Appliance Design November 2011

November 2011 REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE , N A IT C ? N E SO WH IN...

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November 2011

REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

, N A IT C ? N E SO WH INSIDE 12 Metals 18 Quality & Standards 22 Gas Technology 26 Displays & Interfaces

See us after page 16. www.applianceDESIGN.com

Spend less time searching for information and more time using it www.applianceDESIGN.com/buyersguide

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CONTENTS NOVEMBER 2011 volume 59, no. 11 REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

DEPARTMENTS 4 Editorial: If It Plugs In, It Goes In 6 Shipments/Forecasts 8 News Watch 29 New Products

12

18

26

31 Advertiser’s Index 32 Association Report: AHAM

FEATURES METALS 12 Introducing three methods for testing the suitability of monolithic refractories for use in melt-hold furnaces. Before you work with aluminum, learn how the pros work with aluminum, specifically how they decide which furnace linings to use.

QUALITY & STANDARDS

appliance DESIGN ONLINE

GAS TECHNOLOGY

WEB EXTRAS WEB EXTRAS

18 The EPA’s ENERGY STAR program is intent on making Smart Grid a standard part of its ENERGY STAR standards, and suggests how appliance manufacturers can use this to capitalize on smart grid-enabled products.

Smart Grid Survey Sponsored by DNA, our October survey wants your thoughts on the future of smart energy appliances. Take it at http://svy.mk/pb1MDx

Electronic Refrigerator Controller Saves Energy and Reduces Costs Until recently, manufacturers of GDMs, and commercial refrigerators and freezers had two options when selecting a controller: a mechanical thermostat that offered no intelligence or an electronic controller with limited capabilities. Fueling Product Innovation Using life-cycle thinking can help facilitate innovations, rather than limit them.

BLOGS Paul’s European Perspective After three days of IFA, Berlin’s massive consumer electronics and white goods fair, AD’s European correspondent Paul Roggema is ready to (get off his feet and…) declare Samsung the clear victor.

22 With thermal efficiencies in the mid-90s, condensing tankless water heaters use a secondary heat exchanger to lower combustion-gas temperatures in the flue, allowing the use of PVC piping, instead of stainless steel, to build vent runs.

DISPLAYS & INTERFACES 26 Whatever happened to high def displays that flex, screens that talk, and kitchens controlled by mobile phones? AD’s editor goes back to the future to catch up with three display technologies from the early aughts that were supposed to change the way we interface with appliances.

AD TV Corning Gorilla Glass Visually stunning, lightweight, and highly damage-resistant, this gorilla is out to protect the world’s coolest smartphones, tablets, PCs and TVs from everyday wear.

www.applianceDESIGN.com 2 applianceDESIGN November 2011

COVER Technologies like this flexible LCD screen from AD’s January 2003 article “Displays & Indicators: Flex Time” were supposed to have taken over the market by now. Why they haven’t reveals more about the appliance industry than the techs. www.applianceDESIGN.com

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EDITORIAL ®

www.applianceDESIGN.com

If It Plugs In, It Goes In

R

eaders of our monthly e-newsletter might have noticed already that the look of the thing has changed since the summer. They’ll notice even more this month when, about the time you’re reading this issue, appliance DESIGN’s e-newsletter changes its name from the tautological “appliance DESIGN’s e-newsletter” to the snappier “Plugged In.” We also considered changing the name of the magazine, but when AD polled the readers on that you answered back with a resounding “No!” Why all the toponymy? We’re afraid

people will see the word “appliance” and think all you do is white goods. Granted that’s an important part of our industry, but the original equipment engineers that read our magazine are from a niche that includes both consumer and commercial products. Whether it’s a coffee pot or an air conditioner, our readers are involved with products being designed that plug in and are not limited to those appliances in your kitchen or laundry room. We cover almost anything short of military, aerospace, utilities, automotive and agricultural equipment, just so long as it has a motor or other power source like a battery or electrical plug. Before September 2004, the magazine’s name was Appliance Manufacturer. That name stood for 55 years, and changed with the complexity of the equipment. “Design” is the key. Whether you’re creating a device for medical, HVAC, majors, water processing, housewares/white goods, commercial appliances, vending, lab, testing, measurement, lawn & garden, electronics, computers, communications or business equipment, knowing the available technologies, the going expectations of your consumers, and the needs of your niches are the paramount considerations from vision to manufacture of your end product. That’s design. So now it’s official: the name stays like before, and everyone will just have to remember ‘if it plugs in, it goes in.’

publishing staff Darrell Dal Pozzo Group Publisher

(847) 405-4044 [email protected]

Seth Fisher Editor-in-Chief

(248) 244-6248 [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) [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]

Chelsie Taylor Events Marketing Assistant

(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

Seth M. Fisher, Editor-in-Chief E-mail: [email protected] Twitter: @aplncdsgn

President, Group42

Joseph McGuire

President, Association of Home Appliance Manufacturers (AHAM)

Richard Watson

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]

4 applianceDESIGN November 2011

BNP Media Helps People Succeed in Business with Superior Information BNP Media 2401 West Big Beaver Rd., Suite 700, Troy, MI 48084, (248) 362-3700, Fax: (248) 362-0317; www.bnpmedia.com For subscription information or service, please contact Customer Service at: CALL s&AX OREMAIL[email protected]

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78

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SHIPMENTS Product

FORECASTS August-11

August-10

%Chg 5 Mo. 2011 5 Mo. 2010

%Chg

MAJOR APPLIANCES (Thousands of Units) Total

4,358.10

4,382.90

-0.60%

42,189.00

42,418.30

-0.50%

COOKING-TOTAL ELECTRIC COOKING - TOTAL Electric Ranges Electric Ovens Surface Cooking Units GAS COOKING - TOTAL Gas Ranges Gas Ovens Surface Cooking Units MICROWAVE OVENS

1,266.40 312.2 249.1 40.1 23 195.8 172.4 2.6 20.8 758.5

1,246.40 340.1 272.8 43.2 24.1 206.8 179.8 2.9 24.1 699.5

1.60% -8.20% -8.70% -7.20% -4.70% -5.30% -4.10% -10.00% -13.90% 8.40%

10,538.20 2,718.80 2,146.00 357.8 215 1,616.60 1,403.50 23.9 189.2 6,202.80

10,638.60 2,869.20 2,258.20 386 225 1,753.70 1,516.70 26.4 210.6 6,015.70

-0.90% -5.20% -5.00% -7.30% -4.40% -7.80% -7.50% -9.30% -10.20% 3.10%

HOME LAUNDRY - TOTAL AUTOMATIC WASHERS DRYERS - TOTAL Electric Gas

966.2 533.2 433 339.4 93.6

1,050.90 593.2 457.7 358.5 99.1

-8.10% -10.10% -5.40% -5.30% -5.60%

8,789.10 4,879.90 3,909.20 3,138.50 770.7

9,369.10 5,163.50 4,205.60 3,381.20 824.4

-6.20% -5.50% -7.00% -7.20% -6.50%

KITCHEN CLEAN UP - TOTAL DISPOSERS DISHWASHERS - TOTAL Built-In Portable COMPACTORS

889.8 450.7 435.7 431 4.7 3.4

872.2 449.4 419.6 415.6 4 3.2

2.00% 0.30% 3.80% 3.70% 18.30% 6.30%

7,167.50 3,555.40 3,585.70 3,542.60 43.1 26.3

7,261.90 3,523.10 3,710.60 3,667.40 43.1 28.3

-1.30% 0.90% -3.40% -3.40% -0.10% -7.00%

FOOD PRESERVATION - TOTAL REFRIGERATORS 6.5 & OVER FREEZERS - TOTAL Chest Upright

957.9 805.1 152.8 75.6 77.2

998.6 827.1 171.5 101.8 69.7

-4.10% -2.70% -10.90% -25.70% 10.70%

7,250.50 5,993.80 1,256.70 729.4 527.3

7,688.80 6,399.30 1,289.50 767 522.5

-5.70% -6.30% -2.50% -4.90% 0.90%

HOME COMFORT - TOTAL ROOM AIR CONDITIONERS DEHUMIDIFIERS

277.8 196.7 81.1

214.8 129.7 85.1

29.30% 51.60% -4.70%

8,443.70 7,339.70 1,104.00

7,460.00 6,062.30 1,397.70

13.20% 21.10% -21.00%

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.

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2),SLJ[YVUPJZ0UJ

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

2010 2040.7 2023.4 1902.5 2038.6

2011 2024.0 1861.7 1896.8 2046.8

2012 2042.2 1923.1 1955.6 2147.0

For 2011, a 2.2% decline to 7.829 million units For 2012, a 3.0% increase to 8.068 million units Data Source: AHAM Forecast Source: Delano Data Insights

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

2010 1702.0 1659.5 1468.5 1720.8

2011 1609.7 1519.9 1403.9 1695.0

2012 1614.5 1564.0 1453.0 1759.4

For 2011, a 4.9% decline to 6.228 million units For 2012, a 2.6% increase to 6.391 million units Data Source: AHAM Forecast Source: Delano Data Insights

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

2010 434.2 516.0 526.9 480.4

2011 437.5 509.3 528.5 491.0

2012 448.0 524.6 547.5 514.0

For 2011, a 0.4% increase to 1.966 million units For 2012, a 3.5% increase to 2.034 million units Data Source: AHAM Forecast Source: Delano Data Insights

GAS RANGES and OVENS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 656.2 694.4 673.1 766.1

2011 659.1 602.9 633.4 746.9

2012 669.0 631.2 658.7 773.8

For 2011, a 5.3% decline to 2.642 million units For 2012, a 3.4% increase to 2.733 million units Data Source: AHAM Forecast Source: Delano Data Insights

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

2010 506.9 552.6 646.6 747.2

2011 506.0 475.7 615.6 733.7

2012 516.6 488.5 642.7 761.6

For 2011, a 5.0% decline to 2.331 million units For 2012, a 3.4% increase to 2.409 million units Data Source: AHRI Forecast Source: Delano Data Insights

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

2010 551.2 668.4 250.6 82.0

2011 349.8 553.3 279.9 97.4

2012 371.1 593.1 289.2 102.0

For 2011, a 17.5% decline to 1.280 million units For 2012, a 5.9% increase to 1.355 million units Data Source: AHAM Forecast Source: Delano Data Insights Note: All forecasts begin in Q3/2011

6 applianceDESIGN November 2011

www.applianceDESIGN.com

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NEWS WATCH

Group Forms to Promote PLC as Smart Grid Standard welve major players in the smart grid industry in October announced they will form a new global partnership to promote the new power line communications protocol G3-PLC as the standard for smart grid. Singees include Cisco, Enexis, ERDF, Maxim Integrated Products, STMicroelectronics, Texas Instruments, Itron, Landis & Gyr, Nexans, Sagemcom, EDF R&D and Trialog. Power Line Communications (PLC) technology transmits digital information through electrical power lines using OFDM (orthogonal frequency division multiplexing). It would create a smart grid architecture that can work through the power grid itself, as opposed to getting on the Internet. PLC has been adopted as the basis for several major standards such as IEEE, ITU and IEC/CENELEC, which offer interoperability with the current G3-PLC specification available. G3-PLC products are currently available from major semiconductor and equipment manufacturers and it is being field tested by several major utilities and organizations worldwide, including ERDF in France. The alliance hopes to make G3-PLC as much a standard as Bluetooth or WiFi. The alliance’s listed goals are: Promote G3-PLC in Internationally recognized standards organizations (IEEE, ITU, IEC, ISO, etc.) Promote G3-PLC technical features, performance, and overall value Organize certification tests and programs

T

NEW ENVIRONMENTAL STANDARDS FROM ASHRAE

ASHRAE’s new white paper, available free from the association’s site, is meant to serve as the first vendor neutral 8 applianceDESIGN November 2011

Organize and operate the industry users group to maintain the G3-PLC specification and to insure\ interoperability Support utilities in the deployment of the new G3-PLC communications protocol in their respective countries Promote G3-PLC in other applications such as home/building energy management; home automation; vehicle-to-grid and vehicle-to-charging station communications; lighting control and management; factory automation, and optimization of smart grid performance The G3-PLC is designed to operate in 10-490 kHz frequency bands and it is compliant with CENELEC, FCC and ARIB regulatory bodies. The alliance was formed to support G3PLC’s rapid adoption by utilities worldwide in various smart grid applications such as automatic meter management, EV charging, home energy management, lighting control and grid monitoring. Meanwhile the IPSO Alliance (www.ipso-alliance.org) held its fall meeting in Santa Clara, Calif., last month to discuss their advocacy for a complimentary technology, internet protocol (IP), or as they titled the October press reception, “enabling the Internet of things.” Their solution would be to connect devices such as 150 million electric meters through IPv6, which is where the Internet is heading once all of the current IPv4 addresses are used up. In May, appliance DESIGN published IPSO’s white paper “The Smart Grid is Coming” that dug into how that will work.

thermal guideline for liquid cooled data processing environments. Download it from their TC9.9 website at www.tc99. ashraetcs.org. The white paper, 2011 Thermal Guidelines for Liquid Cooled Data Processing Environments, creates data center classes for liquid cooling that can enable fulltime economizers for a number of applications in many climates, according to according to Don Beaty, chair of the subcommittee who created the paper. The increasing heat density of modern electronics is stretching the ability of air to adequately cool the electronic components within servers as well as the data

center facilities that house these servers. To meet this challenge, the use of direct water or refrigerant cooling at the rack or board level is now being deployed. This trend of increasing heat densities combined with the interest in energy and waste heat recovery created the need for liquid cooling guidelines to help bridge the gap between IT equipment design and data center facility design, according to Beaty. Five liquid cooling classes have been created: W1 – Facility Water Supply Temperature of 2ºC to 17ºC W2 – Facility Water Supply Temperature of 2ºC to 27ºC www.applianceDESIGN.com

NEWS WATCH W3 – Facility Water Supply Temperature of 2ºC to 32ºC W4 – Facility Water Supply Temperature of 2ºC to 45ºC W5 – Facility Water Supply Temperature of > 45ºC The white paper includes insight into other considerations for liquid cooling including condensation, operation, water flow rates, pressure, velocity and quality as well as information on interface connections and infrastructure heat rejection devices.

