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Troy (MI) High School got an amazing new space this signed by AME. It includes year—a new Automotive Technology lab—with the help new workstations, desks, of local businesses. Business leaders in the area have seri- shelving, roll carts, and tool ous concerns about the shortage of skilled workers who boxes. Easterbrook reached can work on today’s technology-heavy vehicles. They out to other local business- decided to invest in the lab so that students are ready to es for additional donations enter the workforce right out of high school. which included dealership graphics, signage throughout The auto lab’s curriculum prepares students to take the lab, new lab coats, and money for new tools, and the Student ASE (Automotive Service Excellence) and equipment. Michigan State Mechanic tests. Passing these opens the “It was easy to get other companies on board,” Easter- door to immediate employment as auto technicians, brook said. “The district is providing a good background working in dealership service departments and other in automotive technology and preparing students to be repair facilities, according to the school’s automotive certified. When they finish their training after high school, instructor Dustin Warner. they can have a great job making six figures with no col- “Schools are recognizing the needs of businesses and lege debt.” providing the right learning opportunities to students,” The lab is set up to look like a service center, and said Troy School District Superintendent Rich Machesky. offers three lifts and the same diagnostic tools the stu- “We’re a pipeline to employability, connecting kids with dents will encounter when they enter the workforce after jobs in much-needed fields.” school. David Easterbrook, owner of Troy-based AME compa- “Our vision is to provide world-class learning opportu- nies, got the ball rolling. He shared his ideas for the new nities to all of our students,” Machesky said. “Often times, auto shop with the school principal Remo Rencone. “It’s the skilled trades get left out of the conversation. The dis- nice to have a dream, and then somebody else tells you trict made the decision to partner with these companies to dream bigger,” Roncone said. “The new lab would not and generate a win-win situation for everyone.” have happened without his guidance and support.” To see the lab, visit: https://www.wxyz.com/news/ Easterbrook also founded Ashley’s Dream, named after metro-detroit-high-school-unveils-state-of-the-art-auto- his daughter who was killed in a drunk driving accident, technology-lab five days before her high school graduation in 1997. Since then, the foundation has awarded one student a scholarship through The Ashley Marie Easterbrook Scholarship Foundation. This year that scholarship money went to Troy high school to help create the lab, which was rede-

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4 techdirections X MARCH 2018 March 2018 contents Vol. 77, No. 7

CNC Mineola HS Introduces CNC Technology into Their 12 Curriculum By Maryann Valentine The new “Fab Lab” is inspiring students from various disciplines, and is bringing the student body together at Mineola HS. AUTOMOTIVE TECHNOLOGY Special Focused Issue 13-24 A collection of articles for automotive technology educators. STEM Physics/Engineering Mash-Up Piques Student Interest 27 By Douglas Ripka Nested courses provide a well-rounded STEM experience. page 13 PROFESSIONAL DEVELOPMENT The Time is Ripe for Tech Apprenticeships By Eric Larson 30 How Tech apprenticeships are going to help close the skills-gap that SPECIAL is looming on the horizon. FEATURES Teacher Training Opportunities 32 Excellent options for continuing education to keep your skills and knowledge up to date.

Product Spotlight 33 A selection of excellent products to make your teaching efforts easier and more effective.

COLUMNS 2 Technically Speaking 8 Technology’s Past Vanessa Revelli Dennis Karwatka 6 The News Report 10 Mastering Computers Vanessa Revelli Reid Goldsborough 7 Technology Today 34 More than Fun Alan Pierce

