Appliance Design February 2012

February 2012

REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

RUNNING INTERFERENCE ON

ELECTROMAGNETIC INTERFERENCE INSIDE 12 Shielding & EMI

t! om n E E ve XPO.c R F al E ture c 2, 2012 rtu anufa May i Details on V

18 Joining 22 Controls & Sensors 24 Connectors & Cords

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page 29.

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CONTENTS FEBRUARY 2012 volume 60, no. 2 REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

DEPARTMENTS

18

2 Editorial: Add It to the Cloud 3 Shipments/Forecasts 4 News Watch 11 Design Marts

24

26 New Products 33 Advertiser’s Index

FEATURES SHIELDING & EMI/RFI

RUNNING INTERFERENCE ON

ELECTROMAGNETIC INTERFERENCE appliance DESIGN ONLINE

12 Running Interference on Electromagnetic Interference is an in-depth discussion on the physics of EMI and how this can create havoc for design engineers. The article the discusses seven common pitfalls when dealing with EMI, and how to avoid or handle them.

JOINING 18 The Best Fastener May Be No Fastener. Meet hard polypropylene, a fabrication material for interior elements of appliances that can revolutionize how products are designed. Are these resins ready to warrant a radical shift in fastening across a pantheon of products? It depends.

WEB EXTRAS WEB EXTRAS

It’s a Mobile World Welcome to the growing world of mobility where people want to manage and control their home and apartment systems remotely, conveniently, easily through iPhones, iPads, Droids, laptops, desktops. Meet the ‘Justifier’ – Home Energy Management and Control Electronic home system contractors and utility observers believe that architectures which enable innovation and efficiency must include consumer-controlled energy controls and networks. Such approaches generate benefits from dynamic pricing and energy information derived from smart meter data, Web-enabled thermostats, in-home displays and other devices. Wiring Battle: Homeowners Want Easy Connections; Installers Value Easy Wireless Electronic system contractors who sell, install, and maintain a diversity of home systems say that today – and into the near future, there will be a blending of wired and wireless inside of homes and among appliances, subsystems, control panels, and mobile smartphones.

CONTROLS & SENSORS 22 Hermetic Feedthroughs for Magnetic Bearing Technology is a discussion of advancements in hermetic seals, and how modern epoxies have allowed these essential parts for controlling high-speed magnetic bearing systems to develop.

CONNECTORS & CORDS 24 A New Bronze Age for Custom Contacts is a case study of a small-outfit Utah digital sign manufacturer tasked with building a massive LED board that would stand out among the casino mecca of the Nevada casino landscape. A four-slide stamping/cutting process helped create inexpensive custom contacts out of bronze.

COVER

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A cover on a cover—typical shielding application for electronics. applianceDESIGN February 2012 1

EDITORIAL ®

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Add It to the Cloud

J

ust before last Christmas, Parks Associates published a report that suggested the reborn 3D fad was on its way out again, but that consumer demand for wireless-enabled HDTVs was rising. Somewhere there’s an executive at Comcast or Warner who is astonished that viewers would want to watch the stuff on their computers on their TVs, but otherwise there’s a grand total of zero people in the consumer electronics industry surprised. The implication of this rising demand is unsettling for many in the industry who provide overlapping devices. Cable boxes are the obvious endangered species. Overthe-Internet providers from Apple TV to Hulu to Netflix follow an a la carte model that cable providers have long resisted, but without a means of streaming to the TV consumers have been slow to switch. I believe 2011 was the opening salvos of war between these factions, and this is evidenced in the buildup of Over-IP war machines. The last generation of videogame systems—Xbox 360, Wii, PS3—came wireless-enabled and now serve as Netflix players as or more often than game systems. The early IP cable box Roku* tripled its sales in 2011. Happily, illegal downloading of movies in 2011 decreased for the first time since this was tracked, which website TorrentFreak attributed to the spread of legal alternatives. This is a trend: devices that connect a television to the Internet, priced from $60 to $600, are selling like bananas because users have figured out their cable provider isn’t the only pipeline to the content they want to watch.† This all leads to the question of 2012:

if TV over IP is inevitable, which device is going to bring it? Considering the size of the electronics we’re talking about here, it’s got to be the televisions, right? The sea change to HDTV brought about an echo boom in living room electronics. But if/ when TVs connect to the Internet out of the box, it could bring about a sobering moment for the intermediary device industry now ably filling that niche. WirelessHD (or Wi-Di) was the hot topic around last month’s International Consumer Electronics Show. The G.hn protocol standard promoted by the ITU-T and the HomeGrid Forum will provide the means to make this happen. The light at the end of the tunnel, however, is that a TV with built-in wireless can also connect to any other device on the network. This could be just what the flagging desktop computer industry is waiting for to have its destiny restored as the home’s core device. And with that comes the opportunity for all sorts of appliances to be reintegrated into a centralized home system, with the TV the centerpiece display for completely integrated homes. Dollars to donuts none of it is in 3D. 

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 Lindsay Nagy Production Manager

[email protected] (248) 244-6438 [email protected]

MaTT Britcher Art Director

(480) 334-0286 [email protected]

circulation Hayat Ali-Ghoneim Audience Development Specialist

(248) 250-3096 Alih@bnpmedia

Alison Illes Multimedia Specialist

(248) 244-1730 [email protected]

Catherine M. Ronan Corporate Audience Audit Manager

(248) 244-8259 [email protected]

Kevin Collopy Sr. Account Manager

(800) 223-2194 x684 [email protected]

Shawn Kingston Account Manager

(800) 223-2194 x684 [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

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

John Davis

Business Development Manager, Traulsen

Kevin Henry

* Whoever the design engineer was who thought to put the little fabric tabs on everything—and I know you’re out there—I would like to shake your hand. † Actually for most consumers it still is, but that’s because their cable provider is usually their ISP.

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 2012, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: APPLIANCE DESIGN, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to APPLIANCE DESIGN, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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FORECASTS

SHIPMENTS

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

2011 2024.0 1861.7 1725.9 1959.1

2012 2054.4 1956.6 1820.8 2033.5

2013 2132.4 2048.6 1890.0 2125.0

For 2011, a 5.4% decline to 7.571 million units For 2012, a 3.9% increase to 7.865 million units For 2013, a 4.2% increase to 8.196 million units

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

2011 1609.7 1519.9 1389.6 1605.5

2012 1588.8 1577.7 1452.1 1671.3

2013 1641.2 1636.0 1492.8 1723.1

For 2011, a 6.5% decline to 6.124 million units For 2012, a 2.7% increase to 6.290 million units For 2013, a 3.2% increase to 6.493 million units

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

2011 437.5 509.3 527.1 496.3

2012 455.4 528.7 542.4 511.1

2013 460.4 537.6 554.3 525.5

For 2011, a 0.6% increase to 1.970 million units For 2012, a 3.4% increase to 2.038 million units For 2013, a 2.0% increase to 2.078 million units

Product

November-11 November-10

%Chg 5 Mo. 2011 5 Mo. 2010

%Chg

MAJOR APPLIANCES (Thousands of Units) Total

4,069.70

4,504.20

-9.60%

56,083.50

56,553.10

-0.80%

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

1,307.30 356.3 283.9 47.9 24.4 214.9 187.3 3.7 23.9 736.1

1,435.20 372.3 296.3 50.7 25.3 248.8 219.8 4.7 24.3 814.1

-8.90% -4.30% -4.20% -5.40% -3.60% -13.60% -14.80% -20.80% -1.70% -9.60%

14,863.20 3,868.20 3,065.10 512.9 290.1 2,338.50 2,034.20 34.3 270 8,656.60

15,015.50 4,018.90 3,168.10 546.6 304.3 2,510.00 2,183.40 38.7 288 8,486.50

-1.00% -3.80% -3.20% -6.20% -4.70% -6.80% -6.80% -11.30% -6.30% 2.00%

HOME LAUNDRY - TOTAL AUTOMATIC WASHERS DRYERS - TOTAL Electric Gas

1,102.70 607.4 495.2 392.8 102.4

1,318.60 693.6 625.1 503.3 121.7

-16.40% -12.40% -20.80% -22.00% -15.90%

12,342.40 6,830.60 5,511.80 4,416.10 1,095.70

13,256.10 7,273.80 5,982.30 4,807.50 1,174.80

-6.90% -6.10% -7.90% -8.10% -6.70%

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

853.5 419.7 431.2 426.9 4.4 2.6

812.9 361.8 447.7 442.8 4.9 3.4

5.00% 16.00% -3.70% -3.60% -11.60% -24.70%

10,010.90 4,973.00 5,002.00 4,945.30 56.7 35.9

10,032.70 4,831.50 5,161.80 5,104.00 57.7 39.5

-0.20% 2.90% -3.10% -3.10% -1.80% -9.00%

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

758.8 618 140.8 91.8 49

862.8 697.8 165 91.5 73.5

-12.00% -11.40% -14.60% 0.40% -33.30%

10,050.40 8,240.30 1,810.10 1,082.90 727.1

10,450.80 8,662.90 1,787.90 1,037.10 750.7

-3.80% -4.90% 1.20% 4.40% -3.10%

47.4 15.2 32.2

74.8 56 18.7

-36.60% -72.80% 71.60%

8,816.50 7,483.50 1,333.00

7,798.00 6,280.90 1,517.10

13.10% 19.10% -12.10%

HOME COMFORT - TOTAL ROOM AIR CONDITIONERS DEHUMIDIFIERS

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.

