Manufacturing & Prototyping

Designing and Fabricating a Multiple-Decade Battery

There is a great need for energy sources that can power unattended sensors for more than a decade. Unattended sensors can be located in harsh and remote locations that are often dangerous for personnel maintenance and power source replacement. The power source must last the lifetime of the sensor. Unlike chemical batteries, the higher energy densities of radioisotopes allow the sensors to operate for infrastructure lifetimes (~150 years). Isotope batteries (iBATs) have the potential to become reliable, robust, and maintenance-free power sources for remote, long-term, low-power sensors. iBATs are different from chemical batteries because they are self-contained energy sources using radioisotope decay.

Posted in: Briefs, Aerospace, Defense, Manufacturing & Prototyping, Design processes, Batteries, Fabrication
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Development and Evaluation of the Stingray Amphibious Maritime Unmanned Ground Vehicle

Every year, the U.S. Navy and Marine Corps conduct thousands of Maritime Interdiction Operations (MIOs) to enforce embargoes, intercept contraband, prevent drug and human smuggling, and fight piracy. These operations are usually conducted by Visit, Board, Search, and Seizure (VBSS) teams using rigid-hull inflatable boats (RHIBs) or helicopters. Key performance parameters were developed for a portable, throwable robot that can best support their missions. This robot can be used for advanced reconnaissance as the team is about to board a target vessel, to assist in compartment clearing, and for inspection of flooded compartments and bilges.

Posted in: Briefs, Defense, Manufacturing & Prototyping, Product development, Autonomous vehicles, Marine vehicles and equipment
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Fanjet Evolution — the Next Steps

The global aerospace sector has always represented the cutting edge of practical technology advancement. When the first military jet engines emerged in the post-war 1940s it was clear that commercial applications would soon follow. The leap in performance, payload capability, maintainability, and speed compared to the best that turbo-supercharged piston-engines could offer was truly revolutionary.

Posted in: Articles, Aeronautics, Aerospace, Aviation, Defense, Manufacturing & Prototyping, Propulsion, Engines, Commercial aircraft
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EOS and MTU Advance Quality Measures for Metal-Based Additive Manufacturing

EOS and MTU Aero Engines have partnered to develop quality-assurance measures for metal engine components using additive manufacturing (AM), signing a framework agreement for the joint strategic development of their technologies.

Posted in: Technology Update, Aeronautics, Defense, Manufacturing & Prototyping, Optics, Manufacturing processes, Engine components, Quality assurance
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Silicon Carbide Foam

Silicon carbide (SiC) foam from Goodfellow (Coraopolis, PA) provides the exceptional hardness, high-temperature durability and performance of solid silicon carbide, but in a lightweight foam structure. The matrix of cells and ligaments of silicon carbide foam is completely repeatable, regular and uniform throughout the material, yielding a rigid, highly porous and permeable structure with a controlled density of metal per unit volume. Characteristics of SiC foam include: exceptional hardness (Mohs 9) and resistance to wear and corrosion; can withstand temperatures up to 2200°C; high thermal and electrical conductivity; and low thermal expansion.

Silicon carbide foam is available from stock in a standard pore size of 24 pores per centimeter (60 ppi), with a bulk density of 0.29 g.cm-3, a porosity of 91% and a thickness of 10mm.

For Free Info Visit http://info.hotims.com/55588-510

Posted in: Products, Defense, Consumer Product Manufacturing, Materials
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Dual-Node, Short-Depth 4U Chassis

Advantech (Irvine, CA) has launched the 4U, dual-node, short-depth (350mm), industrial chassis ACP-4D00 designed for machine automation applications that require two computers in one piece of equipment. The dual node architecture allows the user to install two half-size slot SBCs in two sub-systems and integrate them in a compact 4U cage. Each ACP-4D00 node supports a PICMG 1.3 or PCI half-size CPU card with computing power up to desktop Core™ i7, 6-slot backplane with maximum 3 PCIe or PCI expansion slots (3 slots are occupied by CPU card) and 250W or 350W high-efficiency 80 Plus power supply.

