vice President, Public Affairs, Air-Conditioning, Heating, and Refrigeration Institute

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03 05 08 88

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Household Cooking Equipment Household Laundry Equipment Other Consumer Appliances Other Appliance-Related Manufacturer (must indicate product manufactured) __________________________________________ Non-Manufacturing 18 ❑ Product Development and Industrial Design Firm 89 ❑ All Others Not Classified Above (specify) __________________________________________

PLEASE SELECT THE FOLLOWING TYPES OF PRODUCTS THAT YOU RECOMMEND, SPECIFY, APPROVE AND/OR PURCHASE: (SELECT ALL THAT APPLY) 33 45 47 34 28 29 39

❑ ❑ ❑ ❑ ❑ ❑ ❑

46 ❑ 31 ❑ 44 ❑ 30 ❑

8.

API. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 www.apiamerica.com Ark-Plas Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 www.ark-plas.com ASCO Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 www.ascovalve.com/smile Capable Controls Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 www.capablecontrols.com Classic Stripes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 www.classicstripes.com Connolly Bove Lodge & Hutz LLP . . . . . . . . . . . . . . . . . . 25 www.cblh.com Corning Gorilla Glass . . . . . . . . . . . . . . . . . . . . . . . . . . OBC www.corninggorillaglass.com Dow Wire & Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 www.dow.com/ecolibrium Foam Supplies Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 www.ecomatesystems.com InterTek. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 www.intertek.com KB Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 www.kbelectronics.com LLoctite, A Henkel Co. . . . . . . . . . . . . . Cover, 9, 11, 13 www.henkelna.com/loctitestructurals Materion Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC www.materion.com Microchip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 www.microchip.com/mtouch Proto Labs Inc. Protomold. . . . . . . . . . . . . . . . . . . . . . . . . 3 www.protomold.com QuickParts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 www.quickparts.com Tower Manufacturing Corp. . . . . . . . . . . . . . . . . . . . . . . . 38 www.towermfg.com LView our premium Buyers Guide listing online at

www.appliancedesign.com/buyersguide This index is for the convenience of our readers. Every care is taken to make it accurate. appliance DESIGN assumes no responsibility for errors or omissions.

sales team

WHAT IS THE PRIMARY BUSINESS ACTIVITY AT YOUR LOCATION? (SELECT ONE ONLY) Manufacturers of Consumer, Commercial and Business Appliances (including Corporate Headquarters, R&D/Testing Labs, Design/Engineering Facilities)

7.

page number

Motors, Fans, Blowers, Pumps, Motor Controllers Heating Elements/Igniters Connectors, Cords, Wire, Cable, Terminating Machines Controls, Sensors, Thermostats Switches, Relays, Thermal Cutoffs, Circuit Breakers, Fuses Displays, Indicators, Lamps, LEDs Microcontrollers, Integrated Circuits & Other Electronic Components Solenoids, Valves, Actuators Metal Parts (Stampings, Castings, Powder Metal Parts, Springs, Hinges) Plastic Molding/Forming Services Metals (Steel, Aluminum, Copper, Precoated/Prefinished Metals)

43 37 36 35

❑ ❑ ❑ ❑

38 ❑ 32 ❑

42 ❑ 48 ❑ 49 ❑

Plastics, Elastomers Seals, Gaskets & Gasketing Equipment Coatings, Paints, Finishing & Finishing Equipment Decorative Products (Trim, Nameplates, Glass Labels, Graphic Overlays) Software Assembly Equipment & Tools, Welders, Clinching Machines, Brazing Machines, Fasteners, Dispensing Equipment, Adhesives & Tapes Test & Measurement Equipment, Testing & Certification Labs/Services Other (specify) ______________________________ None of the Above

Please select the publication(s) that you personally receive: (select ALL that apply) 2 ❑ Assembly 3 ❑ Machine Design

8 ❑ Design News 11 ❑ Product Design & Development (PD&D)

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Dawn LeRoux [email protected] Phone: (248) 633-4818 Fax: (248) 283-6558 AK, AZ, HI, IA, IL, KS, MI, MN, MO, NE, ND, NM, NV, OK, SD, TX, UT, WI. Western Canada Brad Glazer [email protected] Phone: (216) 233-6943 Fax: (216) 803-6151 AL, AR, CT, DC, DE, FL, GA, IN, KY, LA, MA, MD, ME, MS, NC, NH, NJ, NY, OH, PA, RI, SC, TN, VA, VT, WV. Eastern Canada Jennifer Nagel [email protected] CA, CO, ID, MT, OR, WA, WY. Design Marts, Reprints & Buyers Guide Phone: (248) 244-1729 Fax: (248) 244-2040 international Dawn LeRoux [email protected] Europe & U.K. Phone: 1-248-633-4818 Arlen LUO [email protected] China & Hong Kong, Japan, Korea, Taiwan Phone: 0086-10-88579899 Fax: 0086-10-82160061 applianceDESIGN

June 2011 41

Tough, yet inspiring.

Corning is cooking up new possibilities for tomorrow’s kitchens with Gorilla® Glass. Elegant, lightweight, and incredibly damage resistant, Corning Gorilla Glass enables sleek, seamless designs. And touch-screen compatibility means surfaces can be as smart as they are beautiful. Corning Gorilla Glass already enhances the beauty and durability of today’s coolest electronic devices— and we haven’t even scratched the surface of its potential. Start innovating at CorningGorillaGlass.com

©2011 Corning Incorporated. All rights reserved.