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

2011 659.1 602.9 645.0 728.6

2012 676.9 634.3 673.4 772.3

2013 690.4 664.7 697.6 800.1

For 2011, a 5.5% decline to 2.636 million units For 2012, a 4.6% increase to 2.757 million units For 2013, a 3.5% increase to 2.853 million units

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

2011 506.0 475.7 590.1 724.0

2012 517.1 490.4 617.3 754.4

2013 529.5 508.1 635.2 774.8

For 2011, a 6.4% decline to 2.296 million units For 2012, a 3.6% increase to 2.379 million units For 2013, a 2.9% increase to 2.448 million units

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

2011 349.8 553.3 343.2 118.4

2012 404.0 604.8 367.2 121.4

2013 418.2 635.0 380.1 127.4

For 2011, a 12.1% decline to 1.365 million units For 2012, a 9.7% increase to 1.497 million units For 2013, a 4.2% increase to 1.561 million units Note: All forecasts begin in Q4/2011 Data Source: AHAM Forecast Source: Delano Data Insights

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applianceDESIGN February 2012 3

NEWS WATCH

EPA Approves Oils as Refrigerant Substitutes hree coolants, including propane and butane, to replace CFCs and HCFCs have been approved by the Environmental Protection Agency after much prodding from industry and scientists who said the oil-based substitutes are known to be safe. The EPA on Wednesday, Dec. 15, added three hydrocarbons as acceptable alternatives in household and small commercial refrigerators and freezers. The agency took action after requests from Ben and Jerry’s and General Electric, as well as A.S. Trust & Holdings, and True Manufacturing, a familyowned small business. In a press release the EPA noted these businesses are “helping to clear the way for U.S. companies to use ozone layer-protective hydrocarbon refrigerants.” The three hydrocarbon refrigerants approved as acceptable substitutes, with use conditions, are propane, isobutane, and a chemical known as R-441A. These newly-approved refrigerants can be used to replace ozone-depleting chlorofluorocarbon (CFC)-12 and hydrochlorofluorocarbon (HCFC)-22 in household refrigerators, freezers, combination refrigerator-freezers,

T

LCD INVENTORS WIN TOP ENGINEERING AWARD

The inventors of the liquid crystal display (LCD) will be presented with what many consider the “Nobel Prize of engineering” during a Feb. 21 ceremony in Washington. The National Academy of Engineering (NAE) will honor T. Peter Brody, George H. Heilmeier, Wolfgang Helfrich, and Martin Schadt with the 2012 Charles Stark Draper Prize, which annually recognizes engineers whose accomplishments have significantly benefited society. The prize includes a $500,000 award. According to IEEE, the history of the liquid crystal display dates back to 1968, when a team of engineers and scientists led by George H. Heilmeier devised a method for electronic control of light reflected from liquid crystals and demonstrated the first liquid crystal display. Heilmeier’s work led to the development of the first commercial LCDs used in calculators, watches, and instrumentation. 4 applianceDESIGN February 2012

and commercial stand-alone units. The decision was made under the EPA’s Significant New Alternatives Policy (SNAP) program, which evaluates substitute chemicals and technologies for ozonedepleting substances (ODSs). At the recent 23rd Meeting of the Montreal Protocol Parties, EPA and the U.S. Department of State announced that 108 countries signed a declaration to address hydrofluorocarbons (HFCs). While HFCs are ODS substitutes, they are increasingly contributing to climate change. The approval of hydrocarbons in the U.S. is significant because hydrocarbons are more environmentally friendly substitutes than HFCs. 

Today, it is hard to find a consumer electronics product, medical device, or premium major appliance that doesn’t use the technology. In 2011, more than 206 million LCD TVs were shipped globally, according to market research firm Display Search. “The engineers we are honoring have created windows through which people are learning about and shaping our world,” said NAE President Charles M. Vest. “The LCD is the human interface with much of today’s technology and information.” Draper Laboratory established the engineering prize in 1988 to honor its founder, “Doc” Draper, who is known as the “father of inertial navigation.” The Draper Prize, which is administered by the NAE, is also intended to increase public understanding of the contributions of engineering and technology.

SEARS TO CLOSE STORES, PRICE PRESSURES INCREASE

Sears Holding Corporation, one of the largest appliance retailers, caused quite a

stir last month with its decision to close up to 120 Sears and Kmart stores. In a post-holiday update, the retailer noted that sales were down at both Sears Domestic and Kmart locations. The retailer blamed decreased sales at its Domestic stores on the consumer electronics and home appliance categories, with more than half of the decline occurring in consumer electronics.

Kmart’s decline in quarter-to-date comparable store sales was due to decreases in the consumer electronics category, as well as lower apparel and layaway sales. The combination of lower sales and continued margin pressure -- coupled with expense increases -- led the appliance retailer to decrease its Adjusted EBITDA and, more importantly, announce actions that included closing 100 to 120 of its stores. www.applianceDESIGN.com

NEWS WATCH “Given our performance and the difficult economic environment, especially for big-ticket items, we intend to implement a series of actions to reduce ongoing expenses, adjust our asset base, and accelerate the transformation of our business model,” CEO Lou D’Ambrosio said in a press release. “These actions will better enable us to focus our investments on serving our customers and members through integrated retail – at the store, online and in the home.” The retailer expects the store closures to generate $140 to $170 million of cash after selling off the net inventory in these stores. Sears also plans to get additional revenue from selling and subleasing the properties. It also plans to carefully evaluate store performance going forward. Final determination of the stores to be closed has not yet been made. According to Reuters, news of the closures plummeted the retailers’ shares to their lowest level in three years. Whirlpool Corp., which makes the retailer’s well-

known Kenmore brand, also saw shares decline following the December 27 announcement. However, a report from the Detroit Free Press stated that Whirlpool shares were slightly up in mid-morning trading on December 28. Mike Deneen, an analyst with Freedonia Group, believes the Sears announcement may have bigger indications for the appliance industry. “The fact that Sears downscaled gives more pricing leverage to the big home centers like Lowe’s and Home Depot, which makes things tougher on manufacturers,” Deneen told Appliance DESIGN. With more than 2,000 Kmart and Sears locations, Deneen said 120 closings certainly isn’t “catastrophic,” but he does believe “it’s a bad sign.” Deneen feels that the Sears announcement shows that pricing pressures will only continue to plague appliance manufacturers, unless consumers decide to invest in the emerging smart appliance category. “But, unfortunately, that hasn’t

happened on any wide-scale range yet,” Deneen said.

GLOBAL COMPETITION SEEKS MOST ENERGY EFFICIENT TVS

The Super-efficient Equipment and Appliance Deployment (SEAD) Initiative announced its first SEAD Global Efficiency Medal competition, a global competition created to encourage the production and sale of more energy-efficient electronics and appliances. The first competition, which will start next month, will focus on flat-panel televisions. SEAD is an initiative of the Clean Energy Ministerial (CEM), a high-level global

Richco offers an extensive array of engineered plastic component solutions to meet the functional demands of today’s appliances. From high temperature to sub-zero environments, Richco product solutions optimize overall product performance and efficiency: t Wire & Harness Cable Ties & Clamps t Leveling/Mounting Feet t Custom Fan & Motor Mounting t Protective Grommets & Bushings t Panel Fasteners/Plastic Rivets t Door Bumpers Locking Circuit Board Support

Samples shipped within 24 hours upon request via website or at 1-800-621-1892. For more information and to download 3D models from the Richco website visit www.richco-inc.com/appliance

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applianceDESIGN February 2012 5

NEWS WATCH forum launched by the U.S. Department of Energy (DOE) and other leading governments in July 2010 to advance clean energy technology. Television manufacturers will compete against one another in three television size categories (small, medium and large) in four regions of the world (Australia, the European Union, India, and North America). Products that demonstrate the greatest energy efficiency will be awarded The SEAD Global Efficiency Medal as well as a winning logo that can be on consumer packaging. “The SEAD Global Efficiency Medal awards will help identify the most efficient products on the market, making it easier for consumers in the United States and around the world to reduce energy waste and energy bills,” said Energy Secretary Steven Chu. The timing is good for U.S. manufacturers, which may be gearing up for Energy Star’s more stringent Version 5.0 television specification. The new requirement, which goes into effect in May 2012, calls for a 65 percent power-consumption improvement over Version 3.0 spec and applies the same requirements to all TVs larger than 50 inches. Manufacturers and resellers of commercially available flat-panel television products are eligible to participate in the competition. Products not yet commercially available can also be entered, but will be judged as emerging technologies. Product nominations will be accepted from February 1, 2012 through May 31, 2012. Prospective winners will be required to provide samples of each entry to verify energy efficiency claims, which will be conducted by sponsoring governments based on the televisions’ power consumption per screen area. Winners will be announced this fall, with an international awards ceremony to be held in early 2013. According to the Chicago Tribune, SEAD hopes to hold similar contests for other appliance categories in the future. It is also working to help developing nations come up with appliance standards. For more information, manufacturers can visit the SEAD website at superefficient.org. 6 applianceDESIGN February 2012

MEETINGS THE NAFEM SHOW Feb 10-13, 2012, San Antonio Website: www.nafem.org/educationcertification/annualmeeting.aspx PACIFIC DESIGN & MANUFACTURING/MD&M WEST/ AEROCON ANAHEIM Feb 14-16, 2012, Anaheim, Calif. Website: www.pacdesignshow.com, www.mdmwest.com POWERTEST 2012 Feb 27-1, 2012, Forth Worth, Texas Website: www.powertest.org APEX EXPO 2012 Feb 28-1, 2012, San Diego Website: www.ipcapexexpo.org THE FABRICATOR’S LEADERSHIP SUMMIT: 7TH ANNUAL METAL MATTERS Feb 29-2, 2012, Scottsdale, Ariz. Website: www.fmanet.org/training/ conferences.cfm HEARTH, PATIO & BARBECUE EXPO 2012 Mar 1-3, 2012, Atlanta Website: www.hpbexpo.com