SUMMER FINISHES STRONG FOR MANUFACTURING

Technology orders continued their ascent back to pre-recession levels, totaling

$460.61 million in August according to data provided by the Association for Manufacturing Technology (AMT) and the American Machine Tool Distributors’ Association. While not as high as the July bump, the August numbers were up 88.5% from this month last year. At over $3.4 billion yearto-date, 2011 in manufacturing is up 101 percent over 2010. “Despite news reports that wider economic growth may be stagnating, the manufacturing technology industry is sustaining its momentum,” said Douglas Woods, AMT President. “With orders still up substantially over last year, there is clearly optimism within the industry as firms are seeing future growth opportunities that merit new capital investment.”

AMT/AMTDA press release

MEETINGS November 2011 AHRI ANNUAL MEETING Nov 13-15 / Bonita Springs, Fla. Website: www.ahrinet.org

December BIOMEDEVICE, AN MD&M EVENT Dec 6-7 / San Jose, Calif. Hosted by UBM Canon Website: www.biomedeviceshow.com MD&M ONLINE Dec 13-14 / Online Event Hosted by UBM Canon Website: www.mdmonlineevent.com

January AHR EXPO Jan 23-25 Website: www.ahrexpo.com

February PACIFIC DESIGN & MANUFACTURING, & MD&M WEST Feb 14-16, 2012 / Anaheim, Calif.

Northeast: $64.32 M 9.5% vs. July 64.4% vs. Aug. 2010 64.0% YTD

Central: $140.07 M 30.5% vs. July 115.5% vs. Aug. 2010 105.6% YTD

INTERNATIONAL HARDWARE FAIR Mar 4-7, 2012 / Cologne, Germany Website: www.eisenwarenmesse.com

Southern: $58.18 M 23.0% vs. July 90.1% vs. Aug. 2010 81.1% YTD

Western: $53.35 M 50.2% vs. July 90.1% vs. Aug. 2010 100.6% YTD

DESIGN & MANUFACTURING TEXAS / MD&M TEXAS / QUALITY EXPO SOUTH Mar 14-15, 2012 / Fort Worth, Texas Hosted by UBM Canon Website: www.dm-texas.com

Midwest: $144.68 M 9.3% vs. July 77.4% vs. Aug. 2010 128.9% YTD

Hosted by UBM Canon Website: www.pacdesignshow.com

March

MOSTRA CONVEGNO (THE EXTENSION CONVENTION) Mar 27-30, 2012 / Milan, Italy Website: www.mcexpocomfort.it

April ECOAT 2012 April 11-12, 2012 / Orlando, Fla. Hosted by Electrocat Association Website: www.electrocoat.org/conference

SPE THERMOSET CONFERENCE & EXPO Jan 24-25, 2012/ San Antonio, Texas Join the Society of Plastics Engineers (SPE) in the heart of the San Antonio Riverwalk for their annual, not-for-proﬁt event dedicated to the most innovative thermoset manufacturing techniques, application design, industry news and developments and raw materials. Space is limited to 200 attendees maximum. Over 40 exhibitors. The group offers a special hotel rate for members at the Westin Hotel $178.00 per night. Registration fee: $550 SPE Member, $650 Non-Member Website: www.spetopcon.com E-mail: [email protected] Phone: (630) 247-6733

www.applianceDESIGN.com

The data are based on the totals of actual data reported by companies participating in the USMTO program. The United States Manufacturing Technology Orders (USMTO) report, jointly compiled by the two trade associations representing the production and distribution of manufacturing technology, provides regional and national U.S. orders data of domestic and imported machine tools and related equipment. The regions broke down as follows:

Other economic indicators back up the tale of recovery. The International Council of Shopping Centers (ICSC) forecasts 2011 holiday sales in the Electronics and Appliance store sector in the United States will be up 4 percent over last year, reaching an estimated $23.6 billion. This would be the second year in a row of sector growth after two in the negative, though 2011 is not expected to reach 2010’s 5 percent gain.

AHRI: WE AGREE, DOE, SO LET IT BE

AHRI has sent a letter to the Department of Energy confirming the association’s support for a consensus agreement on DOE’s efficiency standards for residential central air conditioners, heat pumps and furnaces. AHRI president and CEO Stephen Yurek sent a letter to Secretary Steven Chu affirming AHRI support for the agreement reached with efficiency adapplianceDESIGN November 2011 9

NEWS WATCH vocates but asking DOE to hurry up and get final rule finalized so industry would have enough time to comply. The comment period for the rule ended Oct. 17, 2011. The letter urged DOE to adopt its final rule as soon as the comment period ends. Several energy efficiency advocacy groups, DOE and AHRI put forth in 2009 a joint recommendation which has since been making its way through the bureaucratic process. DOE announced in July its direct final rule concerning these devices but that rule must go through a comment period. When that rule was announced in June, AHRI vice president for public affairs Francis Dietz said the association agreed with the ruling except for reservations about stand-by power limits. Despite those reservations, AHRI apparently believes the best thing for its constituents now is to be done with the rule process and start letting manufacturers work toward compliance.

COMPANY NEWS SUNSHOT INITIATIVE UNDERWAY THANKS TO GRANTS

J. P. Sercel Associates (JPSA), Manchester, N.H., MIT and the SunShot Initiative FPACE awardee University of Delaware, have begun a massive research project to lower the cost of crystalline silicon solar cells. The project hopes to make high-yield solar cells a viable energy source under the Department of Energy’s SunShot Initiative program, with a goal of lowering the cost of crystalline silicon solar cells to $0.50/Wp module cost. The University of Delaware received a record $9.1 million from five separate awards under the initiative. The team will use a new device design patented by UD that incorporates silicon structures deposited at low temperature. This project will utilize JPSA’s expertise in UV-VIS-NIR nanosecond and picosecond lasers to pattern and form the contacts on the back of the solar cell, and MIT’s unique characterization and passivation tools for understanding and mitigating defects in silicon. Four U.S companies will provide thin silicon wafers for evaluation of the new solar cell design architecture.

A.O. SMITH INTRODUCES NEW COO

Photo supplied by GE GE’S APPLIANCE PARK JOINS LEED ELITE

A new data center at GE’s Appliance Park headquarters in Louisville, Ky., has reached the pinnacle of green building, earning a LEED Platinum award for energy efficiency and environmentally conscious design. The appliances and lightning division’s building is a retrofit of an unused manufacturing facility. Platinum is the highest-level award of the US Green Building Council’s rating system for environmentally friendly building called LEED, or Leadership in Energy and Environmental Design. Energy efficiency was the key. GE’s Industrial Solutions subsidiary provided its Entellysis lowvoltage switchgear and power-quality systems for the data center. The UPS system from GE’s Digital Energy business and its eBoost technology help cut down on the amount of power the servers eat up.

10 applianceDESIGN November 2011

A. O. Smith, Milwaukee, announced that Ajita G. Rajendra has been named president and chief operating officer, effective Sept 1. Rajendra will be responsible for the company’s water heater operations in North America, China, Europe, and India as well as the company’s water purification business in China. The $1.5 billion business has 17 manufacturing plants around the world and employs approximately 10,000 people. Rajendra also will be responsible for the Lochinvar global boiler business, once the acquisition of that company is complete. Rajendra joined A. O. Smith as president of its Water Products Company in January 2005. He was named an executive vice president of the corporation in 2006. He was previously senior vice president of Kennametal Inc., of Latrobe, Pa., a manufacturer of industrial cutting tools.

MOUSER SECURES HONEYWELL DISTRIBUTION

Mouser Electronics Inc., a design engineering firm and global distributor for semiconductors and electronic components, announced it has signed a new global contract with Honeywell Sensing and Control. The global agreement builds upon the two companies’ current distribution partnership, which has been in place since 2007. “Mouser is an important partner for us as they have years of experience in the distribution of electronic components in support of new design,” said Sean Conley, Honeywell Sensing and Control Director of Global Distribution Sales. “They actively increased Honeywell’s presence throughout the Americas in their catalog and on their website.” Mouser Electronics, a subsidiary of TTI Inc., is part of Warren Buffett’s Berkshire Hathaway family of companies. The company ships globally to over 300,000 customers in 170 countries from its 492,000 sq. ft. facility south of Dallas. Visit www.mouser.com

www.applianceDESIGN.com

NEWS WATCH

VRF STANDARD FROM AHRI

According to an association press release, the Air-Conditioning, Heating, and Refrigeration Institute (AHRI) on Sept. 20 launched a new certification program for Variable Refrigerant Flow MultiSplit Air-Conditioners and Heat Pumps (VRFs). The equipment in the VRF program are rated and tested in accordance with AHRI Standard 1230. Systems sized under 65MBH are currently certified to AHRI Standard 210/240. The certification program covers matched variable refrigerant flow multisplit air-conditioner and multi-split heat pump systems that comply with either the National Appliance Energy Conservation Act (NAECA) or the Energy Policy Act (EPACT), and use distributed refrigerant technology with cooling and heating capacities for outdoor units from 12,000 Btu/h [3508 W] to 300,000 Btu/h [87,692 W] and indoor units from 5,000 Btu/h [1,462 W] to 60,000 Btu/h [17,538 W]. Each indoor unit is designed to condition a single zone. The program applies to variable refrigerant flow multi-split systems consisting of the following matched components: a) an outdoor unit with single or multiple compressors or variable capacity compressor or with a variable speed drive; b) indoor unit(s) that have a coil, air movement device intended for single zone air distribution, and a temperature sensing control; and c) a zone temperature control device. It covers VRF multi-split systems and heat recovery VRF multisplit systems covered in AHRI Standard 1230. Included are multi-split, matched system air-conditioners and heat pumps irrespective of their type of electric power source, or secondary fluid (e.g. air-to-air or water-to-air). There are currently five participants in the program: Carrier, Daikin, LG Elecwww.applianceDESIGN.com

tronics, Mitsubishi, and Sanyo. Testing will be conducted at Intertek’s testing facility in Plano, Tex. Performance data for certified products can be found in the AHRI Directory of Certified Product Performance (www.ahridirectory.org). “As VRFs are gaining popularity in the United States, launching this new certification program is timely,” said Bill Tritsis, AHRI Vice President, Certification. “Hav-

ing a VRF program will provide the assurance that manufacturers’ performance ratings for the equipment have been independently verified, which will likely increase awareness of these products within the United States.” Manufacturers interested in joining the VRF certification program may contact AHRI Certification Engineer Jon Lemmond.

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applianceDESIGN November 2011 11

META ALS S

Figure 1: Furnace zones in an aluminum melt-hold reverb furnace.

Methods of assessing monolithic refractories for material selection in aluminum melt-hold furnaces.

onolithic refractories are well established as linings for a range of holding and melting applications during aluminum processing as they provide optimum productivity and cost effectiveness. A range of products are available and, as aluminum furnaces have their own unique set of operating conditions compared to other refractory applications, suppliers have to offer specifically tailored material solutions. There are three major test methods used by major aluminum producers to assess and approve monolithic refractories for use in the key working zones of an aluminum melting furnace. The results are assessed and compared, and indicate where certain test techniques do not necessarily represent today’s operating conditions. Those operating conditions differ from those in the past as manufacturers have worked to increase productivity by increasing heat input to the furnace to melt the metal faster.

by dr. andy wynn, jo ohn coppack Bacckg gro oun nd and tom steele Monolithics are used to line the metal and Andy Wynn is the Global Technical Director for IFB and Monolithics, John Coppack is the Technical Manager, Castables R&D, and Tom Steele is the Senior Research & Development Technician for Morgan Thermal Ceramics. 12 applianceDESIGN November 2011

non-metal contact regions in typical melthold gas fired reverbatory furnaces. Each region is divided into sub-regions, as illustrated in Figure 1, and each has a different set of operating conditions and hence environment for the furnace lining. Therefore a variety of refractories are required for a complete

furnace lining. End users are melting and holding a variety of fluxing materials, so the monolithic products need to cope with the specific chemistry present in the furnace. Different operating practices with respect to furnace management, for example methods and frequency of cleaning, mean that diverse physical conditions can influence different parts of the furnace. The diverse nature of the furnace environment means aluminum producers need to maintain a complex and lengthy testing scheme for furnace linings. This is to subject potential materials to the full range of conditions that they are likely to experience in service. As there is such a vast range of conditions it is not practical or cost effective to test materials for all types of conditions. This is why aluminum producers have developed a practical set of laboratory tests. The two main failure mechanisms that limit service life are chemical attack (corundum growth or corrosion from flux addition) and mechanical damage (ingot loading, cleaning practices or thermal shock). Producers have developed tests to simulate these as part of their approval program. An understanding of these tests must focus on the metal contact region, as this produces the most aggressive set of conditions and represents the most demanding part of www.applianceDESIGN.com

ME ETALS S

Figure 2: Mold for sample preparation – Method 1.

the furnace in terms of lining performance. Corundum growth is the most significant threat in this area and therefore receives the most attention when designing and testing furnace lining materials. Corundum forms when liquid aluminum reacts with free silica in refractories and this transformation leads to a very large expansion in volume, causing severe distortion and cracking of the lining. [4Al (l) + 3SiO2 (s) Æ2Al2O3 (s) + 3Si]

Figure 3: Mold for sample preparation – method 2.