Currently Advantech offers two PICMG 1.3 CPU cards— PCE-3028 (Intel® Q87), PCE-4128 (Intel® C226), and three PICMG 1.3 backplanes—PCE-3B03-00A1E, PCE-3B06-00A1E, and PCE-3B06-03A1E, for use with ACP-4D00. The system configurations support the latest Intel® 4th generation Core™ i processors, advanced PCIe Gen 3, or legacy PCI expansions.

For Free Info Visit http://info.hotims.com/55588-511

Posted in: Products, Defense, Consumer Product Manufacturing, Automation, Electronics & Computers
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Custom 19” Fan Tray

Verotec (Derry, NH) recently custom designed intelligent fan trays for a major defence project. The 19-inch rackmounted 1U trays have six fans, strategically located within the tray to maximise the cooling of critical elements of the electronic system located above the fan tray. Key issues for the fan tray design were noise levels, current consumption and reliability. A custom control board sequentially powers up each of the fans in order of importance to minimise initial inrush current. An embedded microprocessor controls fan speed using PWM technology.

Reliability is critical, so three separate events will trigger a warning signal: if power is lost to the fan tray, if the controller board itself develops a fault or if the speed of any fan falls below 20% of maximum. The fan cooling the main processor board is deemed to be a critical component, so if its speed falls below 20% the relay latches into the alarm position. If triggered by any of the other five fans, the alarm relay will re-energise when the speed increases above the 20% threshold.

For Free Info Visit http://info.hotims.com/55588-512

Posted in: Products, Defense, Electronics & Computers, Thermal Management, Consumer Product Manufacturing
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Signal Conditioning Modules

Precision Filters Inc. (Ithaca, NY) has introduced a new family of signal conditioning modules for measurement systems built on National Instruments™ rugged, compact, low power cRIO™ platform. The four analog input/output modules condition charge, bridge, dynamic strain, IEPE or voltage-based sensors. With the supplied LabView™ driver VI, you can integrate PFI™ signal conditioning module technology with proven NI™ voltage input A/D modules to build a complete high performance sensor measurement system for charge, voltage, bridge and dynamic strain.

For applications where a rugged, low-power, compact standalone signal conditioning system is required as a front-end for a data acquisition system, the new signal conditioning modules can be housed in low-cost 4-slot or 8-slot chassis and controlled by PFI’s Graphical User Interface software with no code development needed. All modules feature fully programmable gain and excitation and are equipped with Precision Filters’ Test Input for inserting calibration signals at the module input allowing full end-to-end verification.

For Free Info Visit http://info.hotims.com/55588-513

Posted in: Products, Defense, Consumer Product Manufacturing, Measuring Instruments, Test & Measurement
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Flange Couplings

RINGFEDER POWER TRANSMISSION (Westwood, NJ) has announced the launch of its new RfN 5571 series flange coupling for heavy industry. RINGFEDER® flange couplings provide a superior solution to standard press fits. Equipped with the Ringfeder Shrink Disc this new series eliminates the needs for additional components such as keyways or shims. Eliminating the need for heating and cooling of the part reduces installation complexity. RINGFEDER® flange couplings are slip fit with frictional engagement achieved by torqueing the shrink disc screws. Available with hexagon head screws or hexagon socket head cap screws. Some of the advantages provided by this system are: a stronger connection than keyway systems, no wear parts, higher torque carrying capacity, backlash-free shaft hub connection, and a high level of true running accuracy.

For Free Info Visit http://info.hotims.com/55588-514

Posted in: Products, Defense, Consumer Product Manufacturing, Joining & Assembly
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Digital Meter

The New Technology Meter (NTM) from OTEK (Tucson, AZ) has everything you need to measure and control your process while operating with less than 50mW of power. OTEK’s NTM boasts a full tricolor bargraph with 2% resolution and four alarm set points. The NTM includes isolated Serial I/O, isolated O.C.T. or SPDT relays and isolated analog output with P or PID algorithm. OTEK has included signal failure (open or short) detection with date and time transmission. The meter is available in over 30 different input signals. It is also available in loop or signal powered versions, but feature restrictions apply.

The NTM-9 replaces fit, form and function any 6" × 1.74" panel cut-out and has up to two channels. The meter is available in an industrial plastic or a metal housing and can meet nuclear or military grades.

For Free Info Visit http://info.hotims.com/55588-515

Posted in: Products, Defense, Consumer Product Manufacturing, Measuring Instruments
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