INTERNATIONAL HARDWARE FAIR Mar 4-7, 2012, Cologne, Germany Website: www.eisenwarenmesse.com EXPO MANUFACTURA Mar 6-8, 2012, Monterrey, N.L., Mexico Website: www.expomanufactura.com. mx/2012/02informacion12.html 2012 INTERNATIONAL HOME + HOUSEWARES SHOW Mar 10-13, 2012, Chicago Website: www.housewares.org/show/ info/future.aspx HIGH PERFORMANCE BUILDINGS CONFERENCE Mar 12-13, 2012, San Diego Website: www.ashrae.org/events/ page/hpbconf 2012 HVACR & MECHANICAL CONFERENCE FOR EDUCATIONAL PROFESSIONALS Mar 12-14, 2012, Colorado Springs, Colo. Website: www.ahrinet. COMPOSITES MANUFACTURING 2012 Mar 13-15, 2012, Mesa, Ariz. Website: www.sme.org

APEC 2012 Feb 5-9, 2012, Orlando, Fla. APEC 2012 continues the long-standing tradition of addressing issues of immediate and long-term interest to the practicing power electronics engineer. Content includes the power electronics exposition, professional development courses, presentations of peer-reviewed technical papers covering a wide range of topics, and planned networking time at beautiful Coronado Springs resort. Pro travel tip: If possible, dine off-site. Registration fee: Full, Non-Member: $1150; Sessions-Only: $700, SeminarsOnly:$500, Exhibition: Free Website: www.apec-conf.org E-mail: [email protected] Phone: (202) 973-8664 

THERMADOR REVEALS FULLSURFACE INDUCTION AT CES

At a press event at CES in Las Vegas, Thermador launched its latest cooking innovation -- an induction cooktop that eliminates conventional burners and uses full-surface cooking and a natural-mapping user interface. Part of the brand’s new Freedom series, the induction cooktop intelligently recognizes cookware size, shape, and position

to deliver heat wherever the user places the cooking vessel. Thermador claims the cooktop has more than 30 international patents. It is built with 48 individual 3-inch induction heating elements below the surface of the appliance. This translates to a 63-percent more effective cooking area on the surface by eliminating the conventional standard of predefined elements, Thermador claims.

www.applianceDESIGN.com

cool performance

New blowing agent talent discovered. Honeywell’s Solstice™ Liquid Blowing Agent is taking the stage in 2012, and will create an overnight sensation. Taking inspiration from the many qualities that made HFC-245fa famous, this new high-performing molecule promises instant stardom. Its superior insulation performance and GWP of less than 7 blows past the competition. Whether you’re focused on refrigerator, spray foam, panel or any number of other applications, our Solstice Liquid Blowing Agent’s versatility will be music to your ears. It hasn’t gone commercial yet but, when it does, you’ll want to be ready.

To learn more, call 973-455-4334 or visit www.honeywell-solsticeLBA.com. © 2012 Honeywell International Inc. All rights reserved.

NEWS WATCH

COMPANY NEWS LG LAUNCHES NEW ENVIRONMENTAL INITIATIVE

LG Electronics USA, the North American arm of Korean LG Electronics Inc., announced plans to cut its carbon footprint in half. Following a trend set by industry giants GE Appliances and Whirlpool Corp., LG’s initiative aims to reduce greenhouse gas (GHG) emissions by 50 percent by the end of 2020, compared to its 2007 baseline. Like most manufacturers, LG’s energy use represents the vast majority of its GHG emissions. The U.S. appliance and consumer electronics maker has operations in a dozen states, with facilities using about 19.4 million kilowatt hours annually. The initiative includes a wide range of activities, ranging from expanding and enhancing LG’s energy management systems and technology, to purchasing electricity from green power sources and improving facility energy efficiency through HVAC and lighting technologies The company also hopes to cut energy use by increasing computing efficiency in data centers and desktop/ laptop computers, using Energy Star equipment and building materials, and working closely with retailers and em-

ployees to find innovative strategies. “This is an intensive effort focused on our U.S. operations,” John Taylor, VP of Public Affairs at LG Electronics USA, told appliance DESIGN. “Our CEO set the bar high, but there is a lot of enthusiasm internally to meet that goal.” As early as next year, LG will launch a comprehensive employee engagement program to educate employees on ways to save energy, including sustainable transportation and recycling. The appliance maker has already started purchasing 100-percent green energy for its headquarters building in Englewood Cliffs, N.J. LG’s push to reduce GHG emissions follows other environmental initiatives happening across the industry. GE Appliances sparked the “green light” for appliance makers earlier this year with a string of environmental programs. In February, Louisville, Ky.-based GE partnered with the Environmental Protection Agency to form the Responsible Appliance Disposal (RAD) program,

MIRKO MERLO NAMED PRESIDENT OF WALTER AG

As of Jan. 1, metalworking industry veteran Mirko Merlo has taken the takes reigns of cutting tools giant Walter AG, the parent company of Walter USA, Waukesha, Wis. Merlo has held a variety of positions since joining Walter in 1984. Among other duties, he was responsible for the company’s business operations in Brazil, the United Kingdom and Italy and was President of the Western Europe region.

OBJET EXPANDS TO BRAZIL

Objet Ltd., Rehovot, Israel, announced it has signed a distribution agreement with Anacom Eletrônica Ltda, for the Brazil market, according to a press release issued by the companies.

8 applianceDESIGN February 2012

which encourages responsible refrigeration recycling in an effort to protect the ozone layer and reduce GHG emissions. In April, the appliance maker also announced plans to adopt a new foamblowing agent, known as cyclopentane, to reduce the GHG emissions from the foam-blowing process by 99 percent (compared to the foam-blowing agent it replaces). Whirlpool Corp. says emission reductions have been on its radar for years now. The Benton Harbor, Mich.based appliance maker first announced a global greenhouse gas (GHG) reduction target back in 2003, with a goal of reducing emissions by 3 percent in 2008 (compared to 1998 levels). In 2007, the company set a new goal to reduce total greenhouse gas emissions 6.6 percent by 2012 and claims to be on track to meet its target. “There is a lot of great work going on out there in the reduction of green house gases,” LG’s Taylor said. “But we are not aware of anyone who has made a commitment to reduce these emissions by 50 percent.” “I think we all share a common commitment to reducing greenhouse gases and helping to save the planet,” he continued. “We just hope to be a benchmark against which others are measured.”

HAIER RANKED TOP GLOBAL MAJOR APPLIANCES BRAND

Market research firm Euromonitor International has named Chinese appliance maker Haier the number one major appliance brand in the world for the third consecutive year.

GROUPE SEB EXPANDS INTO INDIA, CHINA

French appliance maker Groupe SEB has continued its foray into emerging economies. The small appliance company, known for its Rowena and Krups brands, announced last week acquisitions in both India and China. 

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NEWS WATCH Thermadore, cont. from page 6. The natural-mapping user interface allows users to move their cookware around during the cooking process, including specially shaped cookware such as griddles and oval-shaped pans. The company claims this is especially helpful as users add and remove different dishes during meal preparation -- such as sauces, boiling water, and sautéing.

pliance features a range of 4,600-watt maximum power output with Boost feature and 15-watt minimum power output. Thermador, part of BSH Home Appliances Corporation, plans to start selling the cooktop in July 2012 with a MSRP of $4,949.

WHIRLPOOL VANTAGE RATED TOP QUALITY HE WASHER

The cooktop surface is made from transparent ceramic glass, which allows for the integration of a 6.5-inch color touchscreen. In addition to showing the position of all cookware on the cooking surface, the interface also performs live updates as cookware is moved to a different position. As far as cooking performance, the ap-

10rate.com, an online product review website, recently posted its top 10 highefficiency (HE) washing machines for 2012. Whirlpool took the top spot for quality with its WTW7990XG (Vantage) model, thanks to a 7-inch LCD touch screen and a sleek, tinted glass lid. The washing machine received a 9.5 out of 10 rating, even with a premium priced tag of $2099.

Korean brands LG and Samsung also led the list. The LG WM3875HVCA and WT5101HV models received a 9 out of 10 rating – putting the upand-coming brand right behind Whirlpool. Samsung’s WF431ABP/XAA and WF448AAW models both received a rating of 8.5 out of 10. Frigidaire’s GLTF2940FS model was rated best value. Reviewers were impressed with its high performance features – 3.5 cu ft capacity and 14 wash cycles – and its reasonable price tag of less than $650. The best budget award went to GE for its WBVH5300KWW model. The reviewer, Brittany Rowland, noted that the rotary dial mechanism makes the unit easy to control, and the LED screen is easy to read.

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applianceDESIGN February 2012 9

NEWS WATCH Maytag’s MHWE950WW, Frigidaire’s FAFW4221LW, and Whirlpool’s WFW9500TW rounded out the top 10 list. The online product review site will also soon release its Top 10 Washing Machines overall and its Budget Washing Machines lists.

AHRI COOLING COMMITTEE APPROVES FOUR STANDARDS

AHRI’s Cooling Standards Subcommittee (CSS) convened by Web conference on Nov. 29, 2011, and reviewed revisions to four AHRI standards. Pending follow-up letter ballot votes of absentee members, the CSS approved the following for publication: s !(2)3TANDARD) 0 – 2011, Performance Rating of Water-Chilling and Heat Pump Water-Heating Packages Using the Vapor Compression Cycle s !(2)3TANDARD3) – 2011, Performance Rating of Water-Chilling and Heat Pump Water-Heating Packages Using the Vapor Compression Cycle s !(2)3TANDARD) 0 2011, Performance Rating of Commercial Refrigerated Display Merchandisers and Storage Cabinets for Use with Secondary Refrigerants s !(2)3TANDARD3) 2011, Performance Rating Of Commercial Refrigerated Display Merchandisers and Storage Cabinets for Use with Secondary Refrigerants The standards should be available shortly for free download from the AHRI website. 