The most prevalent laboratory test for corundum growth resistance is the aluminum “cup” test. The objective of this investigation is to understand how different test conditions affect the behavior of the lining materials by evaluating how existing furnace lining materials behave when subjected to aluminum producers’ contact cup test methods. The standard metal contact cup tests of three large aluminum producers are outlined

Material

A

B

C

Material Type

Phosphate Bonded Castale

LCC + non-wetting additive 1 LCC + non-wetting additive 2

Furnace Zone

Belly Band

Lower Walls/Ramp

Hearth

Bond Type

Chemical

Hydraulic

Hydraulic

Material Type

Bauxite

Bauxite

Bauxite

Max Use Temp °C

1450

1400

1300

Material Required cast, kg/m3

2650

2800

2900

Wt% water addition

10:1 solid to liquid

5.5-6.5

5-5.8

Table 1. Characteristics of Metal Contact Materials Studied.

As Supplied

After testing with Material

Alloy

A

B

C

% Si

0.036

0.16

0.35

0.43

% Fe

0.098

0.16

10.25

0.17

% Cu

0.9

0.9

0.9

0.93

% Mn

0.07

0.08

0.077

0.079

% Mg

2.69

0.53

1.43

1.86

% Cr

0.48

0.52

0.52

0.52

% Zn

5.66

5.74

5.8

5.92

% Ti

0.006

0.012

0.005

0.007

Table 2. Method 2 - 7075 alloy analysis. www.applianceDESIGN.com

below. These procedures are routinely used to assess the suitability of monolithic refractories for use in melt-hold furnace linings.

Cup p Metho od 1 Sample preparation: A series of 100mm cubes are cast from compositions mixed at standard water addition (mold and cubes can be seen in Figures 2 and 4.) Each cube has a 50mm deep, slightly tapered hole (55mm diameter at top, 53mm at base). Samples are set overnight, then demolded, cured and dried at 230°F for 18 hours. Half the dried sample cups produced are then pre-fired to 2192°F for 5 hours. Lids of the same material (25mm thick) are also made to minimize loss of volatiles. Test procedure: Typically 7075 alloy is used for testing, supplied as 52mm bar and cut to 50mm lengths. The cut alloy sample is inserted into the hole in the sample cup and the lid is placed on top, unsealed. Both asdried and pre-fired samples are tested at the same time for comparison. The assembled cups are placed in a kiln, heated to 1,832°F at a rate of 302°F / hour and held at temperature for 100 hours. This is followed by natural cooling in the kiln. After cooling, the samples are sectioned vertically, dried, visually assessed for the degree of metal penetration, corundum growth or ease of removal of the aluminum and photographed.

Cup p Metho od 2 Sample preparation: Following the supplier’s mixing recommendation, a standard brick size (230mm height x 114mm width x 76mm depth) of the test material is cast applianceDESIGN November 2011 13

META ALS S

Figure 4: Samples prepared by Method 1 (left) and Method 2 – as fired (right) and after surface roughing (middle).

into a mold that incorporates a curved face to form a cup shape with a maximum depth of 32mm for holding the alloy. The mold is shown in Figure 3. After the recommended curing time, the sample is fired according to the supplier’s recommendation to 1,499°F with a 10 hour hold, and left to cool naturally in the kiln. The curved cup section is then roughened using a diamond saw to expose the refractory grain. Test procedure: The cup sample is raised to 1,499°F in a furnace at a rate not exceeding 302°F / hr. Meanwhile 7075 alloy is melted in a silicon carbide crucible, heated to 1,499°F and sampled for analysis. The molten alloy is then ladled into the brick cavity at 1,499°F to

Figure 5: Materials A, B and C tested by Method 1 – dried (left) and pre-fired to 2,192°F (right). 14 applianceDESIGN November 2011

about 3mm below the top of the brick and held at temperature for 72 hours. The alloy is raked every half hour for the first three hours to remove the oxide film barrier at the metal/refractory interface. After 72 hours the oxide formed on the top of the molten alloy is cleaned and a sample of alloy from the cup is taken for analysis. Any remaining metal is poured off and the cup surface is cleaned with a Superwool blanket pad. The cup is air cooled and sectioned through the center (along the short axis) to assess degree of metal attack. The initial and final chemical analyses of the alloy are compared to determine pickup of silicon and iron.

Sample preparation: Samples are prepared according to the supplier’s recommendations and cast into the same molds as used as Method 1. Following the same setting, curing and drying process, half the dried sample cups are pre-fired to 1,472°F for five and a half hours to 248°F. Test procedure: Four test pieces are heated simultaneously in an electric furnace alongside a quantity of the test alloy in a crucible at 50°F/min to 1,472°F ± 41°F. 160g of pure aluminum (>99.8%) is ladled into the sample hole and the cups are held at 1,472°F for 72 hours. The melt is stirred daily to break the oxide film formed and afterwards is left

Material

A

B

C

Bulk Density, kg/m3 dried @ 110°C

2650

2820

2900

CCS @ 110 °C

30

135

100

CCS @ 800 °C

30

135

100

CCS @ 1000 °C

30

170

100

CCS @ 1300 °C

40

170

85

CCS @ 110 °C

0

0

0

CCS @ 800 °C

-0.1

-0.2

-0.2

CCS @ 1000 °C

-0.1

-0.3

-0.3

CCS @ 1300 °C

-0.3

-0.8

-0.7

Thermal Conductivity @ 600 °C Wm-1 -1K-1

2.42

2.3

2.3

% Al2O3

87

80

77

% SiO2

2

11

12

% CaO

-

1.8

1.4

% Fe2O3

0.6

1.2

1.1

% P2O5

5.4

-

-

Table 3. Properties of Metal Contact Materials Studied. www.applianceDESIGN.com

ME ETALS S

Figure 6: Materials A, B and C tested by Method 2.

to cool naturally in the furnace. It is cut lt diagonally and the cut face inspected for penetration and reaction with metal and photographed.

Three monolithic materials as characterized in Table 1 were tested using the three cup test methods to assess how the different test conditions used by the aluminum producers affect the outcome of the test results. As shown in Figure 5, none of the materials tested using Method 1 show any significant corundum growth, as would be expected since all three materials are routinely used in aluminum furnaces. Material C, which has been pre-fired to 2,192°F, does show a thin layer of corundum formed at the interface with the metal and this suggests that corundum resistance begins to degrade as firing temperature increases. This behavior would have performance implications in service when furnaces are operated more aggressively. The results of Method 2 as seen in Figure 6 show no corundum growth on any sample at lower temperatures of 1,499°F, despite roughening of the contact surface to try to promote reaction. However, the alloy analysis reveals that silicon pick up increases going from material A to B to C. ‘Cup’ test failures (as shown in Figure 8) are normally accompanied by increased concentration of silicon and iron in the alloy after testing.

Figure 7: Materials A, B and C tested by Method 3 – pre-fired to 1,472°F (left) and pre-fired to 2,195°F (right).

Table 3 reveals that the trend in increasing silicon pick up matches the reduction in alumina / silica ratio in the material and as silica content increases, more Si is detected in the alloy. Despite the low testing temperature of Method 2, material C is close to the failure threshold for maximum allowable silicon pick up of 0.5 percent. As with Method 2, the results of Method 3 show no visible signs of corundum growth on any sample. The results indicate that testing at 1,832°F accelerates the corundum reaction and that pre-firing the sample at higher temperatures can cause the non-wetting additive to react with other material constituents and to lose its effectiveness. As all the materials studied are already in use in many furnaces, we would expect that all the materials tested would pass these cup tests and for most test conditions studied that has been observed. However, as the severity of the test conditions increases, more metal/ refractory interaction has been observed,

specifically in material C. This matches general operational observations where it has been noted that material C starts to suffer from corundum growth in more aggressively run furnaces. According to these laboratory tests, metal contact performance appears to start deteriorating as temperature increases to 1,832°F. In the past, such high test temperatures were considered unrealistic as holding temperatures tended to be well below this level. However in more recent times, as aluminum furnaces continue to be pushed harder, chamber temperatures have risen and conditions have become more aggressive for the refractory lining. Therefore test conditions that accelerate the reactions involved, by increasing temperature above traditional aluminum holding temperatures, are now more valid. In particular, corundum growth is often seen to start at hot spots in the furnace, where temperatures can be measured in excess of 1,832°F. This situation is exacerbated by exothermic reactions from salt and dross build-up on the lining. As industry needs have changed, so the furnace environment has changed and therefore the material test methods need to evolve to reflect this. In light of modern aluminum test practices, the testing temperatures of Methods 2 & 3 appear too low, as they do not accelerate corundum growth reactions adequately. Additionally, the high melt surface area in Method 2 promotes excessive

Figure 8: Sub-hearth Gunning material tested by Method 2. www.applianceDESIGN.com

applianceDESIGN November 2011 15

ME ETALS S dross formation and volatilization. Methods 1 and 3 use relatively small alloy samples, which also suffer from volatilization, but this can be controlled to improve test repeatability by covering the sample cup with a refractory lid of test material. Cup test results are further complicated when salts are introduced into the metal contact cup tests. These studies have shown that resistance to corundum growth can alter considerably in the presence of salts and further investigation on this subject is being carried out.

Co onclu usio on

Gas Ignition Controls Features

The metal contact cup test methods used by three aluminum producers for furnace lining selection have been investigated using monolithic materials currently in use in several melt-hold furnaces around the world. Aluminum producers have worked to increase productivity to remain competitive. This is normally achieved by increasing heat input to the furnace using more powerful burners to melt the

metal faster. However this leads to increased metal losses as a result of surface oxidation and to larger heat gradients across the metal, leading to segregation of alloying elements and a reduction in metal quality. These effects are countered by increased use of fluxes to suppress surface oxidization and increased stirring of the metal to achieve homogenization. Given the increasingly challenging environment the refractory lining has to work in, aluminum producers must ensure that their material assessment tests also reflect these changes in conditions. Otherwise the tests will produce unrealistic results and material selection may be compromised. The results of this investigation suggest that those cup tests using lower temperatures are not aggressive enough for assessing lining materials in today’s furnace environment. In the past, such test conditions were adequate, but the test methods have not evolved in line with the furnace conditions which they are trying to simulate.

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A Special Section to

100years

A special presentation from ASSEMBLY appliance DESIGN magazine focusing on the people, products, plants and processes of the past 100 years at Whirlpool.

From Humble Roots to

GLOBAL PRODUCTION POWER

Appliance manufacturing has changed dramatically since 1911. By the late 1950s, Whirlpool was a major player in the household appliance industry. Photo courtesy Whirlpool Corp.

By Austin Weber, Senior Editor [email protected] W - 2 | ASSEMBLY | appliance DESIGN | November 2011

D

uring the past 100 years, Whirlpool Corp. has withstood labor unrest, mergers and acquisitions, product design changes, new technology, new materials, changing consumer tastes, globalization and restructurings. But, through it all, one thing has remained steady—its manufacturing plants and production prowess. Whirlpool traces its roots to the Upton Machine Co., which was started by Lou and Emory Upton in 1911. While working as an insurance salesman in Chicago, Lou acquired a patent for a small, manually operated washing machine. He asked his uncle, Emory, who ran a machine shop in Benton Harbor, MI, if he could attach an electric motor to it. The entrepreneurs designed a gear train and hooked up a small motor to the machine, which featured a wooden tub with ribs enclosed in a metal tank. It was driven by a sprocket gear. The wooden tub rocked back and forth, sloshing dirty clothes over the ribs to get them clean. The Uptons filed a U.S. patent for a “power transmitting device for use in association with clothes washing and wringing machines.” The device contained numerous metal and wood components that were attached with more than 100 screws and tacks. The “constantly rotatable power shaft” provided a “simple, durable, easily running and practically noiseless power-transmitting mechanism” that could supply “oscillating intermittent rotary and reversible motion.”

