Energy Efficiency

Energy efficiency is another “hot” topic. And like many topics in technology, its very prone to misunderstanding and misrepresentation.

For example, a recent prominent engineering magazine published a cover article on the subject of electric cars, one of my favorite topics. And the cover had a really cool graphic comparing the energy density of lead acid batteries to the newer lithium ion batteries which have 4 time better storage capability, and then comparing that to gasoline’s energy density which is eighty three times more power per pound than lead acid technology. Read more

What guarantees Mechatronics success? Communications.

By Leslie Langnau,
Managing Editor
Design World

In an ideal world, if top management had its way, product design and development time would be seconds, (maybe minutes) rather than weeks. Such an idea is reminiscent of the “replicators” from the fictional TV series Star Trek. You simply asked for what you wanted, perhaps specified a few details, and the part or device appeared in seconds.
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Facts or Fiction? Politics or Science.

I recently picked up my monthly copy of one of the pre-eminent magazines in the sciences that I have subscribed to for many years. This month’s cover article was on American energy policy. OK, fine. We are all concerned about the rising prices at the pump and impact (mostly negative) on our economy.

But it freaked me out when I tried to read the article. The entire thing was an editorial based on reader responses to a survey sent out by the magazine. No facts, no science, no specific issue really, not even any survey demographics, no factual support for several pages of random assertions about what different factions in the government are doing wrong and the havoc being wreaked in our economy.

I admit, I got a little irate. Read more

One Size Never Fits All

Sometimes a lot is made of new technology. There is a tendency to talk about the next big thing in whatever field as “The Solution”. But there’s rarely just one solution that works for everyone.

Currently in the “car wars” (a favorite topic, since we are all effected by gasoline prices) many ideas have been advanced as “The Solution”. We heard a lot about bio-fuels reducing our dependency on oil by 30%, but now are primarily contributing to rising food prices. Hydrogen fuel cells will replace gasoline engines, but not anytime soon because we don’t have an infrastructure that can produce hydrogen as a fuel, nor an acceptable means to store it. And so it goes. This progression of ideas, and attempts to market same, makes the point that there is rarely a single solution that suits everyone. Read more

More Mechatronic and Robotic Reflections

The blend of sensors and motion control become crucial in many applications. The dextrous robot hand of recent years cracks eggs like a chef with the aid of sophisticated pressure sensors at the tips of its “fingers”. Check out the Shadow Robot company for some amazing videos of their “air muscle” powered robot hand in action. Lots of interesting work has been done to mimic the human hand. A miracle of grace and efficiency that is hard to duplicate. Read more

Clarity

A national talk-show host I listen to comments “I would rather have clarity than agreement”. I think that is a great platform for discussion. And I approach the blog with the same goal. This posting is an attempt to clarify my previous entry.

I got into the big debate on automobile technology in the 1980’s. It started with a duty cycle chart of engine horsepower and led me to join Unique Mobility in the late 80’s to try and help bring hybrid technology to the California low emission initiative. We were not successful. Primarily because none of the Big 3 automotive companies would agree to supply a vehicle platform for the drivetrain we developed. We did succeed in building a drivetrain for BMW’s EV-1 and EV-2 which were very successful steps along the way.

But the point of my earlier blog was simply to comment on “automobile technology” as the greatest mechatronic challenge of all. You can start with a simple F=ma approach and deal with how much mechanical power must be produced to move the vehicle, which the Big 3 have been messing around with for years. We have cars made out of plastic to reduce vehicle weight (the “m”) in an effort to get lower power solutions which mean more miles per gallon, you know the rest. Read more

Energy Policy

Americans have been focusing on energy reduction in this country for some time. In an upcoming article to be published in Design World, I will detail some of the impact of national energy policy on how electric motors should be built, and how they should be used. The main conclusion of the article from a technical perspective, is that the big energy savings come from control system solutions, not from incremental improvements in electric motors themselves, which the Department of Energy has spent a lot of money pursuing.