10 applianceDESIGN February 2012

CEA: DON’T BLAME ELECTRONICS FOR U.S. ENERGY USE The connection isn’t a hard one to make. Look at all the electronics added to the typical middle class U.S. home in recent years—flat-screen televisions, more and more powerful computers, tablets, Smartphones, blue-ray players, videogame systems, etc.—and concurrent rise in U.S. energy use. But correlation doesn’t necessarily imply causation. And the Consumer Electronics Association (CEA) has released a new study that de-dupes the misconception that electronics are to blame for increases in electricity demand. The report, Energy Consumption of CE in U.S. Homes in 2010, shows that despite their popularity in American homes, consumer electronics (CE) account for a relatively small share - roughly 13 percent - of the average U.S. home’s electricity consumption. There are nearly 2.9 billion CE devices in U.S. households and an average of 25 devices per household, including battery-operated CE devices. Home use of CE devices equaled 13.2 percent of overall residential electricity consumption and 9.3 percent of residential primary energy consumption. Within that 13.2 percent, televisions accounted for 34 percent, PCs 16 percent, and set-top boxes 13 percent. For instance, the study estimated the installed base of televisions rose to 353 million in 2010 from 342 million in 2009, though unit energy consumption declined slightly (details on page 101 of the report) because of the shift from legacy cathode ray tube TVs to more efficient flat-panel TVs. The energy efficiency gains of this trend were detailed in a separate study earlier this year, “Power Consumption Trends in Digital TVs.” “This landmark study provides a recent and comprehensive assessment of CE energy consumption, which is helpful to policy makers and others interested in efficiency trends,” said Douglas Johnson, CEA vice president of technology policy. “Energy efficiency improvements in consumer electronics are driven by innovation, competition and market-oriented programs such as ENERGY STAR.” The study was commissioned by CEA and conducted by the Fraunhofer Center for Sustainable Energy Systems to quantify the electricity consumption of CE products in U.S. households in 2010. Devices covered in depth in the study include: audio-visual equipment, audio video receivers, Blu-ray players, DVD players, televisions, video game consoles, set-top boxes (cable, satellite, telco and stand-alone), computers and peripherals, PCs, computer speakers, monitors, networking equipment and printers. “Given the quick pace of change in our industry, it is important to have a comprehensive assessment from time to time,” Johnson added. “Too often we have seen unnecessary government mandates advanced on the basis of poor data and analysis. We hope this latest study is a welcome contribution to current and future policy and program discussions.” The Fraunhofer report follows a study released by the Brattle Group last month that estimates U.S. energy consumption will drop five to 15 percent by 2020. According to the authors, economists Ahmad Faruqui and Doug Mitarotonda, the drop will occur due to an increase in ENERGY STAR appliances, less usage of incandescent light bulbs, incentives that encourage users not to consume as much energy during peak hours, and other programs that raise awareness of people’s energy consumption.

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

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Want to see YOUR Product here? appliance DESIGN’s Design Engineering readers are interested, active and always looking for information to help them design and specify products and services to use in the creation of their appliances.*

Contact Steven Scheinpflug at (847) 405-4025 or [email protected] for more information. *AM Editorial Readership Study, August 2004

applianceDESIGN February 2012 11

SHIELDING & EMI/RFI

RUNNING INTERFERENCE ON

ELECTROMAGNETIC INTERFERENCE Here’s some helpful rules of thumb when dealing with the physics of EMI, and also seven common pitfalls where those rules might not apply, and how to deal with them. by andrew wieman and mike abbott Andrew Weiman is a partner at Bresslergroup in Philadelphia. Mike Abbott is Vice President & Director of New Product Development at Adaptive Technologies Inc. in Blacksburg, Va. 12 applianceDESIGN February 2012

E

lectromagnetic interference, commonly known simply as EMI, holds the potential to cause problems for any electrical designer. The good news is there are many readily available rules of thumb in designing for EMI that can aid the novice and seasoned designer alike. The bad news is its more or less inevitable that each project holds an unexpected twist that is not anticipated by the rules of thumb or is forced upon you by the constraints of the design. Once you arrive at this point a list of suggestions without a basic understanding of the physics can be a frustrating dead end. What follows is an overview of the basic physics and some rules of thumb that may be new to you as they are gleaned from experience in designing for extreme shielding applications. While a full explanation of the physics involved is outside the scope of this article; the following explanation is designed to explain why, as field strengths increase; serious problems can arise, even when following generally accepted rules of thumb. If radiated energy could be kept away from

electronics in the first place then we wouldn’t even have a problem to solve. Most mechanical designers have seen board level shielding cages or been told to enclose printed circuit boards in metal enclosures; but why? It’s all about impedance matching or better, mismatching. The source impedance of free space, or air, is approximately 377 Ohms. When an RF wave hits a material the energy is reflected, transmitted, and absorbed. The percent of the energy in each category is directly related to the complex impedance mismatch between the material and free space. What this means is that a material with impedance greater than 377 Ohms allows more transmission than reflection. When the impedance is substantially lower than free space, more is reflected. One hundred percent reflection is the best case scenario since no energy can get to your PCB! Unfortunately, there is no such thing as a perfect reflector and as such, there will always be a certain amount of transmission into the shield material. This means that, in all cases, some energy makes it into the shield material. From there, www.applianceDESIGN.com

SHIELDING & EMI/RFI

Figure 1

the physics become a bit more complicated. Figure 1 is provided for visualization of what happens from here. For conductive materials, at least some of the energy is absorbed through the production of eddy currents. All materials have impedance (containing complex terms of resistance, inductance and capacitance). As such, a voltage differential is created across the shield as the eddy currents interact with the material impedance. Due to dissipation and skin effects, higher currents are created at the outer surface than at the inner surface. The better the conductor, the better current cancellation will occur, low voltages will preside, and the closer the inner surface current can get to zero. A more in depth understanding of this phenomenon can be gleaned by examining Ampere’s Law and the Maxwell-Faraday equation. If this can be attained your design can eliminate the RF transmission component through the inner shield surface. The ability of a shield to reach this goal depends upon thickness and conductivity of the shield material. So, as the field strength is increased, the shield either needs to grown thicker or more conductive per unit thickness in order to provide the ability to cancel the inner surface current to zero. Easy, right? Unfortunately, no! The energy being absorbed through eddy currents is dissipated as heat! With increased heat comes increased material resistance. This works against our goal. As such, the material thickness needs to be evaluated for eddy cur-

Figure 2 www.applianceDESIGN.com

rent and thermal mass properties – depending upon the field strength. And now for the final catch. The eddy current loops that we are relying on to dissipate the RF energy can, in high field strengths, induce an inductive coupling with the PCB itself, even when the transmission of RF energy is completely eliminated. This would mean that proximity of the shield to the PCB is also important. This is a particularly insidious problem as

things. The reality is that any discontinuity in the shield, be they holes, slots, penetrations, protrusions (think support post on a plated injection molded part) can act as antennas, retransmitting RF energy into your otherwise wonderfully designed enclosure. Figure 2 presents a simplified explanation of how discontinuities create antennas. As eddy current densities are forced to change, the effective impedance, and therefore skin volt-

The reality is that any discontinuity in the shield, be they holes, slots, penetrations, protrusions can act as antennas, retransmitting RF energy into your otherwise wonderfully designed enclosure.

electronics become smaller and smaller with enclosure real estate becoming more and more of an unavailable commodity. The final discussion of basic physics is based on the fact that rarely can we get away with having an EMI enclosure that has no openings. Most applications require input and output and as such, the shield must be compromised for wire routing, among other

ages, are also forced to change. If the currents are changed enough that the localized skin current is driven away from zero, the entire area around the discontinuity, rather than the feature itself, begins to transmit the RF into the enclosure. This is at first surprising to those that recall the general rule for penetration, that being the depth, d, should be designed as a function of the quarter wavelength of the frequency of concern and the effective diameter, D, of the penetration. So what is really going on when RF and electronics interact? Once systems are exposed to RF, especially powerful RF fields, all physical attributes become important because everything contains a certain amount of parasitic inductance and capacitance. Trace lengths, pin lengths, component heights, component materials, PCB materials, copper layer thickness, trace shapes, trace orientations, and component and trace placement all become remarkably important applianceDESIGN February 2012 13

SHIELDING & EMI/RFI during board design and layout. As the field frequencies get higher, the impedance associated with the parasitic inductance and capacitance inherent in every part of a PCB are no longer negligible. As environmental RF energy enters the PCB system, and the foreign energy results in unwanted trace currents that are then rectified by PN junctions in semiconductor devices. As a simplified mental model, the ramification of this demodulation is a DC offset in the affected areas. When

the amplitude of frequency of this offset changes, which is usually the case, AC signals are generated, resulting in unwanted signals, commands, and noise across the entire system - resulting in poor performance.

Consumer vs. Military The reason that most textbooks treat design for EMI at an elementary level is that the standards for consumer products is 10V/m across a broad range of frequencies.