Upton Machine sold its first electric motor-driven wringer washing machines to the Federal Electric division of Chicago-based Commonwealth Edison. At first, daily production numbered four machines or less. The devices were manually assembled in a back corner of the machine shop. The first major order for 100 washing machines came almost immediately. However, a problem arose when a cast-iron gear in the transmission failed in every single machine. Upon learning of the issue, Lou Upton replaced the defective parts with a new cut-steel gear. Impressed with the fledgling company’s business ethics, the customer doubled its order to 200 washing machines. A century ago, washing machines were primitive devices that consisted of a large wooden barrel attached to cast-iron legs and an odd assortment of gears, cranks, levers, springs, pulleys and belts. The rotary washing machine had actually been invented more than 60 years before. But, electric washing machines were still relatively new in 1911. A U.S. patent was issued to Alva Fisher just one year earlier for a “drive mechanism for washing machines.” It featured a “pulley driven from a small electric motor” mounted on a cross brace under the machine. “Before 1920, agitators were typically suspended from the lid of the tub with the gear systems, which drove them, being mounted on top of the lid,” says Lee Maxwell, a retired electrical engineer in Eaton, CO, who has amassed the world’s largest collection of antique washing machines and written a book on the subject. More than 100 manufacturers produced a wide variety of washing machines a century ago. The Uptons had to compete with wellestablished companies, such as the Thor Appliance Co., a trademark used by the Hurley Machine Div.

of the Electric Household Utilities Corp., and Western Electric Co., which specialized in telephones. Both companies operated large factories in Chicago. Another leading Appliance Manufacturer at the time was the Maytag Washing Machine Co., which was founded by Frederick Maytag in 1893 (the company was acquired by Whirlpool in 2006). Maytag built his first washer in 1907 to supplement his line of agricultural equipment. “It seems like everyone and his nephew knew how to build a better washer in the early 1900s, and they set out to do it,” says Maxwell. “By the 1920s, there were more than 700 manufacturers of washing machines. Most succumbed to mergers, buyouts and bankruptcies.” Back in 1911, electric washing machines were still considered to be a modern marvel. Period advertisements touted such features as “Just a ‘twist of the wrist’ starts or stops the machine!” and “You turn on the power as easily as you turn on the light, and back and forth goes the tub, washing the clothes for dear life.” Other ads proclaimed “Now electricity makes the washer go. Doesn’t that sound like a new era for women?” and “The hardest drudgery there is about housework done by two cents’ worth of electricity.” Before Maytag and the Uptons came along, most washing machines were still hand-operated contraptions. Others were dog-, sheepand goat-powered, using a treadmill. “The electric motor was the single most important factor which enabled the washing machine to

become a common household appliance,” claims Maxwell. By the 1920s, the most widely used power unit was the 0.25 hp, 110-volt, 60-cycle induction motor. Some manufacturers, such as Maytag, also mass-produced gasoline-powered machines, which were popular with farmers and other rural consumers. Maytag built its own two-cycle gas engines between 1916 and 1952, when it switched to engines produced by Briggs and Stratton.

(Top) This is what the Nineteen Hundred Corp. plant in Binghamton, NY, looked like in 1920. Photo courtesy Whirlpool Corp. (Bottom) Maytag’s Model 80 Gyrafoam washer was mass-produced

Manual Assembly Early Maytag and Whirlpool factories were similar to other manufacturing facilities of the period. For example, the Nineteen Hundred Washer Co. operated a three-story brick factory in Binghamton, NY. November 2011

in Newton, IA, during the 1920s. Photo courtesy Whirlpool Corp.

| ASSEMBLY | appliance DESIGN | W - 3

Whirlpool CENTENNIAL It mass-produced machines under brand names such as Cataract, Kenmore and Whirlpool. Maytag operated a large factory in Newton, IA, which quickly became known as the “Washing Machine Capital of the World.” It offered two types of electric machines. More than 57,000 Model 41 machines were built on Maytag assembly lines between 1911 and 1925, while more than 48,000 Model 42 units were produced between 1911 and 1924. Maytag’s factory was five stories tall. “The manufacturing process would start on the top floors and gradually progress to the lower floors,” says Leland Smith, a retired industrial engineer who worked at Maytag for 40 years, starting in the mid-1950s. “Elevators were used to move materials and finished products up and down.” Assemblers in early appliance factories worked at long workbenches positioned near large windows. The benches were equipped with vises and numerous hand tools, such as screwdrivers, pliers, files, wrenches and hammers. A maze of overhead line shafts and leather belts, which turned constantly, supplied power to presses, riveters, drill presses, lathes and other machines, which were placed parallel to the shafting. Building a washing machine was a laborious process. Workers typically moved from workstation to work-

A Century of Progress 1907—Maytag introduces a line of electric wringer-washers. Photo courtesy Whirlpool Corp.

1911—Upton Machine Co. is founded by Lou and Emory Upton in Benton Harbor, MI, to produce electric motordriven wringer washers.

1915—Maytag develops a gasoline-powered washing machine for customers in rural areas without electricity.

W - 4 | ASSEMBLY | appliance DESIGN | November 2011

Maytag engineers replaced wood parts, such as frames, cabinets and support legs, with sturdier metal components starting in 1918. By the early 1920s, they perfected reversible swinging wringers and a gyrating agitation system. The machines featured forward, stop and reverse controls, thanks to a clutch mechanism that used bevel gears. As more people demanded electric washing machines, Upton Machine also continued to grow. By 1925, it had become the sole supplier of electric- and gasoline-powered washing machines to Sears, Roebuck & Co. During this time period, the company borrowed an idea from the auto industry when it installed moving assembly lines at its St. Joseph, MI, plant. Increased demand forced Upton to merge with the Nineteen Hundred Washer Co. in 1929 and a new plant was built in St. Joseph. During the 1930s, washing machines became more streamlined as engineers experimented with new materials, such as Bakelite plastic, and new features, such as motorized agitation. The Nineteen Hundred Corp. survived the Great Depression. In fact, it even expanded and modernized its factories. For instance, the company installed an overhead conveyor system at the St. Joseph factory in 1937.

station performing a specific task or a series of assembly tasks. Parts and components were hand delivered to each workstation. In the early days, cooperages were an important part of washing machine factories. Wash tubs were made from wooden staves held together with steel bands. Cypress and white cedar were widely used, because they resisted rotting. However, wood tubs were prone to leaks. Maytag engineers experimented with copper tubs, but the lye used in early soaps corroded the material. In 1919, they succeeded in casting the industry’s first aluminum washer tub, which most experts claimed couldn’t be done. As aluminum tubs replaced wooden barrels, foundries became a key operation. Maytag mass-produced 3 million cast-aluminum square tubs between 1922 and 1941. By the end of the 1920s, porcelain-coated steel tubs also became popular. The Maytag Gyrofoam was introduced in 1922 and quickly cornered the market. In fact, consumer demand for the machine boosted Maytag production more than 300 percent between 1923 and 1926. In 1927, the 1 millionth Maytag washer rolled off the assembly line in Newton. The trendsetting machine featured a gyrator agitation system that was driven by rack-and-pinion gearing. 1916—Upton Machine Co. sells its ﬁrst order of washers to Sears, Roebuck & Co., beginning a long business relationship.

1924—One out of every ﬁve washing machines in the United States is made at Maytag’s assembly plant in Newton, IA.

1919—The ﬁrst residential KitchenAid stand mixer is introduced.

1934—Amana Refrigeration Inc. is founded.

1929—Growing demand requires Upton Machine Co. to merge with Nineteen Hundred Washer Co. of Binghamton, NY. The new ﬁrm, The Nineteen Hundred Corp., adds large manufacturing facilities in Michigan and New York.

During World War II, the company ceased manufacturing washers. Factories were modified to produce components for the P-40 Warhawk aircraft and other military vehicles. More than 2 million pounds of war materials were produced, including anti-aircraft guns, aircraft propeller pitch controls, trailing edges for fighter wings, hydraulic steering mechanisms for tank retrievers, carburetor parts, pumps, gears and gear cases. The company began producing washers again in the summer of 1945, anticipating that within three years, consumer demand would be twice that of 1941.

Age of Expansion The modern era of Whirlpool began in 1950 when the Nineteen Hundred Corp. was renamed Whirlpool Corp., in honor of its signature brand, and it began producing dryers and irons. That same year, Maytag opened a new, dedicated factory in Newton, IA, for assembling automatic washers. Whirlpool boasted $48 million in sales and annual earnings of $3 million. The company capitalized on that success and diversified into other household appliances. During the boom years of the 1950s, it acquired several appliance companies in the Midwest. For instance, in 1955, Whirlpool

1941—The Nineteen Hundred Corp. and Maytag shift operations to support World War II production efforts.

1938—The Nineteen Hundred Corp. invents the ﬁrst washer with motorized agitation.

purchased Motor Products Corp.’s manufacturing facilities in Marion, OH, and turned it into a dryer production plant. That same year, it bought International Harvester’s refrigeration plant in Evansville, IN. But, one of the first strategic moves of the newly named Whirlpool Corp. was the acquisition of the Clyde Porcelain Steel Co. in 1952. The 250,000-square-foot Clyde, OH, facility was converted into a wringer washer production plant. In 1954, Whirlpool purchased an adjacent 170,000-square-foot plant from Bendix Corp., a leading manufacturer of belt-drive washing machines. By the time an article about the plant appeared in the January 1961 issue of ASSEMBLY (then known as Assembly Engineering), the Clyde facility was the backbone of Whirlpool’s expanding appliance empire. An engineer at the factory explained how an automatic machine was used for the precision insertion of two bearings and one seal into the chrome-plated tubes that fit inside the hollow post of the rotary basket in washers. “Bearings, seals and tubes must all close limit switches before the machine will sequence and operate,” explained the engineer. “This eliminates any chance of producing partial or defective assemblies. With this machine, one man loads two bearings and one seal into each of

1948—Maytag starts building a second assembly plant in Newton, IA. Photo courtesy Phillips Screw Co.

1947—Amana (then the Raytheon Co.) invents the ﬁrst microwave oven. After an employee naming contest, the new machine is dubbed the Radarange.

635 tubes per hour, a fast rate for precise assembly.” Meanwhile, Maytag engineers developed a helical drive system in 1956 that revolutionized the appliance industry by eliminating many moving parts and simplifying assembly. It allowed washers to switch from agitation to spin cycle with a reversible motor.

By the early 1930s, moving conveyors were a common sight in Whirlpool plants. Photo courtesy Whirlpool Corp.

The typical Whirlpool automatic washer in the late 1950s contained 144 assembly components and 312 threaded fasteners and parts, such as plugs, shelf supports, grommets and spacers. Throughout the 1960s and 1970s, appliance engineers attempted to simplify mechanical complexity and streamline assemblies. By 1977, the average washing machine contained 25 percent fewer fasteners and 20 percent fewer

1950—The Nineteen Hundred Corp. changes its name to Whirlpool Corp.

1957—Whirlpool introduces the “Miracle Kitchen,” a line of imaginative, futuristic appliances.

1955—Whirlpool Corp. acquires a dryer assembly plant in Marion, OH, and a refrigerator assembly plant in Evansville, IN. ﬁrst side1949—Amana introduces the ﬁrst by-side refrigerator. Photo courtesy Whirlpool Corp.

November 2011

| ASSEMBLY | appliance DESIGN | W - 5

Whirlpool CENTENNIAL A new batch of washers move down the assembly line in the 1930s. Photo courtesy Whirlpool Corp.

assembly components than a 1959 vertically integrated, “producing model. “The change in the number more components in-house than and type of fasteners used in the any other appliance maker,” accordappliances reflected the development ing to an article in the November of thread-rolling and self-drilling 1993 issue of Appliance Manufacscrews, improved locking fasteners, turer. “Typical components made inand other cold-headed innovations house include die castings, rubber that eliminate costly operations and and cold-headed parts.” extra components,” claimed a news According to retired engineer Leland Smith, Maytag made its own screws and bolts up until the 1950s. “We tried to do as much in-house production as possible,” he points out. “The philosophy was ‘If we make the product ourselves, we can control the quality.’” But, that strategy started to change in the 1980s. For many plastic parts, Maytag decided that in-house production was not as competitive as buying from outside vendors. “We must be good with inhouse parts or we get out of the business,” proclaimed Robert Paulson, the company’s vice president of manufacturing. Plastic has had a profound item in the January 1978 issue of Appliance Manufacturer (the for- influence on appliance manufacturmer name of applianceDESIGN, ers during the last 50 years. Maytag started using plastic in the late ASSEMBLY’s sister publication). During the mid-1970s, Whirl- 1940s,” recalls Smith. “It was first pool decided to vertically integrate used to replace aluminum in agiits manufacturing operations to tators. Maytag started an in-house reduce dependence on outside sup- plastic injection molding departpliers. The company started assem- ment in the early 1960s.” According to an article in the May bling its own hermetic motors at a 1978 issue of Appliance Manufacplant in Danville, KY. Maytag was also traditionally turer, the industry at the time used 1967—The “Maytag Repairman” debuts in advertising. Photo courtesy Whirlpool Corp.

1960—Whirlpool wins NASA contract to design and build America’s ﬁrst “space kitchen.” Photo courtesy Life magazine

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1969—Whirlpool introduces the trash compactor.

1986—Whirlpool tops $4 billion in sales.

1977—Whirlpool tops $2 billion in sales for the ﬁrst time. 1967—Whirlpool tops $1 billion in sales for the ﬁrst time in company history.

12 times the amount of plastic it consumed in 1960. As a wide variety of metal parts were replaced with ABS, polypropylene and polystyrene, it opened the door for new assembly processes such as adhesive bonding and ultrasonic welding. “Porcelain is no longer competitive,” a Whirlpool executive told Appliance Manufacturer in August 1986. “Plastic is now very acceptable in the marketplace and in many respects allows greater design flexibility, which affords improved utility for the consumer. Plastic, too, allows the product to be designed for greater energy efficiency.” That trend, coupled with a new software-based tool called Design for Manufacturing (DFM), had a profound impact on Maytag engineers when they embarked on an ambitious project in the early 1980s. Their goal was to simplify the transmission used in washers. The engineers were also forced to redesign another key component—the agitator. “We evaluated die-cast gears, plastic gears, plastic components and castings,” recalled Maytag’s head of research and development in an article published in the February 1990 issue of Appliance Manufacturer. “This project represents our greatest DFM cooperative effort between manufacturing and research and development in anything we’ve ever done.”