It is reasonable that the government concerns itself with how energy is used. But what is appropriate for implementing policy? Is it in the national interest to develop better washers and dryers? better refrigerators? better air conditioning systems? Or is this the domain of private enterprise? Business that is for profit and normally makes the investment in product development sometimes gets a hand from government. Read more

My first brush with Mechatronics came courtesy of White Sands Missile Range

Imagine a missile launch,” my boss explained. “It comes out of the silo without warning, goes like a streak, and sometimes explodes on launch. We want an unmanned tracking mount that will sit close to the launch area, pick up the missile, and track it — no matter what.”

The engineering assignment was pure Mechatronics. Make the mechanical pieces strong but light enough for the accelerations and slew rates to come. Give the drives enough power, speed, and responsiveness. Make sure the sensors could pick up the bird, lock on it and follow it to the death. Fashion controls that would tie it all together and make it all work.

It was, in short, classic Mechatronics, though we never used that word. It would be two years later, in 1969, before Tetsuro Mori, a senior engineer at Yaskawa, coined it. But how the practice of Mechatronics, and the engineering disciplines it uses, have grown in the years since then. Read more

Mechatronics’ Present and Future

Having just gotten back from the annual extravaganza known as the Consumer Electronics Show, I’m happy to report that the outlook for mechatronics is definitely positive. The integration of electronics and mechanical systems was clearly in evidence at CES, on both the micro and macro level.

To start small, one of the more impressive in-suite demos was presented by Microvision of Redmond, WA. The company has developed what it calls the PicoP engine for projecting video and images onto any reflective surface. The engine consists of a MEMS chip with a mirror that can steer RGB laser light to raster the image onto the surface. An entire system was contained in a case about the size of an iPod. There were also a lot of new game controllers that rely upon the ability to sense motion to provide an extra dimension to gaming, as well as hepatic feed back systems to let you feel the pain.

At the other end of the size spectrum, there were the huge MEMS micromirror projection systems in the Texas Instruments booth. There were also several concept cars from Ford demonstrating the use of electronic systems for control of steering, abs, air-bags, and other critical systems that were once strictly mechanical. This list could continue to grow, but it’s clear that the marriage of electronics and mechanics is still on very solid footing.

I also saw a number of display systems, and while they didn’t rely on mechanics in the larger sense, it was their physical performance that started me thinking about the future of mechatronics. What I was hearing is that this one type of display system, while its appearance was excellent, was having problems related to material stability over time. It was critical to the products success, yet it was something that was only found out once many, many units were in production.

Today we are at a stage where we can simulate the interaction of mechanical and electronic systems with a good degree of accuracy. But when it comes to the performance of materials over time, or in a particular design for that matter, we seem to still be in the dark ages. The materials/chemical engineer can use his or her expertise to suggest what is likely to happen, and has tools for creating new molecular compounds, but I know of no system today that will allow you to integrate that knowledge into the realm of electromechanical design.

Once we’ve tackled the problems that mechatronics poses to unifying electromechanical design, I hope we’ll be able to take the next step into materials science and bring in the ability to alter or design new materials that will fulfill the end requirements of product in new and unique ways. But I guess we have to learn to walk before we can run (and after having been all over the huge Las Vegas Convention Center for CES, I’m happy for now to still be able to walk).

Mechatronics Training

If mechatronics wasn’t difficult enough to define (concisely), try and get a degree in it! Interestingly, with the increased attention that mechatronics is receiving around the globe there are established degree programs in Europe and Australia. Some schools in the US are picking up on the trend. The electric car races, Darpa Challenge and battling robot competitions, with some very hefty cash prizes, have stimulated interest from thousands of participants and spectators alike.

The latest innovation is the partnering of schools, automation equipment suppliers and funding from the Department of Labor. DOL (Department of Labor) estimates that 10 million technical factory jobs could go unfilled by the year 2020 without an aggressive effort to train students and teachers. The assessment of American labor’s capability to deal with emerging technology trends on the factory floor has lead DOL to contribute millions of dollars in cooperation with schools and equipment companies to make state-of-the-art training available on a large scale. Read more

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