The recommendations outlined below result from lessons learned in more stringent environments. For most Army applications, the ubiquitous presence of high powered radios requires EMI protection to 20V/m, four times the energy content than most commercial applications. Even more extreme, the US Navy routinely experiences 200V/m (400 times the energy of commercial applications) and often has peaks as high as 30,000 V/m for some flight deck radar systems. In these

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SHIELDING & EMI/RFI fields, it is common to experience melting cables, over voltages in circuitry, electrical arcing to ground (or people), semiconductor failure, equipment heating, noise corruption in data, and outright melting of plastic components. The good news for the designer of consumer products and appliances is that the level of rigor required for the Navy flight deck is not required. Even better, if the same design guidelines are applied for low field strengths as are used for high fields, every design can be made more efficient and effective.

Design Advice From High RF Field Applications In low field strength design, analog and digital circuits are often treated using the same approach. In reality, analog and digital have different requirements from both system and board level design.

1

PROBLEM 1: Analog systems are very sensitive to stray capacitance Remedies 1. Avoid multi-ground plane boards. 2. Avoid long trace lengths as a means of reducing stray capacitance. Analog OpAmps are especially sensitive to both input and output capacitance and can become unstable and ring at high frequencies causing self induced EMI problems. In the worst cases, resonances will be excited when exposed to the right RF environment. 3. Keep bypass loops to a minimum to prevent FET and/or BJT junctions from rectifying AM RF. Introduction of an inductor and capacitor to a PN junction is the building block of an AM radio. 4. Closed Loop control systems and analog feedback paths will have extra poles due to parasitic capacitance that can be a factor when trying to stabilize the path.

which pins are digital and which are analog – place accordingly b. Wherever possible, use couplers across split planes c. Decouple analog and digital power using RF current absorbers like SMT ferrites d. Use a star pattern for power wherever possible rather than using a totem pole configuration as the totem pole transfers noise from one power system to another

flow can resonate the system cavity where the PCB is located and induce/excite currents in traces that would have otherwise been clean. Remedy Avoid the use of pigtails whenever possible. Use low impedance, circumferential terminations whenever possible. Fill gaps with conductive gaskets.

6 3 PROBLEM 3: Regulators can be a major source of EMI

Remedies 1. Linear Regulators a. Bypass BJT regulators with very large low impedance caps before and after device to same ground. b. Keeps internal analog feedback tied to same ground as power output and load so that noise isn’t induced in feedback path and subsequently will be reinforced back to the output. 2. Switching regulators a. Use high quality ceramic output filter caps with very low ESR. b. Keep traces short and wide. Use angles where possible to allow shortest noncornered current paths as possible c. Use synchronous mode wherever possible. Single frequencies can be filtered much more effectively than spread spectrum. If analog electronics are not susceptible to spread-spectrum switching then use the spread spectrum, the converter will be more efficient.

PROBLEM 6: Shield cavities and cable terminations can induce EMI if not designed properly. Remedies Pay attention to the skin effect. If currents are on the outside of one shielding conductor induced by impinging RF, keep in on the outside of the next conductor as best as possible. This comes into play when penetrating a PCB cavity with a shielded cable. Some design points of interest include: 1. Terminated shield with as low impedance as possible. 2. Avoid shield pigtails. 3. Terminate the cable shield as close to the edge of the conductive enclosure as possible at the entry point. 4. Make all cable shield terminations circumferential wherever possible. 5. Ferrites internal to the shielded cavity can improve performance of cable penetration

7 4 2 5 PROBLEM 2: Digital circuits require different treatments from those of analog.

Remedies 1. Digital electronics require at least one ground plane and sometimes more. a. This will counteract trace inductance which causes ringing b. Make sure that there are plenty of available uninterrupted return paths for the signal/power currents to mirror (example - avoid placing vias in the way). 2. Never cross digital return currents over analog planes and vice versus. a. Understand mixed signal IC’s and

16 applianceDESIGN February 2012

PROBLEM 4: Battery operated systems have no ground. How do you bypass RF interference in floating systems? The key is keeping common-mode to differential conversion down so that the line to system ground reference impedance is very low for RF energy. This can be accomplished in the following ways: 1. Matched traces 2. Matched filters 3. Proper system grounding 4. Proper shielding PROBLEM 5: Cable shield pigtails can cause significant EMI. This is for two primary reasons. First, lead inductance makes conductivity of RF currents fall off with increasing frequency. The result is that the shield becomes ineffective above 10MHz when a pigtail of only one inch is used. Second, those RF currents that can

PROBLEM 7: Using inappropriate shielding material can compromise EMI protection Remedies 1. Use copper if possible and make sure the thickness is deeper than deepest known skin effect 2. Design cable shielding appropriately for the field strength a. For field strengths as high as 200V/m, a double shield is absolutely necessary b. In order of preference, use braid over braid, then spiral over braid, then foil over braid, then foil over spiral. c. If cables must be coiled you must use spiral shields so try to use both a spiral and foil shield As we mentioned at the start of this article each project has its unique challenges that require their own unique solutions. We hope that this article helps to demystify the basic physics as well as provides some applicable takeaways to apply to your next design challenge. Good luck!  www.applianceDESIGN.com

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JOINING

The Best Fastener May Be No Fastener Hard polypropylene fabrication materials for interior elements can take the question of joining out the equation, but are these resins developed enough yet to warrant such a radical shift?

T

raditionally, the internal components of medical devices, computers and other electronic products are mounted to metal boards or trays using screws, wires or other fasteners. These board or trays are then mounted to the product’s outer housing using an additional set of screws, wires or fasteners. As a result, the assembly of the final product can become a logistical and manufacturing nightmare that is not only labor intensive, but often puts the product designers at odds with the teams responsible for sourcing the components and manufacturing the products. Each one of the screws and fasteners must also be purchased, inventoried and tracked which often places additional stress and demands on an already stressed system.

What if you didn’t need them?

by scott novak Scott Novak is vice president of marketing and business development for Protexic, now a part of Sonoco, Arlington Heights, Ill. He can be reached at 847-632-9622, e-mail scott.novak@ tegrant.com, or visit www.protexic.com. 18 applianceDESIGN February 2012

For applications able to use molded expanded polypropylene (EPP), most if not all of the screws and fasteners can be eliminated. EPP is a closed-cell plastic foam bead produced by combining polypropylene resin with heat, pressure and CO2 in an autoclave. The result is a hollow bead with a polypropylene surface that has outstanding cushioning properties and a high strength to weight ratio. The use of EPP as an interior chassis has been around since the 1980s, based off of

the electronic packaging assembly concept (E-PAC) that was developed by HewlettPackard and later spun off to the German firm DMT for licensing and further development. The foam can be molded into complex shapes using steam heat & pressure. Beads are introduced under pressure into an aluminum mold and are heated to their melting point using superheated steam. The heat causes the gas inside each bead to expand which allows the surface of the beads to fuse into one another. The finished parts are then cooled and ejected from the mold. Tooling prices are dependent on both the size and complexity of the part but generally range from $10,000 to $50,000 which makes this process a good option for applications with medium or high production volumes. The resiliency of the material allows components such as printed circuit boards, fans and power supplies to be held in place using a friction fit, thus fewer screws and fasteners. The components are simply slid or snapped into place and then held in place by the foam. Current applications utilize a sandwich approach with top and bottom foam pieces that lock the components between them. Instead of securing a cooling fan to a wall or chassis with screws, EPP can be used to sandwich the foam and hold it in place. The resilient nature of the foam will also dampen any www.applianceDESIGN.com

JOINING

vibration or noise created by the fan. Assembly can also be simplified by pressfitting the components into the internal chassis. Press fitting makes it easier to disassemble for any service or maintenance that is needed or for full recyclability of the product at its end of life.

Design and Prototyping Using foam to create the inner chassis of a product gives product designers more flexibility in their designs as they can decouple the functionality of the inner chassis and the outer housing. The rigidity and strength provided by the foam chassis reduces the strength required from the outer housing and allows thinner gauge materials to be used. In some cases, it also allows products with different interior configurations to be made without having to change the outer housing. EPP has excellent cushioning properties and will protect the internal components in case of drops and falls. A variety of textures can be molded into the foam and in certain applications such as solar hot water heater control panels; the EPP foam is used as the outer housing as well. Another benefit of using EPP to create an internal chassis is the ability to mold different types of channels into the foam. Channels can be molded into the foam to provide runs for wires, cables and tubing to be routed. Ribs molded into the sides of these runs allow the wires, cables and tubing to simply snap into place during assembly without any further need for attachments. Channels can be molded into the foam to manage the airflow throughout a product and provide pinpoint cooling where it is needed. By directing the airflow within the chassis to precisely where it is needed, smaller fans can be used, possibly allowing a quieter and more energy efficient design. This feature is especially beneficial for portable devices. Once a design has been roughed out, an iniwww.applianceDESIGN.com

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JOINING tial prototype can be produced using a CNC milling machine to cut a billet of the EPP material. No special tooling is required to create the prototype. The components can be assembled into place on the prototype and modifications can be made directly to the foam using a razor knife and/or hot wire cutter. The improvements are then added to the CAD model and the next iteration of the prototype can be quickly made. It is not uncommon for product designers, as they become more comfortable with the material, to mock up proofs of concept from foam blocks using razor knives and hot glue guns.