About the cover: Taking an artistic approach to looking at the intricacies of a vehicle’s engine. Cover design by Sharon K. Miller. page 12 www.techdirections.com CONTENTS 5 The audio series offers listeners access to current and valuable infor- the news report mation to give them better insights into the opportunities and challenges facing the collision repair industry. Vanessa Revelli “We are confident that listeners [email protected] will find the new podcast series to be a valuable resource,” said John Van Autonomous Vehicle of roads with intersections, traffic Alstyne, I-CAR’S CEO & president. Test Facility Offers signals, street lighting, sidewalks, fire “They can expect to hear about how Real-World Advantages hydrants, simulated buildings, and I-CAR is supporting the collision In January PPG announced its obstacles like construction barriers repair industry with innovative solu- partnership with the University of and pedestrian crash dummies. Mc- tions to help them navigate the many Michigan’s (U-M’s) Mcity, a public- ity also funds academic research and ongoing technical challenges.” private partnership that brings works with its partners to deploy con- The first episode, entitled “The together industry, government, and nected and automated vehicles in Ann Future of Diagnostics,” offers reflec- academia to improve transportation Arbor and Southeast Michigan. tion and perspective on one of the safety, sustainability and accessi- “Autonomous vehicle technology most pressing issues industrywide. It bility for the benefit of the society. offers numerous real-world advan- is hosted by Elise Quadrozzi, I-CAR’s Mcity’s work vice president of education & techni- includes operat- cal services. This episode features ing the Mcity Test Jake Rodenroth, director of client Facility, the world’s services, Collision Diagnostics Ser- first purpose-built vices, Plano, Texas; Mike Anderson, proving ground president/owner of Collision Advice for testing autono- Consulting, Alexandria, Virginia; and mous vehicles, Gerry Poirier, national APD strategy connected-vehicle manager, Farmers Insurance®, At- systems, and re- lanta, Georgia. lated technologies. The discussion centers on per- University Michigan of PPG is the first spectives from industry thought paints and coat- Mcity autonomous vehicle test facility leaders regarding the concerns, ings manufacturer needs, solutions, and advancements to join the Mcity partnership. tages, and the ability to test such related to diagnostics. The discus- A leader in advanced paints and technologies safely and thoroughly sion includes questions that were coatings technologies for the auto- is essential for proving the viability included in I-CAR’s inaugural Colli- motive industry, PPG is developing of advanced mobility solutions,” said sion Reporter magazine, focusing on a broad portfolio of coatings to im- Huei Peng, director, Mcity. “Our state- Diagnostics, published in July. prove functionality and enable broad of-the-art facility offers a controlled These podcasts bring together deployment of autonomous vehicles. environment for manufacturers like a multitude of industry resources These developments include exterior PPG to develop and hone the capa- to provide relevant and accessible coatings that enhance vehicle vis- bilities of autonomous vehicles and information. The Driving the Conver- ibility to radar and light detection related technologies.” sation series looks at technical issues and ranging (LIDAR) systems, as well through various levels of business as easy-to-clean coatings that help Driving the Conversation impact. It is focused around techni- prevent obstruction of autonomous Podcast Keeps Listeners cal training, information, and related vehicle sensors. Up-to-Date with the Industry services to equip the collision repair The Mcity Test Facility, which I-CAR is introducing an informa- industry with the resources needed opened in 2015, was developed by tive new hot-topic industry discus- to contribute to complete, safe, and U-M with support from the Michigan sion audio series through internet quality repairs that optimize busi- Department of Transportation. The podcasts. The monthly series of pod- ness performance, reduce risk, pro- facility aims to re-create a range of casts, called Driving the Conversation, vide career development pathways, operating challenges faced by ve- includes informative and engaging and advance industry professional- hicles on the road with simulated discussions from industry thought ism. Listeners can subscribe to the urban and suburban environments. leaders on noteworthy topics. podcast series on iTunes or Google Located on U-M’s North Campus, the The series features industry lead- Play Music. facility offers more than 16 acres of ers providing their view on a variety roads and traffic infrastructure, in- of topics related to the rapid changes Vanessa Revelli is managing editor cluding approximately five lane-miles within the collision repair industry. of techdirections.