1989—Maytag acquires vacuum manufacturer Hoover Co.

1993—Whirlpool 1993 Whirlpool Asia establishes ofﬁces in Tokyo, Hong Kong and Singapore. Photo courtesy Whirlpool Corp.

The new Dependable Drive transmission system featured four main components—a small pinion gear, a torque block, a yoke block and large bevel gear. It used only 40 parts overall, compared to 65 parts in the previous design. The nine-year R&D effort resulted in a “fresh approach to machining and assembly operations.” The redesign lent itself to automated assembly, which was a big improvement, because the old transmission was manually assembled. And, the new design was so successful that Maytag increased its transmission warranty from five to 10 years. During the 1960s, the appliance industry continued to consolidate. For instance, in 1966, Whirlpool acquired the Norge refrigeration plant in Fort Smith, AR. Meanwhile, Raytheon Co. acquired a small company in Iowa called Amana Refrigeration Inc. (it was eventually acquired by Maytag in 2001). A cover story in the October 1965 issue of Assembly Engineering explained how Amana massproduced refrigerators, food freezers, refrigerator-freezers, air conditioners and dehumidifiers on five assembly lines in a state-of-the-art factory. Welding and brazing played a key role in the assembly process. For instance, one of the early steps in the assembly of an upright freezer was heliarc welding of the

1994—Whirlpool breaks ground on a new plant in Tulsa, 1999—Whirlpool tops $10 billion in sales. OK, to make gas and electric ranges.

1996—Whirlpool begins assembling KitchenAid appliances at a new plant in Greenville, OH.

aluminum tubing joints in the freez- the work coming to them; each task er line. The plant used an automat- is performed on a stationary unit; ed welding operation to join corner workers work at their own pace; and seams of the freezer door shell. But, through turntables, no rotating of after the compressor and insulation heavy ovens is required.” was added to the cabinet on the In addition, assemblers “work on final assembly line, tubing lines were one side of the line. Components are joined manually by gas torch brazing. supplied to each workstation, and subassembly operations, such as the New Tools and Technology In 1967, Amana unveiled a new fangled device called the Radarange, which was based on microwave technology developed by a Raytheon engineer in the mid-1940s. The 100volt oven fit on a countertop and cost just under $500. By the early 1980s, microwaves became a must-have device in American kitchens and the average price dropped dramatically. Growing market demand forced Amana to launch its first major redesign and develop a line of midpriced units. The company invested $12 million in a “cost- blower, are positioned right next to effective automated production line.” the line.” Amana engineers were inspired The 33,000-square-foot facility was featured in the July 1985 issue of by float lines they saw while touring television assembly plants in Appliance Manufacturer. The main assembly line featured Japan. The new equipment was a float (nonsynchronous) conveyor manufactured to Amana’s specificavs. a slat conveyor that was used for tions using technology developed the premium product. According by Hirita Corp. Seven computers to the article, “advantages of float controlled the new assembly lines, over slat include: each workstation which featured a 1,492-foot-long becomes a specialized task center; conveyor, 65 workstations and 26 workers remain at one location, with turntables on the main line. A door

2003—Whirlpool becomes the world’s ﬁrst appliance manufacturer to set a target for reducing greenhouse gas emissions.

2000—Whirlpool selects a vanguard of 75 employees to learn innovation methodologies. The effort would later spawn a host of new products. 2000—Whirlpool debuts in the Assembly Top 50.

2006—Whirlpool acquires Maytag, Jenn-Air and Amana brands.

2007—Whirlpool tops $19 billion in sales. 2004—Maytag’s dishwasher 2004 M t ’ di h h assembly bl plant in Jackson, TN, wins the Shingo Prize for Excellence in Manufacturing. Photo courtesy Whirlpool Corp.

November 2011

Early appliance assembly was a manually intense process. Photo courtesy Whirlpool Corp.

2011—Maytag’s assembly plant in Clyde, OH, produces 1 million washers in just 35 weeks.

2010—Whirlpool invests $85 million to build a new headquarters in Benton Harbor, MI, and an additional $120 million to build a new assembly plant in Cleveland, TN.

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Whirlpool CENTENNIAL The aluminum foundry was an important part of Maytag’s early operations. Photo courtesy Whirlpool Corp.

assembly float line consisted of a 96-foot long conveyor and 11 workstations. Cycle time was 4.5 seconds per workstation. Each assembly task was performed on a 29.5 by 29.5-inch pallet. Once finished with a task, assemblers pressed a hand switch or foot pedal to send the pallet to the next workstation. Inline testing and packaging were performed downstream. A computer-controlled scanning operation that measured emission leakage

around the door, window and back of the oven replaced a manual scanning operation. By the start of the 1970s, Whirlpool offered appliances to handle laundry, home heating and cooling, and the full cycle of food preservation, preparation, consumption and cleanup in the kitchen. However, appliance manufacturers were forced to comply with a slew of new regulations stemming from the creation of government agencies, such as EPA and OSHA,

which were both established in 1970.

Energy and the Environment Recognizing the need for energy and material conservation, Whirlpool established a new business model in 1970 that focused on energy efficiency and environmental sustainability. The Office for Environmental Control implemented numerous standards across all the company’s operations. But, the price tag for compliance was hefty. “Every manufacturer in our industry has felt the financial jolt of environmental standards, either directly in the form of expenditures for capital equipment, or indirectly in the form of increased prices from suppliers passing along their increased costs emanating from environmental requirements,” said John Platts, Whirlpool’s president, in an article in the September 1977 issue of Appliance Manufacturer.

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Platts, who served as president of Whirlpool from 1962 to 1977, worked his way up through the ranks. He started working at the company in 1941 as an assembler on the wringer washer line at the St. Joseph, MI, factory. “Our company spent more than $30 million on pollution control equipment and related operational expenses during the last decade, and present projections indicate we’ll be spending another $9 million on pollution control equipment in the next six years,” Platts pointed out. According to an article in the September 1979 issue of Appliance Manufacturer, Whirlpool’s “additional costs as a result of government regulation [added] up to $20,187,331.” Out of that total, $3,156,769 was for EPArelated expenses, while $1,207,167 was OSHA related. An article in the September 1977 issue of Appliance Manufacturer examined one type of production solution that Whirlpool engineers were forced to implement as a result

of more stringent regulations. The Evansville, IN, plant switched from water to gas leak testing on its room air conditioner line. “Clearly, in these times of faster and faster assembly, the water test belongs in another era,” the article proclaimed. Air conditioners were carried to the testing station by an overhead, powered monorail conveyor. Whirlpool invested $45,000 in a machine that used a mixture of 80 percent dry air and 20 percent refrigerant, in addition to quick-connect couplings to help speed the testing process. “With the tracer gas system, the air conditioner is 70 percent complete when we test it, compared to 30 percent when we used the water test,” explained a manufacturing engineer who worked on the project. “And, with the gas test, we don’t have to strip any preassembled components from the air conditioner frame.” A decade later, appliance manufacturers were forced to comply

with energy-efficiency requirements mandated by the U.S. Department of Energy. Whirlpool’s Fort Smith, AR, refrigerator assembly plant installed a new PC-based test system that ran 24 hours a day, seven days a week. Quality assurance tests on production units were run for 72 straight hours under varying climate-controlled conditions. The configuration allowed Whirlpool engineers to test 48

Maytag and Whirlpool made many parts inhouse to ensure consistent quality. Photo courtesy Whirlpool Corp.

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Whirlpool CENTENNIAL (Top) The Marion, OH, dryer plant was acquired in 1955. Photo courtesy Whirlpool Corp. (Bottom) Early washers were assembled on benches at the Upton Machine Co. in Benton Harbor, MI. Photo courtesy Whirlpool Corp.

refrigerators simultaneously, with different test parameters for each unit if necessary. It increased testing capacity by 33 percent. Data on voltage, watts per hour, inside temperature, defrost cycles and compressor run times were collected from thermocouple and transducer sensors. By the early 1990s, Whirlpool engineers had redesigned the company’s refrigerator-freezers to be 20 percent to 25 percent more energy efficient. That change altered assembly procedures in the Fort Smith plant. “Refrigerant systems are no longer built separate from the cabinets,” explained a manufacturing engineer. “Therefore, we no longer need the previously used elevators and overhead conveyors to route partially

W - 10 | ASSEMBLY | appliance DESIGN | November 2011

completed cabinets. “Portions of the refrigerant system are installed before adding the foam-in-place insulation,” added the engineer. “The electrical wiring system is placed inside the foam, eliminating any wiring or tubing on the back of the unit, giving it a cleanback design.” Whirlpool also invested in new types of production technology throughout the 1990s. For instance, programmable logic controllers (PLCs) had a profound affect on the company’s assembly lines. An article in the December 1991 issue of ASSEMBLY examined how PLCs had recently replaced relay logic as the predominant control technology at Whirlpool’s Findlay, OH, plant that assembled 8,000 dishwashers and free-standing electric ranges daily. According to a control engineer, “there was little automation in the plant a decade ago, with 90 percent of assembly manual.” There were only five PLCs used in the factory. By the early 1990s, however, more than 200 PLCs were in use throughout the Findlay plant. “We use PLCs in a variety of areas, and our use has increased in the last three to four years,” explained a senior control engineer. “Currently, we have PLCs in the assembly, subassembly, metal fabrication, welding and plastic press areas. The controllers are used extensively in our dishwasher pump, tub and rack assemblies.” Whirlpool used servo motion control technology for precision placement of parts and welds. For instance, on the dishwasher rack, workers welded one index at a time with a servo motion control transfer inserting the rack into the welder area. Most of the Findlay plant’s early PLC technology was installed with test equipment for both the range and dishwasher lines. “Now, we have PLCs more integrated on the line to store the parameters for line speed settings and other control

settings,” the engineer pointed out in the article. “Plus, they track downtime information and production requirements.” Whirlpool’s Fort Smith refrigerator plant was busy investing in automated guided vehicle (AGV) technology around the same time. A $1 million system was installed to serve the factory’s new assembly layouts. An article in the July 1993 issue of Appliance Manufacturer explained how AGVs reduced work-in-process inventory from 300 cabinets for two assembly lines to just 45 cabinets for three lines. “Because the automated system requires a single human operator, labor costs are much lower, resulting in a one-year payback when compared with a manual system using hand carts and a dozen workers per shift,” the article explained. “[And], cabinet damage has effectively been eliminated by the AGV system. By continuously matching vehicles to priorities, the material handling system automatically balances the assembly lines.” The Fort Smith plant also installed two identical fabrication cells for refrigerator and freezer doors that required no manual changeover for height, width and depth. “Through the use of programmable operations, changeover between two models can be achieved in two minutes,” claimed a manufacturing engineer. “The automatic plasma arc weld stations, for instance, have a programmable vertical feed adjustment to accommodate different door thicknesses,” added the engineer.“The welders use only the door metal to close the seam and require no filler materials.” Whirlpool also invested in robotic technology during the 1980s. For instance, an early application was material handling at the Clyde, OH, plant. In 1981, engineers began planning a revamped production facility for assembling a redesigned line of automatic washing machines dubbed Design 2000. The new products

After toying with the idea of entering the furniture or garden products market, Whirlpool management decided to stick to household appliances. The company formed several strategic joint-ventures in Europe, China and India to gain a manufacturing foothold in those regions. Those efforts eventually paid off. By 1996, Whirlpool manufactured appliances in 12 countries, while 38 percent of corporate revenue was generated from overseas. To standardize parts and production processes around the world, Whirlpool focused on technology Global Player Today, Whirlpool operates more transfer between continents. “When than 65 manufacturing and product we set up project teams, engineers development facilities around the from North America spend time world. But, 25 years ago, the company here in Europe and European engiwas primarily only focused on North neers spend time there in North and South America. An aggressive America,” explained Halvar Johansglobalization drive during the late son, vice president of manufactur1980s and early 1990s doubled Whirl- ing at Whirlpool Europe B.V. in an pool’s revenues and transformed the article in the February 1995 issue of company into the largest appliance Appliance Manufacturer. manufacturer in the world. “[We’re maintaining] an ever-

featured direct-drive instead of beltdriven motors, high-spin speed and 30 percent fewer parts. Robots were installed to tend 1,500-ton presses that molded several different sizes of plastic tubs. “The tubs are automatically removed from the molds by robots,” said an article in the June 1985 issue of ASSEMBLY. “The parts are placed by robots onto belt conveyors, where they pass through an automatic pierce fixture which removes the disc gate from the part.”

growing database tracking cost and quality at each of [our] plants to ensure that best practices are recognized and transferred,” added Johansson. “At our factories, we’ve given our plant directors ownership of continuous improvement efforts.” Whirlpool also implemented flow-line manufacturing processes at its European operations. “All assembly and testing operations for a given product are integrated and performed on a single assembly line,” said Johansson. “That line can be used for multiple models. Our goal

During the 1960s, small groups of employees at the Marion, OH, plant built complete products, such as these ovens, on short spur lines as a method of increasing the variety of assembly line jobs. Photo courtesy Whirlpool Corp.