Learning a New Paradigm While advances in software have made the transition from 2D to 3D much simpler, in many cases, it is the manufacturing and sourcing teams that are the strongest advocates for the process because of the way it improves the manufacturability of the products and shortens the bill of materials. For designers such a radical shift is like learning to ride a bicycle all over again, or perhaps

This unique solar hot water heater pump case uses foam in place of hard plastic to reduce the required amount of fasteners for assembly. The pipe and valve components snap into the foam.

more like teaching Lance Armstrong to ride a Harley. The biggest challenge in using EPP foam is often getting the product designers to think differently about how a product is designed and manufactured. Most product designers have always taken the use of fasteners as a given and as a result, have a great deal of experience and comfort with them. A foam concept requires designers to think very differently about how to design the product. They must

shift their thinking from a 2D view to a 3D view in order to capitalize on the opportunities that the foam provides to reduce the number of parts. This professional reticence among design engineers has contributed to the relative slowness of the technology to take hold. However recent improvements in the molding process and tooling technologies have allowed even more complicated shapes to be molded and have improved the surface finish to provide additional protection or greater cosmetic value. These sophisticated shapes further enhance the ability of the EPP to hold components in place without the need for additional screws or fasteners and simplify the process to assemble the final product. Perhaps such recent improvements will convince more design engineers to give foam a cut. 

In the world of rapidly changing technologies and a shifting marketplace, find answers here.

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Your Designs, Henkel’s Expertise Together, we make your appliances an integral part of everyday life. Henkel and its Loctite® brand are proud of our partnerships with major appliance manufacturers to bring beauty, performance, and convenience to so many homes.

!DHESIVESs3EALANTSs-ETAL#LEANERSs,UBRICANTSs#ONVERSION#OATINGS

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. 8282 (1/12)

CONTROLS & SENSORS AC compressor with stud seals.

HERMETIC FEEDTHROUGHS FOR MAGNETIC BEARING TECHNOLOGY A discussion of advancements in hermetic seals and how these are essential for controlling highspeed magnetic bearing systems.

by ed douglas Ed Douglas is president of Douglas Electrical Components Inc. (DECo). A thirdgeneration owner, Douglas has over 15 years of engineering and management experience within the semiconductor, vacuum deposition systems and electrical component manufacturing industries. 22 applianceDESIGN February 2012

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he development of magnetic bearing technology has advanced the science of high-speed rotating machinery. Offering oil-free and high-speed, virtually zero-friction operation up to 100,000 rpm with the ability to function in high-vacuum environments, magnetic bearings are finding increased use in applications ranging from high-efficiency HVAC compressors to semiconductor, biotech and green technologies including windmills, turbines and flywheel energy storage. With the advent of magnetic bearings and magnetic-mechanical hybrids, engineers gained bearing solutions with very low and predictable friction, the ability to run without lubrication, and the capability of high performance in a vacuum – the ideal bearings for high-speed vacuum applications. However, these same engineers also gained the challenge of supplying power, control and monitoring cables into and out of a sealed vacuum environment, leading to a need for reliable hermetic seals. Engineering and specifying hermetic seals for magnetic bearing applications are relatively new design challenges. While early applications and experiments in NASA laboratories could make use of homegrown ceramic or metal hermetic seals, developing and testing a customized seal for commercial applications

and quantities presents different types of challenges. One such challenge lies in the quantity of leads required to get through a small space, because the larger the hole in the chamber, the greater the risk of leakage. Smaller, highdensity feedthroughs are better than multiple hermetic connectors due to the same risk of leakage. Then there are the issues with mating a hermetic connector in an environment that is submerged, which is often the case with flywheel applications, since flywheel chambers are sometimes encased in heat transfer fluid. Further, there is the risk associated with the use of welding to hermetically seal the feedthrough to the chamber wall. Often, process control issues with welding create unanticipated temperature fluctuations that could damage both delicate electronics as well as the electrical feedthroughs.

Epoxies Make the Difference Fortunately the past decade has seen tremendous advances in material science and the application of these new materials to high-vacuum hermetic seal and feedthrough technology. Modern material science has developed epoxy compounds able to withstand temperature and environmental conditions previously only met by glass, metal and ceramic seals. With epoxy seals, standard or custom conwww.applianceDESIGN.com

CONTROLS & SENSORS

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nectors are sealed in a fully-potted, highperformance epoxy compound. Epoxy-based hermetic seals offer unlimited design options with performance equal to or better than older technologies, at a lower price and with faster turn-around time. Epoxy-based hermetic seals also enable greater configuration flexibility while maintaining high performance. With designers often trying to significantly reduce system size, co-location of associated electronic and control systems can present challenges in how feedthroughs will be successfully situated. Thus, control and power feedthroughs that fit into tight areas and turn corners while maintaining vacuum require custom housing designs, often with unique geometries and specialty materials. As epoxy seals can be configured in any form factor, accommodating highly customized applications is no problem.

Getting Power Into a Sealed Environment While today’s magnetic bearings enable new technologies and efficiencies, they are also vulnerable to new types of potential problems which require an evolved understanding of how to prevent them. These advanced applications can be put at risk when the challenge of getting signals and power into and out of the vacuum environment is underestimated. Often the vacuum environment and heat transfer fluid require that special attention be paid to material selection. For control systems on high-speed rotating machinery, speed, temperature and vibration all need constant monitoring via numerous thermistors and other sensors, often incorporating shielded and/or twisted wires to maintain signal integrity. For power transfer, copper post studs or heavygauge wire feedthroughs must be accommodated, depending on current requirements. In all cases, small and high density feedthroughs provide less risk of leakage than multiple connectors. In the case of chambers that are submerged in a heat transfer fluid, feedthroughs must also be leakproof and resistant to what-

ever fluid is in use. Understanding parameters such as out-gassing, permeability and material compatibility is critical in developing solutions that will perform as desired over the 20+ years of operation that most of these units require. Consulting hermetic feedthrough experts during the design phase can ensure that these small but necessary components do not become the failure points for an otherwise successful project. Over the years, it has been our experience that missteps often occur when engineers: s 5NDERESTIMATETHEIMPORTANCEOFTHE feedthrough in their final design or product; s /VERESTIMATETHEIRABILITYTOBUILDSOME thing in-house; s /VERESTIMATETHEEASEOFFINDINGTHERIGHT feedthrough solution; s 5NDERESTIMATETHELEAD time that will be involved when they find a vendor; s %NDUPWITHDELAYS expenses and embarrassment that a little preplanning could have eliminated. It’s true that there are some situations in which the application is straightforward, and an off-the-shelf feedthrough may suffice. But there are frequently design, material or envelope considerations that require a customized solution. For example, if an existing bulkhead already has NPT penetrations, a matching feedthrough should be sourced to hopefully avoid drilling and rethreading the penetration. Often, a design may require more wires than can fit into an off-the-shelf feedthrough. Rather than

adding another penetration or enlarging the existing penetration (if either option is even feasible), a better solution is to design a feedthrough to precisely match the conductor requirements within the existing envelope. Design engineers know that magnetic bearing failure due to loss of vacuum can be catastrophic. Purchasing departments know that commercializing a product requires a reliable, cost-effective supplier of every component – including the hermetic seals. Traditional metal and ceramic seals are costly, not easily customized, and have long lead times for prototyping and delivery. By using new technology in epoxy-based hermetic feedthroughs, failure due to vacuum loss is decreased, cost of hermetic feedthroughs is decreased and reliability is increased to the benefit of engineers and purchasing departments. 

Magnetic bearing on the NASA G2. www.applianceDESIGN.com

applianceDESIGN February 2012 23

CONNECTORS & CORDS

W E N A

E Z N O R B r o f E G A M CONTACTS O T S U C

A case study concerning a Utah digital sign manufacturer who worked with a parts manufacturer to develop five custom bronze electrical cotactors.

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he smallest metal parts can often be among the most critical components in larger products, and how they are specified, designed and manufactured can play a vital role in overall product reliability and cost. While small and seemingly insignificant, electrical grounding contacts keep sophisticated electronic or electrical equipment operational by conducting stray electricity safely to the ground. For this reason, even the lowly electrical contact requires the proper design and manufacturing considerations when designing the larger system. When it comes to electrical contacts, variability in requirements from part dimensions and materials to contact area, location, and spring quality can make ordering from a parts catalog difficult. Complicating matters, the design engineer doesn’t necessarily know what features are going to be a manufacturing problem or add significant expense. Choosing a competent manufacturing partner and using the best manufacturing technology for the job can have big payoffs in design reliability and cost.

by del williams Seeing Signs Del Williams is a technical writer based in Torrance, California. He writes about health, business, technology, and educational issues, and has an M.A. in English from C.S.U. Dominguez Hills. 24 applianceDESIGN February 2012

Brent Brown is an engineering consultant for Yesco, a Salt Lake City-based designer and fabricator of custom signs, electronic displays, and outdoor media. Brown will take on some challenging jobs, e.g. a 135-ft. tall, dou-

ble-faced, 100-ft. by 50-ft. LED sign for the Wynn Las Vegas casino hotel. The hotel called for 10,000 printed circuit board sub-assemblies controlling computer sequenced LED lights for a “message center” with a moving eraser that glides silently up and down over the LED board, appearing to change the graphics as it goes. Brown quickly realized he would need some custom parts to design and manufacture the right group of grounding clips for the sub-assemblies. “At first, you look for an off-the-shelf part that’s manufactured in higher quantities but unless it’s a very common application you typically end up having to design it yourself,” said Brown. “An offthe-shelf part seldom works as well as if you designed it for the purpose and in this case it had to be custom. “Since the displays are typically in service for 10 to 15 years outdoors, quality, corrosion, cost per part, spring tension, and spring-back were among the issues considered for these contacts.” After Brown defined the first part, a surface mounted grounding contact to be soldered onto PCBs on tiny pads, he talked to a variety of companies and e-mailed them concept drawings to find out who had the expertise to help with its design and manufacture. “We had a number of companies quote the part and tooling, including those using hard, www.applianceDESIGN.com

CONNECTORS & CORDS

A custom integrated fabrication process is often necessary for producing smaller metal products of complex configurations or in lesser volumes. Improvements in stamping processes are making this less expensive. The above were created using a process of four sliding stamps against a center tool.

dedicated tooling such as power press progressive dies. But the tooling and parts were too expensive.”