6 techdirections X MARCH 2018 stores to provide customers with information about a specific product technologytoday that they are looking at. In each case people in close prox- imity to each other could all hear Alan Pierce different audio beamed to their loca- [email protected]; on Twitter @ TechToday_US tion. Everyone outside of the sweet spot for sound would be completely Samsung’s S-Ray Demonstrated at CES 2018 oblivious that a person sitting or The Consumer Electronics Show spot for sound can be, Dr. Tae-Young standing inches from them is hear- (CES) is held in January in Las Ve- Kim, the project leader, used a Mini ing what they cannot hear. Samsung gas. When it comes to consumer S-Ray sound speaker that was de- did not have pricing, or even a date electronics, CES is the place to go signed to have an extremely narrow when this technology will become to see evolutionary, revolutionary, beam. He moved the sound speaker available to the public. This Samsung and/or incremental technology ad- as if he was shining the sound wave YouTube video can provide some vances. beam toward my ear. When he more insight into this new technol- In the 1965-1970 TV series Get moved the sound speaker, which was ogy: https://www.youtube.com/ Smart, the “cone of silence” was a about 2' from my ear, so it was no watch?v=3dbZuzs46E4. fictional device that was supposed longer aimed at my ear, the sound to keep a conversation completely disappeared. A small movement in Taking It a Step Further secret by preventing anyone outside either direction from the sweet spot 1. How do you see this technology of the cone from hearing what was eliminated my ability to hear the being adopted for use in all the differ- said inside the cone. Like most of music. Photo 2 shows the different ent areas of technology? the tools that the bumbling secret size units that the Creative Lab team 2. What do you see as the most agents of the show used, the cone of brought to CES to demonstrate their unusual applications for this technol- silence didn’t work. You can find an technology. ogy? episode that includes Agent 99 and the Chief using the cone of silence online at https://www.youtube.com/ watch?v=HWtPPWi6OMQ . The concept behind this prop, designed to make the audience laugh when they watched the show, was actually unveiled by Samsung at this year’s CES. Samsung’s S-Wave focuses sound waves into a directional wave that can be projected as if the sound was a focused narrow beam of light. The light beam is a tool to help you understand how Photo 1—The black Samsung the sound is focused into a direc- band around the tional beam. Their directional sound author's neck projects Photo 2—To demonstrate this technology, the beam, which is totally invisible, can the audio directly into engineers from the Samsung Creative Lab brought only be heard if you are located in a his ears. three different sized and shaped sound projectors. physical sweet spot aligned with the beam of sound. To be honest, if this demonstra- 3. Active noise cancellation is now At the Samsung Creative Lab tion was taking place at a booth used to silence environmental sound. booth I had the opportunity to dis- without Samsung’s reputation, I Do you feel the engineers who devel- cuss S-Wave with the project team would have had difficulty believing oped this technology should explore that developed the S-Ray. I also tried what I was hearing and seeing. They using their system to not only coral out the prototype units they brought were showing me that sound waves sound waves into a directional beam with them to demonstrate their tech- could be corralled into a tight beam. but also to silence environmental nology. The black neck band I am Besides the obvious use of elimi- noise that is not part of their audio? wearing in Photo 1 focuses the sound nating ear buds and headsets, this Why? so it reaches only my ears. A person technology can be used in museums standing next to me wouldn’t be able to provide audio for the exhibits, on If this column sparked an activity to hear the audio coming from the airplanes to provide individual audio please email me photos and a short head band. that matches the movie playing at description for posting on my web- To show just how small the sweet your seat. It could also be used in site. www.techdirections.com TECHNOLOGY TODAY 7 smoothly as a team throughout their professional lives. technology’s past In looking for new technical opportunities in 1921, Crosley was attracted to radios for the consumer Dennis Karwatka market. They were increasing in [email protected] popularity but he felt they were over- priced. The cheapest radio he found Powel Crosley and His Technical Successes for his young son cost $130. Like Americans living in the 1930s and was a businessman who provided a almost all those purchased in stores, 1940s were familiar with the Crosley middle-class lifestyle for the family. it was a large and heavy floor model. name. They knew Crosley attended It took Crosley only a few months to about Crosley local public establish a factory to make less ex- radios, Crosley schools and pensive radios. His small Pup model automobiles, and the University cost less than $10. Crosley became Crosley Field in of Cincinnati, the world's largest radio manufac- Cincinnati, OH. All although he did turer in 1924. He went on to obtain were named after not graduate. a commercial broadcasters license Powel Crosley, a One of his for Cincinnati station WLW ("World's self-made innova- early jobs as a Largest Wireless" at 700 AM). A nomi- tor who had a chauffeur re- nal 50,000-watt radio station, it had variety of inter- quired that he the most powerful transmitter in the ests. maintain the au- world. Born in Cincin- Powel Crosley, circa 1920s tomobile as well But the automobile was always at nati in 1886, Cro- as drive it. He the back of Crosley's mind. He want- sley was the oldest of four children. enjoyed the work and, until about 25, ed to provide cars that were inexpen- He was close to his brother Lewis Crosley was employed at various au- sive both to purchase and to oper- throughout their lives. Their father tomobile businesses. He was earning ate. His first Crosley automobile was about $20/week when he invented a built in Richmond, IN, and came out device that allowed quicker repairs in 1939. He displayed it at the World's of flat tires. Crosley borrowed $500 Fair in New York City. The small car from his father for part interest in a used a two-cylinder air-cooled 12 hp manufacturing business he named In- engine built by the Waukesha En- syde Tyre, which he later purchased gine Company. The car was 4' wide, from his other investors. It was the 10' long, weighed 925 pounds, and first of his many successful ventures. cost only $325. The Crosley’s fuel Crosley married Gwendolyn Aiken at economy was a remarkable 50 miles that time, and they had two children. per gallon. Crosley's brother Lewis returned About 6,000 were built through from World War I service and be- 1942, when World War II caused came the company's manufacturing American automobile production to manager. The two brothers operated cease. Crosley resumed production after the war and built small sedans, sports cars, pickup trucks, panel vans, and other vehicles. Those vehicles had more power- Above, Crosley Pup ful four-cylinder engines model was the world's and some were the world's smallest tube-type radio first production models to feature disc brakes. In all, Crosley sold a total of about 75,000 cars before