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| ASSEMBLY | appliance DESIGN | W - 11

Whirlpool CENTENNIAL Whirlpool acquired its Clyde, OH, washer plant in 1952. Photo courtesy Whirlpool Corp.

is to achieve more commonality of components and more modularity in our manufacturing lines.” Manufacturing and design engineers developed an affordable, compact washer that“can be manufactured on offshore turf using resident talent and materials.” The World Washer featured lightweight construction and 15 percent to 20 percent fewer parts than traditional Whirlpool automatics.

W - 12 | ASSEMBLY | appliance DESIGN | November 2011

An article in the November 1990 issue of Appliance Manufacturer explained how it was assembled in Brazil, India and Mexico using “low investment, flexible manufacturing processes.” “We wanted to reduce the size of the appliance and make sure the operators in these plants could be trained to provide acceptable quality assemblies,” explained Tony Mason, Whirlpool’s director of international product design. “We designed most of the unit in modules. For example, the drive and support assembly, as well as the control system, are put together as packages that can be tested before proceeding to the next phase of assembly. Ninety five percent of our material needs are met through local suppliers.” Maytag engineers were also busy adjusting to the pressures of globalization. “The marketplace is forcing us to be more flexible and to produce models on demand,” Robert Paulson, Maytag’s vice president of

manufacturing, told Appliance Manufacturer in a November 1993 article. “This requires us to apply world-class concepts. You are worldclass when you can sell 40 percent of your products outside the U.S.” According to Paulson, the company was “paying more attention to inventory management and just-intime, as well as to more advanced technologies.” The appliance manufacturer was also keeping an eye on offshore assembly. For instance, in 2001, it announced a $2 million effort to establish a manufacturing base in Mexico. “To expand its ongoing cost management initiatives, Maytag will establish a subassembly operation in Mexico to support its major appliance manufacturing operations in the United States,” reported an article in the November 2001 issue of Appliance Manufacturer. “Currently, the subassembly of product components and parts is performed at each of Maytag’s major

During World War II and the Korean War, Whirlpool’s assembly lines turned out aircraft wings. Photo courtesy Whirlpool Corp.

appliance production facilities in the United States, or the work is done by outside suppliers,” the article pointed out. “The new Mexican operation will supply subassemblies that go into finished products, and it will allow [Maytag’s] U.S. manufacturing operations to become more focused on fabrication of parts and final assembly of innovative, high-quality products.” To stay competitive, Maytag also launched a Lean Sigma initiative in 1998. “The initiative is being practiced throughout all the Maytag operations, including Jackson, TN, where an 18-month effort transformed a half-mile long continuous-line dishwasher assembly operation into seven assembly cells capable of a wide range of productmix capabilities,” explained a November 1991 Appliance Manufacturer article. The transformation freed up 43,000 square feet of manufacturing space, improved productivity by 15 percent, improved quality by 55 percent, increased assembly capacity by 50 percent and reduced work-in-process by 60 percent. By November 2005, when an article about the plant appeared in ASSEMBLY, the impressive statistics kept piling up. For instance, the facility had reduced OSHArecordable injury rates by 64 percent while improving first-pass quality yields by 84 percent. The 13-year-old plant had also reduced its internal defect rate by 32 percent and lowered hours per unit by 27 percent. Assemblers built more than 100 dishwasher models daily, with brands including Amana, Jenn-Air and Maytag. “Our goal is to deliver the right product at the right time,” said Terry Spalding, director of manufacturing. “We have the flexibility in our facility to immediately respond to customer demand. Teams can adjust assembly cells with minimal notice to changes in the schedule. Through the use of our lean manufacturing principles, we have the ability to produce any model dishwasher at any hour of the day.” A November 2011

| ASSEMBLY | appliance DESIGN | W - 13

Henkel Congratulates Whirlpool RQ
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For more information, call 1.800.LOCTITE (562.8483) or visit www.henkelna.com/appliances. Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and/or its afﬁliates in the U.S. and elsewhere. ® = registered in the U.S. Patent and Trademark Ofﬁce. Whirlpool is a registered trademark of Whirlpool Corporation. © Henkel Corporation, 2011. All rights reserved. 7910 (10/11)

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QUALITY AND STANDARDS

ENERGY STAR LABEL AND SMART GRID Capitalizing on the potential for smart grid: opportunities from smart grid enabled appliances.

by amanda stevens Amanda Stevens is program manager of the ENERGY STAR appliance program at the U.S. Environmental Protection Agency. Contact her at [email protected] for more information and for how to directly participate. 18 applianceDESIGN November 2011

T

he Smart Grid and the technologies embodied within it are a set of investments that will bring the century-old electricity grid into the 21st century, using information to move electricity more efficiency, reliably, and affordably. Smart Grid technologies have the potential to dramatically change the way that we consume energy, by enabling the biggest energy users in the home – the heating and cooling systems, refrigerator, water heater, pool pump, dishwasher, and clothes washer – to communicate with the electric utility, and with the consumer’s permission, make small adjustments in how a product operates. These small changes might save consumers money and would add up to big benefits for the electric grid as a whole. The Smart Grid can also benefit the environment by helping to integrate cleaner sources of electricity generation, including intermittent renewables and combined heat and power; deliver transmission and distribution system energy efficiency; provide zero-emissions options for grid reliability; and remove information barriers to energy efficiency in homes and buildings. Recognized by more than 80 percent of U.S. consumers, the ENERGY STAR label is a powerful market force, helping purchas-

ers identify products that save energy and protect the environment while delivering the features and functionality of value to them. EPA has long encouraged the implementation of “intelligent” energy-saving features and functionalities that consumers expect with their ENERGY STAR product. Now, as an extension to this, EPA is working closely with a variety of stakeholders, including manufacturers, utilities, and efficiency advocacy groups, to consider how the ENERGY STAR program can help advance the market for smart grid enabled products in ways that deliver immediate consumer benefit as well as long-term system benefits. Broadly speaking, Smart Grid technologies fall into three basic categories: (1) advanced information and communication technologies that improve the operation of transmission and distribution systems; (2) advanced metering infrastructure (AMI, or “smart meters”) to replace legacy metering infrastructure; and (3) technologies, devices and services that access and leverage energy usage information, such as “smart” thermostats or appliances that turn on when energy is cheaper or cleaner. At a basic level, a smart grid enabled product is one that has the capability to serve as www.applianceDESIGN.com

QUALITY AND STANDARDS Texas Instruments announced four new system solutions for Smart Grid and metering applications in early October. Their PLC Development Kit recently received PRIME certification

a new energy resource for the electric grid, by reducing or delaying its operation in response to signals communicated from a utility or third-party service operator. For instance, in the future when new demand response programs are established, a refrigerator could respond to a signal by shifting its defrost cycle and ice making to a period of the day when energy demand or costs are lower. Widely deployed, smart grid enabled products could help utilities better manage peak demand, offsetting the construction of new power plants and supporting the decommissioning of power plants in load pockets. Smart grid enabled products could also balance supply and demand to improve grid reliability and support the increased penetration of intermittent, clean energy sources and electric vehicles, while avoiding the need to use dieselfired back-up generators for grid reliability. Substantial environmental benefits in terms of reductions in greenhouse gas emissions and criteria air pollutants could be realized. These benefits are exciting, but it is also important to note the path forward in building a smarter electricity grid will be, given the nature and sheer size of the electricity industry, evolutionary. As a result, the full potential of smart grid enabled products will not be realized in the next few years, but rather, will depend on further build-out of new AMI, variable electricity pricing, and further evolution in the rules for load participation in markets, such as those for spinning reserves. In the meantime, some peak demand benefit can be gained through intermediate steps, such as the addition of internal clocks and new intelligence that automatically schedules energy-intensive tasks like refrigerator defrosting, for off-peak periods. www.applianceDESIGN.com

The core of a smart-grid enabled product is its communication capability. This connectivity can provide consumers with a host of new features and functionalities that enable them to, for instance, receive feedback on individual appliances’ energy use and personalized energy saving tips, remotely operate/schedule an appliance from their mobile device or the internet, and utilize time-saving remote diagnostic functionality in lieu of a traditional service call on a malfunctioning appliance. At the 2011 Consumer Electronics Show earlier this year, for the first time appliance manufacturers turned out en mass to showcase their future lineups of these connected “smart” appliances, which are only now just staring to arrive on retail floors in the U.S.

Advancing Smart Grid Functionality in ENERGY STAR Labeled Products There are various ways the ENERGY STAR Program could be leveraged to accelerate the adoption of smart grid functionality in the product categories it covers. As part of ongoing efforts to keep ENERGY STAR specifications up-to-date, the Agency has initiated revisions for a number of relevant product categories, including Room Air Conditioners, Refrigerator/Freezers, and Climate Controls. Several options presented below are currently under active consideration and discussion with stakeholders in the context of these revisions. For each product category, EPA is tailoring its approach on smart grid in recognition of unique opportunities and market conditions. Extra Recognition for Smart Grid Functionality: For product categories

such as the home appliances, where smart grid functionality and connectivity is still a very nascent technology, EPA is proposing to highlight smart grid enabled products among those with the ENERGY STAR label. This could be accomplished, for example, by designating them as “Smart Grid Capable” or “Connected” on ENERGY STAR qualified product lists, so that rebate programs and other interested stakeholders are better able to promote them. Allowance: For certain products, EPA is considering providing a small allowance against the ENERGY STAR levels, to help jump start the market for smart grid enabled products. This approach provides manufacturers with the flexibility to shift investments that would otherwise go toward achieving the next few percentage points in energy savings, to the widespread integration of smart grid features in those products. Part of the Criteria to Earn the ENERGY STAR: EPA is developing a new program specification for Climate Controls (aka programmable communicating thermostats). To be eligible for ENERGY STAR, EPA has proposed Climate Controls have the ability to communicate with sources external to the HVAC system for purposes of energy management and remote control.

Delivering Near Term Benefits As smart grid functionality is considered, it is essential that the ENERGY STAR program deliver on its promise to provide tangible value to the product purchaser. More specifically, EPA believes it essential that ENERGY STAR products with smart grid functionality not only have demand response capabilities that could enable grid benefits and longerterm savings opportunities that ultimately benefit consumers, but also provide new consumer-oriented functionality of immediate value, such as: Enhanced Energy Awareness – When applianceDESIGN

November 2011 19

QUALITY AND STANDARDS appliances and other energy-consuming devices or systems report their energy consumption, consumers can benefit from actionable information that disaggregates home energy consumption to identify usage for HVAC, water heating, refrigeration, and laundry, for example. This data can also be leveraged by new devices and applications that suggest and/or automate changes that will optimize energy use, suggesting settings which minimize energy costs or suggesting

in an energy-savings mode during an unexpected “away” period or turn their system back on a few hours before returning home, or even check to ensure they remembered to turn off the oven before leaving the house. Fault Reporting and Diagnostics – Appliances that are properly maintained are more energy efficient; ensuring that faults and performance degradations are detected and reported would help keep appliances operating at peak efficiency. Appliances linked to a

“Innovation is supported by the use of open standards and protocols that maximize interoperability, such as those that will be recognized by the National Institute of Standards and Technology” when its time to consider replacing an old, inefficient appliance. Giving Consumers More Control – Remote management capability could enable new convenience features and energy-savings opportunities. For example, consumers might be able to turn on their heater or air conditioner from work, remotely place their home

home area network could provide consumers alerts/reminders, for example, when coils should be cleaned, when a filter needs to be changed, or when a door has been inadvertently left open, wasting energy. Open Standards & Consumer Choice – Innovation is supported by the use of open standards and protocols that maxi-

mize interoperability, such as those that will be recognized by the National Institute of Standards and Technology (NIST) Smart Grid Interoperability Panel (SGIP). Smart grid and building networking standards are still in development. ENERGY STAR smart grid enabled appliances should be compatible with other suppliers’ products or services where possible, providing consumers with more choice and enabling them to take advantage of third-party offerings. Ultimate Control with Consumer – As demand response opportunities evolve, it is critical that consumers retain ultimate control over their appliances’ response to such signals. Thus, appliances should provide consumers with an easy-to-execute option to override any demand response action requested by their utility. Manufacturers have signaled that smart grid enabled products will likely begin appearing in store aisles next year. The ENERGY STAR program is working to incent the widespread integration and adoption of these new intelligent capabilities and to make sure consumer interests are a big consideration as these new technologies advance into the market.