The Process Makes the Penny He eventually found a partner in a Bristol, Conn.-based parts supplier called Fourslide, which specialized in the integrated stamping and forming parts operation. The supplier, said Brown, was chosen as the least expensive for both the tooling and the parts, that price point made possible by a special tooling process. The process begins with the raw material in flat strip form off a coil, which is stamped or blanked in the progressive die section of the machine, which is a fully functional but lighter version of the progressive die found in most power presses. Its trick is a process that typically starts with material the width of the finished part, generating less scrap.

The Right Material Each time Brown emailed the parts supplier a concept drawing or sketch of the part he wanted, he received an e-mail back with suggestions and minor tweaks to help with part manufacturability and cost. To provide a good combination of spring properties and electrical conductivity for the grounding clip at reasonable cost, the supplier suggested using phosphor bronze as a material over beryllium copper since the spring properties and electrical conductivity of the four-times-as-expensive copper wasn’t necessary for the applicawww.applianceDESIGN.com

tion. Going with bronze eliminated the cost of a secondary heat treating operation along with the risk of material deformation. Through testing, Brown determined that half hard phosphor bronze was sufficient for the application, noting that bronze’s anticorrosive properties would helps with the application’s outdoor weather requirements. Satisfied with the first surface mounted grounding contact produced, Brown designed an additional two types of surfacemounted grounding contacts, plus two types of pin-mounted grounding contacts whose pins go through holes in PCBs perpendicular to its pads. “Depending on which configuration of grounding contact it is, the tab that sticks up from the circuit board is the spring and conductor at the same time,” said Brown.

Prototypes Arrive From the time Brown placed orders to the time the first article parts were shipped for his approval took about eight weeks for all five types of parts. Two months may seem

like a long time but the parts manufacturer informed Brown that many progressive dies can take 12 weeks or longer since power press progressive die work requires more complex tooling changes, and is typically done overseas with substantially longer lead times. In testing, Brown mounted the prototype grounding contacts on circuit boards and put them into the sub-assemblies. He checked for compression to see whether the parts yielded or not, whether they were hard enough to maintain contact strength, and if they met additional requirements. “The prototypes and products worked the first time, and we haven’t had any trouble with them,” said Brown. “Because the grounding clips resist corrosion and don’t lose spring, they should be good for many years. If we do another sub-assembly that requires a different grounding contact, it would be relatively easy.” An animated demonstration of the manufacturing process is available at www.fourslide.com/fourslide-reference.htm.  applianceDESIGN February 2012 25

NEW PRODUCTS Walter USA Meller Sapphire Optics The company introduced its custom fabricated sapphire windows and lenses. The glass can be produced in sizes up to 10 inches dia., depending upon the diameter to thickness aspect ratio, and are impervious to most chemicals, water, and fast moving particles. Featuring transmission from the UV to IR (270 nm to 4.7 microns), they are clear as glass, second only to diamond in hardness (Moh 9), and can withstand up to 1,000°C. Visit www.melleroptics.com

Thomas Division, a Gardner Denver Company The most recent addition to the company’s Jade products line are two diaphragm miniature brushless DC pumps. The 1410 and 1420 Series are equipped with an electronically commutated brushless DC motor. The high torque and speed range of the motor allows step-less variation of the performance of pneumatic diaphragm pumps (ranging from 2.5 to 11.0 lpm) so that the flow versus pressure/vacuum curve is held more linear than with a standard DC motor or other BLDC motors. In addition, the electronic commutation is virtually maintenance-free. Visit www.gardnerdenver.com

4HE COMPANYS NEW 0ROTOsMAX 5LTRA SOLID carbide end mills come in two diameter ranges, the smaller of which features excellent concentricity properties, essential for small diameters at high speeds. The ballnose end mill was specifically engineered for machining of hard materials. The end mills come in two different diameter ranges: the standard versions from 3-12 mm diameter and the mini versions for small to extremely small contours, ranging from 0.1-2.5 mm. For the smaller diameter range, the reduced neck and its reach of up to 10xD are beneficial for the machining of deep cavities. Visit www.walter-tools.com/us

Advantech Control Company The Traceable Dishwasher Metal Thermometer reports the maximum and minimum temperatures achieved during the dishwashing cycle. It ensures proper cleaning by providing proof of meeting the temperature regulation of achieving 180°F (82°C) during dishwashing. Waterproof and metal construction make it suitable for applications in wet labs, wash-down areas and outdoors. Features include a °F/°C switch, minimum and maximum memory readings over any time period, and a HOLD switch (freezes the display to capture a temperature). Visit www.control3.com 26 applianceDESIGN February 2012

Capable Controls Inc. The company’s Series 5X microprocessorbased, intelligent direct spark or intermittent pilot ignition control modules were designed for OEM and replacement applications. The control module was designed for commercial, residential and industrial systems. The internal circuitry monitors system gas valve, wiring and igniter while automatically shutting down the system in the event of a failed or shorted circuit. The 5X Series has been approved by CSA for U.S. and Canada usage. Visit www.capablecontrols.com

The MIO-2260. MIO-2260 is designed with the Intel Atom N455 single core processor and DDR3 memory support. It is an all-inone ultra small size embedded single board computer (SBC) measuring only 100 x 72 mm (same dimension as a 2.5-inch Hard Disk) which is easy to embed into spacelimited systems, making it a perfect fit for power saving environments. MIO-2260 is equipped with flexible multiple I/O expansion and interfaces. This small all-in-one module helps deliver more efficient scheduling using less development resources so designers may retain their specialist domain knowhow. Visit www.advantech.com/EmbCore www.applianceDESIGN.com

NEW PRODUCTS

Anderson Power Products The SPEC Pak High Power Connector is the latest addition to the company’s line of sealed power for environmental conditions. The connector has power handling capacity from 75 to 260 amps and an IP68-rated waterproof environmentally sealed shell, making it ideal for portable and test equipment. It features a UL94 V-0 flammability rating and a UL 746C F1 weather-ability rating. It is compatible with industry-standard PG threaded sealing glands and has sturdy aluminum latches with lockout/tagout capability. Visit www.andersonpower.com

Hyson Products, a business of Barnes Group Inc. The Di-Dro Advanced Forming System is a hydraulic system that provides high force in a small footprint, and a delayed return for increased part quality. The soft hit and low return force of the Di-Dro decrease press wear and extend press life. Both modular and custom designed systems are available, and described in a supportive brochure to help designers select the right system. Visit www.hysonproducts.com

Geometric The company has released its latest solids-based CNC programming solution, CAMWorks 2012. The new version features support for SolidWorks 2012, as well as improvements to enable faster and easier programming and to produce more efficient tool paths. These features include: feature recognition performance and improvements; Version 4.0 of VoluMill with the new non-concentric milling technology that reduces cutting-tool loads and evacuates chips more efficiently; the ability to add new tools into the TechDB from within CAMWorks; shaded display of “Contain” and “Avoid” areas; and turning roughing operations that now support user-identified inserts. Visit www.camworks.com

ICM Controls Corp. Quickfilter Technologies A powerful 3-channel audio processor or seamless insertion into an audio serial digital data path, the single-chip QF3DFX Profound Sound Audio Processor is easily configured using the company’s QFPro Design Software with royalty- free user-tunable advanced audio algorithms for psychoacoustic effects such as bass enhancement, high frequency restoration, and virtual surround sound. The processor can be configured to interface with I2S or TDM based audio systems and operate over a range of data rates up to 48 ksps, supporting data resolutions of 16 or 24 bits. Visit www.quickfiltertech.com www.applianceDESIGN.com

The company has four new Intermittent Pilot Ignition (IPI) Controls to expand its replacement heating controls lineup. The controls, which can be used with intermittent pilot boilers, furnaces, and other heating appliances, are low-cost replacements of the original OEM control. The new IPI controls include the ICM295 and ICM296, which replace the Carrier LH33WZ510 and LH33WZ512 ignition controls, and the ICM2901 and ICM2902, which replace the JCI G770RJA-1 and G776RGD-14 ignition controls. Each offers compatibility with both liquid propane and natural gas. The ICM295 is a continuous spark unit, while the other three offer a 100-percent safety lockout feature. Visit www.icmcontrols.com

CimCool Fluid Technology The Cimperial 1072D is a soluble oil recommended for machining and grinding operations with poor water quality. The solution can be used in heavy to severe duty machining and grinding operations on mild steels, stainless steels, hardened steels, exotics and most aluminum alloys, including MIC 6. The fluid has a good mix stability in high hardness, high sulfate, and high chloride water conditions. Visit www.cimcool.com applianceDESIGN February 2012 27

NEW PRODUCTS alternative to PVC and Neoprene jacketed flat cables. The company’s exclusive crystalclear silicone encapsulation is tear-resistant, needs no external armor or conduit for protection, and will not deform or wear during a lifetime of more than 10 million cycles, even under tight bending radius and highspeed flexing conditions. Visit www.cicoil.com

ComNet Communication Networks The company has introduced the first of many new models from its CopperLine product offering. The CLFE4US1TPC is a unique Ethernet switch that combines four 10/100TX Ethernet signals and transports them over one coaxial cable or RJ-45 cable. The CLFE4US1TPC can extend the transmission distance to 1,500 meters using COAX or 900 meters using RJ-45 cable. This product is designed for applications where existing copper media, such as coaxial cable or twisted pair (UTP) is currently installed and an upgrade to an IP–based system is required. Visit www.comnet.net