Dennis Karwatka is Right, Crosley with professor emeritus, Depart- WLW's transmitter in ment of Applied Engineer- the 1920s ing and Technology, More- head (KY) State University.

8 techdirections X MARCH 2018 wealthy and owned eight homes, six yachts, 14 airplanes, and Bull Island off the coast of South Carolina. He Right, 1947 convertible, also established companies that with Crosley in the built household appliances, private driver's seat airplanes, and military equipment. A tall, pleasant man who enjoyed hunt- ing and ﬁshing, Crosley died unex- pectedly in 1961.

References Geogano, G. N. (Ed.) (1973). The complete encyclopedia of motor cars. Left, 1951 Hot Shot E. P. Dutton Publishers. model McClure, Rusty, et al. (2006). Cros- ley—Two brothers and a business empire that transformed the na- tion. Clerist Press Publications. Right, Crosley Field in the 1960s ending production in 1952. was named Crosley Field. It Crosley owned the Cincinnati was torn down in 1972. Reds baseball team between 1934 Crosley personally and 1961. He arranged major league knew American presidents, baseball's ﬁrst night game in 1935. movie stars, and industrial The stadium where the Reds played giants. He became quite

www.techdirections.com TECHNOLOGY’S PAST 9 sits underground along the border between Switzerland and France. The mastering computers first Web browser, text based, was released to the public in 1991. And the Internet preexisted the Reid Goldsborough Web, with the U.S. government build- [email protected] ing connected computer networks in the 1960s to support its research A Quarter Century of the Graphical Web activities. This included ARPANET, Twenty-five years ago, the world at the University of Illinois at Urbana- the Advanced Research Projects as we know it changed when Mosaic Champaign. Agency Network, created in 1969 and was released. With Mosaic, not only could you This was the first useful, and first see text and graphics on the same widely used program that let people page and click your way from one With Mosaic, you could more easily navigate this newfangled site to another, you could do so ad see text and graphics Internet service called the World infinitum. Mosaic was free for non- Wide Web. Most important, you commercial use, with public funding on the same page and could see images on the same page provided by programs initiated by click your way from one as text. This caused the Web to ex- then Senator Al Gore of Tennessee. site to another. plode in popularity. The Web itself came into exis- Mosaic was developed by two tence four years earlier. It was in- graduate students, Marc Andreessen vented in 1989 by Tim Berners-Lee, considered to be the founding of the and Eric Bina, with the National Cen- a British physicist and computer Internet. ter for Supercomputing Applications scientist who was working at the The Web was predicted earlier, by time for CERN, the European Orga- the science fiction writer Arthur C. Reid Goldsborough is a syndicated nization for Nuclear Research. CERN Clarke in his groundbreaking novel columnist and author of the book currently operates the Large Hadron 2001: A Space Odyssey, published in Straight Talk About the Information Collider, the world's largest sub- 1968. Much earlier than this, another Superhighway. atomic particle accelerator, which science fiction writer, H. G. Wells,