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GAS TECHNOLOGY

TANKLESS WATER HEATERS With thermal efficiencies in the mid-nineties, condensing tankless water heaters use a secondary heat exchanger to lower combustion-gas temperatures in the flue, allowing the use of PVC piping, instead of stainless steel, to build vent runs.

by Jason Corey Jason Corey, a five-year veteran of the tankless water heating business, serves as Midwest branch manager for Noritz America, based at the company’s suburban Chicago location. He can be reached at: (866) 766-7489 or e-mail [email protected] 22 applianceDESIGN November 2011

D

espite the worst construction market in memory, the popularity of condensing technology in tankless water heaters has risen steadily in recent years. Once building revives in earnest around the country, even more dramatic growth in this category is anticipated. Greater energy savings have played an important, but still secondary role in the rising profile of condensing tankless water heaters due to their efficiency gains – 10 to 15 percentage points over conventional units. Like their counterparts, all condensing units carry the Energy Star label. But as impressive as these energy savings are, ease of installation remains the main growth driver for this technology. Condensing tankless water heaters use a secondary heat exchanger to boost efficiency by capturing more heat from combustion gases as they escape up the flue. This heatabsorption process in turn cools these gases enough to permit venting with less costly, more installer-friendly PVC piping, rather than Category III stainless steel. PVC venting makes tankless far more attractive for first-time installers, many of whom have never used stainless steel. When I tell attendees at my workshops that they can use PVC, their eyes light up. Virtually every service tech knows PVC inside and out. What’s more, the material requires zero clearance to combustibles. All of which is why, as more and more homeowners request

a tankless replacement for their tank-type water heaters, the path of least resistance will be to go condensing tankless to vent with PVC. Tankless technology has been the preferred method of heating water for domestic use for decades in numerous countries worldwide. Condensing technology hasn’t been around for as long, but it has proven itself equally reliable in numerous applications, residential and commercial. There are still plenty of questions as we delve deeper into the factors behind the popularity gains for condensing technology, its installation, and how to present this technology to your customers, be they home builders, commercial specifiers or consumers. So let’s ask those questions.

How much more does a condensing tankless water heater cost versus a conventional tankless unit? The numbers vary by locale, but on average installing contractors can expect to pay 30 to 40 percent more. However the additional cost to your customer may be in the range of only 15 to 20 percent per installation because you will be using PVC venting at $1.53 per foot right now versus $25 per foot for Category III Stainless Steel. That huge savings in venting costs helps defray the additional equipment cost. www.applianceDESIGN.com

GAS TECHNOLOGY demand system with no hot water storage and no pilot light burning 24/7. When a hotwater appliance, faucet or fixture is turned on, the tankless system senses flow and a spark igniter activates the gas burner. As cold water enters the system, the heat exchanger rapidly raises the temperature of the flow to the designated set point before the water proceeds to its destination. However long the fixture or appliance operates, the tankless unit will meet the demand for water at the set temperature, i.e. “endless hot water.” A condensing unit uses the same sequence of steps to generate hot water, but also incorporates a secondary heat exchanger to capture more heat from the combustion gases before they enter the venting at the top of the flue. This secondary heat exchanger then preheats the incoming water on its way to the primary heat exchanger, increasing the unit’s efficiency.

How much heat does the secondary exchanger absorb? The author shows a condensing tankless water heater with the front cover removed and with the secondary heat exchanger at the top of the unit. A condensing unit incorporates a secondary heat exchanger, located at the top of the water heater, to capture more heat from the combustion gases before they enter the venting at the top of the flue. This secondary heat exchanger then preheats the incoming water on its way to the primary heat exchanger, increasing the unit’s efficiency.

How much more energy will condensing tankless water heaters save over their conventional counterparts? As already noted, the efficiency gain is about 10 to 15 percentage points, maxing out at around 95 percent. That is not as dramatic an improvement as switching from tank to tankless, but it is not insignificant over the estimated 20-year life of the water heater. An efficiency rating in the mid-nineties will make most homeowners sit up and take notice. This is a great selling tactic; if you have a choice between, say, 84 and 95 percent, wouldn’t you opt for the latter in most instances?

Is condensing tankless technology better suited to certain sections of the country? The technology will work equally well everywhere, regardless of weather conditions. But the fact is in warmer climates, tankless water heaters are often mounted www.applianceDESIGN.com

outdoors, eliminating the need for venting. In these cases, the PVC venting advantage is not relevant. If the end user or homeowner is not interested in the additional efficiency, the less-expensive conventional tankless will be the likely choice. After all, tankless is still much more efficient than a traditional tank-type water heater, not to mention all of the space savings because of its wall-mount capability. This why condensing tankless water heaters are more popular in the Midwest, the Northeast and Canada, where water heaters must be installed indoors and the PVC venting advantage is critical. In the Midwest storage tank water heaters are often located in the middle of the basement, so the installer will usually place the tankless replacement in the very same spot, running PVC vent lines up to 25 feet. Being able to extend a vent line that far without worrying about material costs is a huge attraction.

How does a condensing tankless water heater work? Like any tankless water heater, it is an on-

In a conventional tankless unit, the gas temperature at the top of the flue is between 330°F and 360°F. In a condensing unit, the secondary heat exchanger will lower this temperature to around 105°F to 130°F — a major difference without sacrificing hotwater output or water pressure. This reduction is why venting with PVC is permitted.

What happens to the condensate? The process of reducing combustion-gas temperatures necessarily creates condensate in the flue: an acid-water mixture that drips back into the water heater and through the secondary heat exchanger. If that device is made of aluminum or copper, the unit will likely corrode over time, undermining both performance and longevity. A secondary heat exchanger made entirely of stainless steel will not have this corrosion problem, extending the life of the water heater, albeit at a higher unit cost.

Is condensing tankless any more difficult to install than a conventional model? No, and with PVC venting, installation should go more quickly and easily. The installer can build the vent run using fourinch PVC throughout. Or, if the termination point in the wall is three inches and the homeowner does not wish to enlarge it, the installer can reduce the run to that smaller size. applianceDESIGN

November 2011 23

GAS TECHNOLOGY The biggest installation difference is the need to install a condensate line, but this requirement should not add much time or cost to the installation. A condensing tankless model typically has a half-inch port at its base. Following local codes, the installer simply runs a pipe from this port to a nearby drain. Finally, a condensing tankless unit will be slightly larger than a conventional unit with comparable specifications — but not by much. The larger dimensions should not impact handling on the job site, nor will they lessen the inherent space-savings advantage of tankless. A great example is the ability to install a tankless water heater in a crawl space — not exactly an easy proposition for a tanktype water heater.

Will a condensing tankless water heater require a larger gas line? That is a possibility. The typical gas storage water heater offers inputs of 40,000 to 50,000 BTU, while the most popular condensing units are modulating devices that max out at 199,000 BTU. So the installer must be aware of the possible need to upsize the gas line from half-inch to three-quarter inch. That shouldn’t be a negative, because the size of the gas main coming into a dwelling is usually three-quarter inch as well. We tell our trainees that they must be mindful of proper pipe sizing for both the gas supply and the gas draw.

How does a contractor sell his consumer customer on using condensing tankless? The more difficult selling job will likely be switching the customer from tank to tankless. As I tell contractors who attend my training sessions, the first question to ask a homeowner customer is, “Have you ever run out of hot water?” If the answer is yes, you have probably a better-than-50-percent chance of persuading him or her to make the switch. Anyone who has suffered through a cold-water shower never wants to experience that misery again, and tankless provides that reassurance: “Endless hot water” is by far the No. 1 reason a consumer goes tankless. Once the contractor has persuaded the consumer to switch, selling up to a condensing tankless solution should not be difficult. As I noted earlier, using PVC venting lowers installation time and expense, helping to defray the extra cost of a condensing unit. Consumers will happily welcome anything 24 applianceDESIGN November 2011

that gets the installer off the job — and life back to normal — more quickly.

longer need to worry that the water heaters

How does the builder benefit by offering condensing tankless?

water and ruining floors and furnishings.

Like the homeowner, builders appreciate it when plumbers spend less time on the job, but condensing technology offers builders an even bigger plus. They are forever seeking new ways to differentiate their built product from that of their competitors. Condensing technology represents the elite end of the tankless water-heating segment, offering superior energy efficiency for a relatively modest up-charge. This technology can truly help separate them from their competition. Tankless, in general, can also add value to their homes. With the current emphasis on smaller floor plans, builders look to tankless for better space utilization, and not just because of its smaller footprint. Basements and other utility areas can be turned into active living spaces, because homeowners no

will malfunction, spilling 40 or 50 gallons of

What is the near-term outlook for condensing tankless technology? The ability to use PVC venting is a genuine game-changer for the tankless water heating business. As the building industry emerges from the recession and housing begins to rebound, tankless water heater sales are bound to increase. This will be tempered somewhat by projections of slower housing growth in colder climate regions that make up the tankless wheelhouse. Much of this growth will derive from condensing technology, as a critical mass of installers discover for themselves how easy it is to install a condensing tankless water heater with PVC venting.

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DISPLAYS & INTERFACES

2003

2000

IT’S THE FUTURE, SO W It’s almost 2012, so where’s the cool new gadgetry? We look back at some technologies that eight to ten years ago seemed just over the horizon.

S

teven Spielberg’s Back to the Future Part II (1989) treated viewers to a 2015 with flying cars, hoverboards, power shoelaces and the abolishment of all lawyers. The future also featured such impossibilities as split-screen TVs, video conferencing, online credit card transactions, and a major league baseball team in Miami (further stretching credulity, the Cubs win the World Series). We’ve made some of our own predictions at appliance DESIGN along the way. Even in the last decade, technologies that seemed just a few years away were expected to be ubiquitous in appliances by now. Others in their infancy 10 years ago are now part of every interface. Let’s look back at a few of these technologies discussed in the pages of AD, and how far they’ve come.

Plastic/Flexible Displays

by seth m. fisher Seth is the Chief Editor of appliance DESIGN, having joined the team in July 2011. Previously he was Associate Editor and Publisher of Pollution Engineering magazine, since 2003. 26 applianceDESIGN November 2011

Then: In 2003 Viztec Inc. of Twinsburg, Ohio, announced their plastic LCD wristwatches would be available by 2004, with cell phone applications soon to follow. The company was founded in 1998 with the goal of commercializing technology developed at the Liquid Crystal Institute at Kent State University. By May 2004, ultra-thin, lightweight, large-area displays flexible enough to be rolled up were “much closer to becoming commercially feasible,” according to researchers at Philips Electronics in The

Netherlands. The researchers, based in Eindhoven, announced they were already routinely producing prototypes of such displays using inexpensive materials and were only a few years away from going into mass production. Applications such as electronic books and magazines, and other portable electronic products with collapsible displays were expected to be all the rage by 2011. For existing portable applications, the technology could provide lighter and much more rugged displays. The 2003 prototype was an organicbased, QVGA (320 x 240 pixels) activematrix, 5-in. diagonal, grayscale display with a resolution of 85 dpi and a bending radius of 2 cm. The display combined a 25-micron thick, active-matrix back plane with a 200-micron front plane of reflective “electronic ink” developed by E-Ink Corp., Cambridge, Mass. In the last quarter of 2001, Cambridge Display Technology (CDT), a company that sprang out of Cambridge University research, signed strategic collaboration agreements with both Dow Chemical and DuPont Displays to accelerate the commercialization of light-emitting polymer (LEP) displays. Also called organic LEDs, polymer LEDs or PolyLEDs, LEPs use polymers as their semiconductor material. The displays promised thinner, lighter and more www.applianceDESIGN.com

DISPLAYS & INTERFACES

2005

WHERE’S THE FUTURE? power-efficient displays than LCDs, with brighter, richer colors and sharper resolution. Because they’re emissive, they would need no backlighting, and be viewable from all angles. In liquid form, LEPs can ink-jet printed onto various substrates, offering the potential for low-cost, highvolume production. Being able to print to plastic would permit the design of displays with nonplanar form factors and possibly unique shapes. Now: Stress on the flexible substrate while bending and thermal expansion are still holding back PolyLED technology, however electronic ink has become the key component of reading devices like the Amazon Kindle and in digital signage. According to Robert L. Mitchell of Computerworld, “It’s not the display media that are keeping flexible displays off the market. Instead, the delay is caused largely by manufacturing issues, including how to affix thin film transistor arrays to a flexible substrate and how to produce the displays at large volumes cost effectively.” Despite the cool factor being way high, the practical application is wanting. The appliance industry has been slower to incorporate digital paper technologies because there’s little need for them—consumers for the most part are happy with other display technologies and OEM designers haven’t been able to justify a cost hike for a radical new look. Also the high www.applianceDESIGN.com

heat involved in depositing non-carbon elements makes it hard to meld the displays to plastic. Consumers and producers are used to making non-flexible products. Ironically the outlook for flexible displays is to affix them to a back-plate. Glass does make a good substrate. LEPs are used in all sorts of appliances, from small devices to portable electronics, however in monochrome. Philips spent a

hailed as the first commercial products on the market that utilize SoundVu technology developed by NXT plc, of London. NXT released a prototype mobile phone with the speaker technology in late 2001, but the NEC partnership was expected to help launch the new concept. In this application, the acrylic protection screen of the LCD monitor was employed as a sound emitter by means of manipulation

“Philips spent a few years trying to finish and popularize the technology, then sold off its polyLED subsidiary in 2005.”

few years trying to finish and popularize the technology, then sold off its polyLED subsidiary in 2005. Polymers are considered the next phase of multicolor flat-screen displays but are a bit hung up on how to power them without massively complicated fabrication. Self-assembled nanowires may hold the key to unlocking the next generation.

Talking Screens Then: In 2002, NEC, Tokyo, introduced two integrated computers whose LCD monitors serve as speakers. The NEC Valuestar T and the Valuestar FS were

of exciters at the edges of the screen. NXT said the method could be used for any type of flat screen product, from mobile phones to flat-screen televisions. Now: “Valuestar” is now better known as a Canadian version of Groupon, but NEC has been using the name for its line of allin-one PCs for personal entertainment (which use regular speakers). Emo Labs at DEMO 2009 revealed a similar technology they call “Edge Motion.” The speakers are actually thin membranes. Meanwhile NXT has incorporated their flat panel loudspeakers into their HiWave applianceDESIGN

November 2011 27

DISPLAYS & INTERFACES

Future?