Wurth Electronics Midcom The T8 transformer series was specifically designed for T8-sized tube LED applications. These transformers are built using two new packages that according to the company are the only transformer packages in the industry designed specifically for the T8 bulb form factor. The patentpending designs feature half-rounded cores to maximize core cross-sectional area. Up to 30W power is available on the throughhole design and 20W on the surface-mount packages.Visit www.we-online.com/midcom

Cicoil The company’s Festoon Cables are designed for continuous flexing and extreme temperature applications (-65°C to +260°C). Ideal in overhead crane, gantry and material handling systems, the UV-resistant cables are an 28 applianceDESIGN February 2012

Opto Diode, a division of ITW

Danfoss Need a quick pressure to temperature converter for refrigerants? There’s a free app for that! Based on the well-known Danfoss Refrigerant Slider, KoolApp converts mobile devices that use Android and Apple IOS into user-friendly pressure-to-temperature refrigerant converters. Designed for installers, distributors and producers of air-conditioning and refrigeration equipment, the app enables users to enter exact figures or use the slide ruler to obtain precise, accurate conversions, based on NIST Refrigerant Properties and Antoine equations. The app offers 48 different refrigerants, including R744, R290 and R32, and allows users to switch between Celsius and Fahrenheit and bar and psi. Refrigerant data includes the global warming potential (GWP), ozone depletion potential (ODP), critical temperature and boiling point. Visit www.danfoss.us

With the recent acquisition of International Radiation Detectors (IRD), the company’s new product line includes the IRD SXUV 100 Ultraviolet/Extreme Ultraviolet (UV/EUV) Photodiodes. The advanced photon detectors feature very high radiation hardness and are designed for long-lifetime operation in high particle flux environments with no loss of responsiveness. The IRD SXUV 100 photodiodes have a 10 mm x 10 mm square active area. The nitrided metal silicide front window of the diode permits operation without loss of performance in high humidity. Visit www.optodiode.com

Precision Glass & Optics The company now has an exclusive West Coast distributorship agreement with Schott North America for their new Schott Supremax 33 rolled sheet borosilicate glass. The new product has an identical composition as Schott’s popular Borofloat rolled glass, which is 12 percent lighter than soda lime glass. Offered in thicknesses from 28.6 mm or 1 1/8 inches, up to 66.70 mm or 2 5/8 inches, the physical and chemical properties of rolled borosilicate glass include low thermal expansion, high thermal resistance, excellent light transmission, and superior chemical durability. Visit www.pgo.com www.applianceDESIGN.com

Over 25 years I have attended or exhibited at trade shows in many sectors around the world. I never thought that there could be a virtual equivalent to a physical show until Tech ManufactureXPO. I made a good number of contacts and had some very interesting discussions. The content, quality of exhibitors and the mechanics of navigating the show were excellent. It was well worth my time. Congratulations on an innovative event! - D.Paul Zito,, W.E.S.T. Forwardingg Services

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NEW PRODUCTS

WaterFurnace Intl. Dynasonics, a division of Racine Federated The new DXN portable ultrasonic flow and heat meter features hybrid metering technology that automatically switches between transit time and Doppler modes, as needed. It features a 7-inch, full-color touchscreen, the ability to store site-specific settings using plain text, and is available in a variety of kit configurations, from a basic kit that includes two sets of transit time transducers, cabling and a carrying case, to a complete kit with transit time, Doppler, RTD and wall thickness gauge. Visit www.dynasonics.com

Nextreme Thermal Solutions The company has developed two new energy harvesting subsystems for the plumbing and HVAC industries that use thin-film thermoelectric technology to convert available thermal energy into electric power. Thermobility uses differences in temperature to enable power anywhere there is an adequate heat source. The company is actively applying Thermobility energy harvesting in the development of plumbing subsystems and HVAC because heat differences in plumbing fixtures and HVAC provide excellent sources of thermal energy. Visit www.nextreme.com

The new Versatec Base is a compact water source heat pump for water loop and geothermal applications. The model exceeds ASHRAE 90.1 efficiencies, while utilizing environmentally friendly R410A refrigerant. Available in capacities of 018-070 MBtuh output, the heat pump features a reciprocating single-capacity compressor paired with a PSC blower motor. Optional X13 and variable-speed electronically commutated motors (ECM 2.3) are available. Visit www.waterfurnace.com

Teknor Apex Company

Newport Oriel The Sol-UV Solar Simulator is an advanced solar simulator for demanding photobiological applications such as testing overthe-counter sunscreen products’ sun protection factor (SPF). The new unit simulates solar ultraviolet radiation required to induce a minimum erythemal response for in-vivo SPF testing and can be used for invitro methods as well. The solar simulator features a patent-pending optical design to achieve spectral compliance, using a proprietary filter and unique geometry to meet all applicable standards for a light source for SPF testing. Visit www.newport.com/ Sol-UV-PR10 30 applianceDESIGN February 2012

H2W Technologies Linear Induction Motors (LIMs) can move large, heavy loads quickly and reliably. Capable of accelerations over 5 g’s and velocities up to 17 m/sec (675 in/sec) these linear induction motors are used in applications such as conventional or palletized conveyor systems, inter-terminal airport people movers, baggage handling, crane drives, and theme park rides. The LMG06-650-SSE is able to generate 2900 N (651 Lb) of thrust. At a 3-percent duty cycle and operating at 400 VAC, 75 Hz, the synchronous velocity of this LIM is 17 m/sec. Visit www.h2wtech.com

A new series of wet-grip thermoplastic elastomer (TPE) compounds for injection molding promises to add to the enormous popularity of soft-touch features in consumer products by retaining a non-slip surface and secure grip even when wet. The company will introduce the TPEs at NPE2012 (Booth 58038). The styrenic block copolymer compounds minimize or eliminate a problem encountered with many standard TPEs in soft-touch applications like grips, handles, knobs, and cushions. The Monprene products retain their rubber-like traction when wet, while providing the same elasticity and other key mechanical properties. They are available in hardnesses from 10 to 45 Shore A and can be applied onto a variety of substrates by means of two-shot, coinjection, or insert molding. Visit www.teknorapex.com www.applianceDESIGN.com

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NEW PRODUCTS

Equipment Solutions Technifor The LaserTop bench top enclosure, with attached hand-held controller, makes incorporating laser marking technology into any manufacturing operation a simple process. The streamlined metallic CDRH Class 1 workstation (25” x 23.5” x 30.5”) fits a standard workbench or table. The large, balanced U-shaped vertical movement door supports the easy loading/unloading of parts. The roomy (22” x 22” x 14”) marking chamber has an embedded light and enough space for a rotary device or tag feeder. Visit www.technifor.us

The RVC-5 Rotational Voice Coil Motor is a rotational voice coil stages with the precision of a galvanometer and the compact size f a resonant scanner. The rotational voice coil motor creates rotational translation using a flexure bearing by tilting a precision mirror, grating or other user supplied load +/- 5 degrees. Developed using advanced FEA technology, the motor measures just 25 mm x 40 mm x 15 mm. The non-contact electro-optic sensor directly monitors the user load with micro-radian scale resolution, and can be commanded to oscillate or move to any fixed point in its angular range following a completely linear velocity move profile. Visit www.equipsolutions.com

PEM

Dallas Centering

C.A.P.S. captive panel screws integrate a captive screw with anti cross-threading feature and a PC/ABS colored knob for a set of fasteners good for applications where subsequent access to an assembly may be required. These spring-loaded assemblies install permanently in aluminum or steel sheets as thin as .036 inches and can be supplied in self-clinching, flaring or floating mounting styles. Knobs can be specified in standard black, red, orange, yellow, green, blue, violet, or metallic. A Phillips drive enables tool access and the robust knurled knob allows for hand operation. Visit www.pemnet.com

The Dallas automatic centering reel handles coils up to 20,000 lb., with a maximum coil width of 36 inches, 72 inches O.D. and I.D. range of 20 inches to 24 inches. It has a threading drive that supports the coil, permitting smooth unwinding of the material. Coil loading is simple because the reel support arms contract. This allows for ease of coil loading and automatic expansion of the coil I.D. centers and holds it in balance. A drum type reel mandrel expands and contracts with a wedge design arrangement that regulates the expansion pressure eliminating distortion of the coil I.D. Visit www.dallasindustries.com

32 applianceDESIGN February 2012

Standex Electronics The company introduced its non-contact proximity alarm that combines audio and visual alerts. When the trigger element nears the base element, an LED indicator light is illuminated and an audio warning sounds. The technology is built around magnetic reed switches which sense proximity without contact. The battery-powered device requires no wires or hookups, and build around the GR150 and GR200 magnetic reed switches. Measuring as small as 3.7 mm in length, these extremely small reed switches retain magnetic sensitivity of 2-4 AT, typical operating time of 0.2 milliseconds and a release time of 0.1 milliseconds. Visit www.standexelectronics.com,

Systematic Automation Inc. The company has developed a compact and efficient modular ultraviolet conveyor for curing coatings, adhesives and pigmented inks. It features a curing system with a UV lamp delivering 400 watts per inch of curing power. Touch screen control panel mounts anywhere on a conveyor, machine or system. A black pigmented Teflon coating on the conveyor belt extends the life of the belt. Dozens of standard configurations are available. Modular design permits low cost customization. Visit www.systauto.com  www.applianceDESIGN.com

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Branson Ultrasonics Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 www.bransonultrasonics.com Design & Manufacturing Texas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 www.dm-texas.com Henkel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 www.henkelna.com/appliances

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Richco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 www.richco-inc.com/appliance Sensirion Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 www.sensirion.com TECH ManufactureXPO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 www.techmanufacturexpo.com Underwriters Laboratories Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BC www.ul.com/advantage

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