2010 Direct sound feedback from touch sensors equipped with NXT’s HIHX14C exciters could be the answer for consumers who feel like they’re texting with two left feet.

haptic touch and audio exciters for touch panels and screens. A pair of HIHX14C exciters disperses bending waves evenly across the surface of touch panels so that users experience the effect of depressing mechanical keys when touching the panel surface. According to the company the simulated mechanical movement enhances the human interface enabling faster and more accurate keystrokes. The same transducers simultaneously convert the touch screens into flat panel loudspeakers with nominally flat response from 200Hz to 15kHz. The exciters are designed for use with touch screens up to 19 inches and include a 14mm diameter voice coil mounted on plastic suspension.

The Connected Kitchen Then: It’s 6:00 p.m., you’re about to leave the office, and you promised your spouse that you’d have dinner ready by 6:30. So you load up your kitchen application, and tell your oven at home to get cooking. Immediately it converts from its daytime job as a refrigerator and goes into bake mode. If you get caught in traffic, no worries, you’ve got it set to go to “warm” mode as soon as the timer’s up. One of the big attractions at the 2005 Consumer Electronics Show was the ConnectIo Intelligent Oven, developed by TMIO of Cleveland, Ohio. The oven received two separate Innovations Design 28 applianceDESIGN November 2011

and Engineering Awards from the Consumer Electronics Association, the show’s sponsor. The oven had a refrigeration mode to keep food fresh until it was ready to be cooked. Second, it had an interconnectivity feature to permit “remote control by a cell phone, computer, or PDA.” The big hang-up for such a device was to have a home display module that could withstand being attached to a refrigerator that suddenly becomes an oven at about

floor model, but few kitchens ever caught on to that level of plugged in. However the Internet oven-fridge is projected to make a comeback because of smart grid technology. The same touch-screen system developed for the ConnectIo is currently undergoing a bit of a refit to serve as part of a full powercontrol system. Presumably the smart grid interfaces will also allow consumers to manage other parts of their systems. Mp3 players, video conferencing, and soft

“The big hang-up for such a device was to have a home display module that could withstand being attached to a refrigerator that suddenly becomes an oven.”

the time the end user is leaving the office. It would also need to withstand messy chef fingers and be useable through an oven mitt. 3M Touch Systems provided control panels that fit the bill. The ClearTek 6.5-inch capacitive touch screen used was remarkably robust against temperature variations, scratches and cleaning solvents. The system was digitally connected to the Internet so that users could manipulate their home screens using the company’s website. The touch screen kitchen was born. Now: Surely by now there must be an app for that? Consumers loved to play with the

phones are also being implemented into what must now be called a mini-computer more than a touch interface with features. Rather than a cell or digital signal, the appliances are expected to use the home WiFi signal. The high cost of such systems is keeping them out of the wider consumer market, but Internet refrigerators connected to wireless apps are available, as are Internet ovens, Internet washing machines (you get a text message when your load is completed), and Internet bathroom scales, so you can automatically plug your weight data into a spreadsheet. www.applianceDESIGN.com

NEW PRODUCTS Genteq, a division of Regal Beloit Corp. Texas Instruments

GlobTek

TI is getting into the smart grid biz, announcing four new system solutions for Smart Grid and metering applications. The company introduced the new PLC Development Kit (TMDSPLCKIT-V3) that recently received PRIME certification. Coupling the TMS320F2806x Piccol floating-point microcontroller and new AFE031 analog front end (AFE), the kit analog and digital systems. Visit www.ti.com/grid-plc-lp

The GT-41135 series of wall plug-in power supplies with interchangeable blades include plugs for North America, Europe, U.K., Australia, China, Korea Class II, S. Africa, Argentina, and IEC Inlet available in single blade installation or sold as a kit. The plugs feature double-enforced insulation mechanical configurations, and regulated output voltages from 5 to 48Vdc in 0.1V increments, up to 12W of continuous output power. Style enclosed power supplies are housed in an impact-resistant, non-vented polycarbonate case, with thermal conduction cooling. Case dimensions: 43.5mm x 74mm x 35.3mm. Visit www.globtek.com

The Eon 42 motor is a variable speed, constant torque motor designed for direct drive blower applications such as fan coils, kitchen ventilators, air curtains and unit heaters/coolers. The energy efficient motor has a fair range of horsepowers (1/15 hp, 1/8 hp and ¼ hp), voltages and mechanical features, and is relatively easy to install. The company has added a fully potted single control board, additional transient protection (6kV), improved I/O protection and its proprietary BlakBox onboard memory. The latter feature provides substantial built-in performance monitoring. Visit www.thedealertoolbox.com.

CTI Electronics

Control Company

Thomas, a Gardner Denver Company

It’s a clipboard calculator for HVAC and refrigeration professionals. The company’s clipboard/calculator includes its proprietary Traceable timer, an attached pen holder, and a hole in the back that allows the unit to be hung on the wall. An eight-digit, solar-powered calculator can handle most routine lab calculations: add, subtract, multiply, divide, chain calculation, constants, powers, reciprocal values, percent calculations, square root, and memory. Another version of the clipboard replaces the timer with a retractable tape measure. Visit www.control3.com

Many new innovative pumps and compressors have been added to the Thomas Global Catalog. This release features updated specification and performance data on hundreds of WOB-L, articulated piston, diaphragm, rotary and linear oil-less air compressors/vacuum pumps. Liquid pump technologies include peristaltic, linear and diaphragm. Detailed technology & model series selection guides assist users in quickly identifying the optimal solution. To view or download a copy of the Thomas Global Catalog. Visit www.gd-thomas.com

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The KIF6000-Bx Backlit Series, introduced in July, is a line of compact illuminated keyboards that include the company’s original Industrial Mouse pointer. The industrial grade keyboard provides water tight NEMA 4 (IP66) sealing and was designed for mobile applications. They have a small footprint, 101/104 key functionality, and a high-precision pointing device, all with protection against vibration and/or EMI/ RFI signals. U.S. English (QWERTY) is standard, but most W. European languages (Gm., Fr., It., Sp., Pg.) are also available upon request. Visit www.ctielectronics.com

Airpot The Airpel Plus line of low-friction air cylinder actuators can execute extremely precise movements, including high speeds and extremely short travel distances. The inert qualities and tight tolerances of the glass and graphite mateapplianceDESIGN November 2011 29

NEW PRODUCTS rials used allow engineers to develop systems that will move, hold, or press accurately and with near perfect repeatability. It uses the company’s borosilicate glass cylinder and graphite piston technology, but adapted the piston configuration from their frictionless Airpel-AB Air Bearing Actuators. Visit www.airpot.com

340-page book may be ordered under ordering code EPC:62018-7600 at www.epcos.com/publications

Tharo Systems OSRAM Opto Semiconductors ZMDI The Dresden company is entering the smart power management industry, launching a configurable, true-digital, high-performance PWM controller for non-isolated DC/DC POL supplies. The ZSPM1000 and ZSPM 9000 are the first of the company’s planned line of small, fully configurable POL solutions. The ZSPM1000 operates as synchronous step-down converter in a single-rail and single-phase configuration. In combination with the ZSPM9000, the company’s compact MOSFET with integrated power-stage driver, the ZSPM1000 enables smart digital POL solutions for area constraint and high-performance applications. Visit www.zmdi.com

A new LED in a compact package doubles brightness for projection applications. The OSTAR Compact 2x2 uses one set of red, converted green and blue LEDs, and can thus achieve a luminous flux of 400 lm from the projector. The new version has been designed specifically for imager diagonals between 0.4 inches and 0.55 inches. If multiple sets of these LEDs are combined for larger imager diagonals, the high brightness levels needed for office projector applications can be achieved. With dimensions of 5.8mm x 4.6mm nd an output of 85 lm per mm² of footprint, it is a very bright LED for its package class. Visit www.osram-os.com

The latest version of the company’s EasyLabel 5 software includes XML (Extensible Markup Language) support for Oracle enterprise management systems. The program’s XML Monitor will watch a file directory or TCP/ IP port and will automatically print RFID or bar code labels when a compatible XML file is received. This feature provides a direct connection to Oracle or any other application capable of generating a properly formatted XML file. It will make printing RFID or bar code labels from the supply chain or manufacturing software seamless. A complimentary trial edition is available for download www.tharo.com

\

Douglas Electrical Components JTAG Technologies

TDK-EPC The company has published its comprehensive EPCOS Data Book for SIOV Metal Oxide Varistors, 2011 edition. The book presents a range of ThermoFuse (ETFV) and FailSafe varistors (SFS) along with block and strap varistors. New additions include several varistor types with extended voltage ranges. The 30 applianceDESIGN November 2011

The new JTAG/boundary-scan hardware interface is compatible with the MAC-Panel ‘Scout’ mass interconnect system. The JT 2147/DAK is a signal conditioning module that allows seamless connections from JTAG Technologies PXI DataBlaster to the Scout’s connection system. Based on the company’s QuadPod architecture the JT 2147/DAK was designed in the MAC Panel ‘Direct Access Kit’ (DAK) form factor. Visit www.jtag.com

The company has developed back-potted epoxy hermetic seals as an alternative to ceramic or glass seals. The back-potted epoxy seals provide a fully harnessed pressure and vacuum sealing solution that can be customized. Design engineers can specify from a range of commonly available plastic and metal connectors, from jam-nut and o-ring to wall mount, radial o-ring and others including the accommodation of fiber optic connectors and cables. Visit www.douglaselectrical.com Q www.applianceDESIGN.com

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ASSOCIATION REPORT: AHAM

Be Aware of State Legislation Joseph M. McGuire President Association of Home Appliance Manufacturers

ompanies most often keep their finger on the pulse of Washington, D.C., for insight into legislation and regulation that may be become law and impact their business. While the focus on Washington should remain sharp, companies should not neglect the potential of state agencies and legislatures to quickly enact laws, many times without the benefit of technical justification. AHAM has amped up its presence in the states to counter unproductive and harmful state legislation that impacts the home appliance industry and to encourage measures which would promote and provide consumer rebates, tax credits and holidays for the purchase of efficient products. In the past year alone, AHAM met with 24 state agencies, and monitored approximately 160 bills that held the potential to affect AHAM products. AHAM took action on 18 bills that would have negatively impacted the industry in 2011. Of these, we effectively influenced 17 bills in AHAM’s favor or stopped them altogether. AHAM’s work in the states resulted in the avoidance of regulations that could have cost home appliance manufacturing companies and consumers $800 million in negative product impacts in 2011. In six states, AHAM worked for the global standard de minimis thresholds of 0.1 percent for decabrominated diphenyl ether (DecaBDE) to be found within consumer products. In Maryland, AHAM was successful in its efforts to pass emergency legislation this year allowing the de minimis amount allowance of this substance that was originally banned 100 percent in 2010. Multiple states took up bills related to Extended Producer Responsibility (EPR), the term describing mandatory product recycling requirements. The goals of such bills vary, including efforts to deal with landfill overcrowding or other environmental causes. AHAM’s perspective is that proposed “solutions” don’t increase costs unnecessarily and create additional problems. Often these bills roll through committees, picking up support, strength and speed along the way without a full vetting of the bills’ impacts. Many of the bills may die in committee, and others may be deferred to future legislative sessions, but all must be monitored closely as they each have the potential to place unnecessary burden on the

C

32 applianceDESIGN November 2011

industry and increase cost to the consumer. In the case of EPR, it is AHAM’s responsibility to educate public officials about the major appliance industry’s over 90-percent recycling rate. Many policymakers are unaware of the very effective solid waste management system in place in the United States for the proper recycling of major home appliances. And portable appliances do not contain the materials which have been the focus of previous state efforts aimed at consumer electronics. Many times proponents argue that municipalities should shift this cost and responsibility to product producers, but they do not include in their proposal a corresponding reduction in a consumer’s sanitation bill. Examples of these bills include a pending and aggressive Massachusetts bill that would create an EPR framework and commission to oversee its efforts. Fortunately, AHAM has had the opportunity to provide insight directly to Massachusetts legislators about the measure’s ramifications; we are waiting for a satisfactory outcome. Bills were considered, but did not become law, in Nebraska and New York. Connecticut and Nevada considered bills which would have created a framework to establish authority for energy efficiency standards for appliances. Both state bills exempted major appliances which are already covered by federal standards (although CT did include regulation for commercial clothes washers), but left the door open for portable and floor care products to be included. AHAM traveled to both states to oppose these measures and stop a patchwork of 50 state standards for manufacturers that would drive up the cost of appliances to consumers. Nevada’s bill was defeated by a narrow full Senate vote. AHAM’s next focus in Connecticut will be to positively influence regulations that come from the enacted legislation. Each year AHAM attends several state legislative conferences which scope out “model legislation” for the coming legislative sessions. These model bills essentially provide the states with template language that can be adjusted to match individual state needs. AHAM attends these sessions as opportunities to educate and advocate industry’s positions directly with legislators. AHAM can say with certainty that EPR and material/chemical bans will be a focus for several years to come. www.applianceDESIGN.com

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