10 techdirections X MARCH 2018 predicted a "World Brain" in a col- did-in previous online services such during these years with the introduc- lection of essays between 1936 and as CompuServe, America Online, tion of social networking sites such 1938. Prodigy, and Genie; forced many as Facebook and Twitter, blogs at The year after Mosaic was re- newspapers and several prominent sites such as Blogspot, wikis such as leased, in 1994, the World Wide Web encyclopedias out of business; and Wikipedia, video-sharing sites such Consortium was created at the Mas- dramatically changed the television, as YouTube, and photo-sharing sites sachusetts Institute of Technology. music, radio, film, and travel indus- such as Instagram, available now It received funding from the U.S. tries, among others. not only through computers but also Defense Advanced Research Projects Multimedia offerings through the smartphones and other devices. Agency, an agency of the U.S. Depart- Web have been made possible with The World Wide Web was key to ment of Defense responsible for the the popularization since 2000 of high- the development of the Information development of new technology for speed cable, fiber-optic, and satellite Age, and Mosaic, released a quarter use by the military and which had access to the Internet. The Web has century ago, was key to the develop- pioneered the Internet in the 1960s. also become even more interactive ment of the Web. The World Wide Web Consortium's purpose was, and still is, to create standards and recommendations to improve the quality of the Web. In 1994 Marc Andreessen moved on and cofounded the for-profit Netscape Communications (origi- nally known as Mosaic Communica- tions Corporation), which released an improved version of Mosaic called Netscape. Netscape dominated the Web browser market through the 1990s, and Mosaic, which started it all, was discontinued in 1997. Netscape was eventually swept aside by Microsoft's Internet Explorer, and Internet Explorer was later swept aside by Google Chrome. Netscape used original programming code, though Microsoft li- censed Mosaic's code to create Inter- net Explorer. Microsoft's bundling of Internet Explorer with Windows, later determined by courts in the U.S. and Europe to be an illegal monopolistic practice, is what doomed Netscape. After being acquired by America Online in 1999, Netscape was discontinued in 2008. Mozilla Firefox, released in 2002 and still in existence, also used programming code from Mosaic. Private companies began realizing the profit potential of having a Web presence beginning in 1996, and the commercialization of the Web kicked in between 1996 and 1998. This led to the dot-com boom and bust of 1999 to 2001 when trillions of dollars were made and lost as a result of what Federal Reserve Chairman Alan Greenspan at the time accurately termed "irrational exuberance." Nonetheless, the Web transformed the business landscape. It eventually www.techdirections.com MASTERING COMPUTERS 11 Mineola HS Introduces CNC Technology into Their Curriculum

By Maryann Valentine

AGER to learn, the stu- is incredible to be able to see these instructor,” said Paul Sommer, tech dents at Mineola High students take their ideas from incep- expert/teacher at MHS. School (MHS), Long Island, tion to completion, using CAD/CAM “Having a space like this is NY, work hard day to day, technology,” said Smith. unique. We are the only school on not only in their core “The school was able to transform Long Island to have made the com- Eclasses like math, science, and ELA, the lab from a conventional shop to mitment to adding this technology but also enthusiastically in the wood- an advanced lab for students to learn and advanced learning which ben- shop, to learn everyday skills. The and enhance their engineering skills. efits our students. Another benefit school recently updated their entire Tech Ed woodworking and metal- working classroom, switching from conventional methods of producing projects to an exclusive “Fab Lab” that consists of some of the most Determined advanced technological equipment technical used in the industry. education The new Fab Lab at MHS is student from equipped with machinery that few Mineola other schools have on the Island—a High School CNC plasma cutter and CNC router operating from Techno CNC Systems. Whitney Techno CNC Smith, principal at MHS, spoke proud- System’s HD ly about the new lab and how it has Series CNC effectively and efficiently changed the Router for her way the students are learning. senior project “Adding CNC to our high school program was really the next step for us,” stated Smith. “We are always on the cutting edge of technology. We are always searching for the best tools for our students. We have always had a traditional woodshop and metalshop, but now we are focusing The technology in the Fab Lab has about the space is that the 8th grade on showing the students the latest changed everything. All our 8th grad- students are all given a chance to and greatest technology in automa- ers get introduced to the equipment find a passion in CNC, thus getting tion, and the students are very ex- and do a problem-solving activity. them excited for the more advanced cited about it. We already knew our They get introduced to Aspire CAD/ tech courses offered in grades 9-12. students had great ideas, but now, it CAM software by choosing a letter of We also partnered with Queensbor- the alphabet, setting up the job, and ough Community College, where Maryann Valentine is the marketing creating a toolpath. The students are students can receive college credits manager at Techno CNC Systems in shown how to setup and operate the for courses taken,” Smith said. Bohemia, NY. CNC router under the direction of the Continued on page 25.

12 techdirections X MARCH 2018

Special Focused Issue contents March 2018

AUTOMOTIVE TECHNOLOGY

Home, James By Jeff Bogue 15 A look at autonomous vehicle technology, and how it is expected to change in the future.

page 15

Five Ways 3D Printing Is Transforming the 18 Automotive Industry By Stratasys, Inc. 3D printing is a game changer for the automotive industry by saving lots of money and time, as well as allowing full customization.

page 18

Helping Students Understand Automotive Electricity 21 By Rob Thompson Students often struggle with electricity basics. Giving them easy-to- understand visuals, and hands-on examples, help them understand these concepts. page 21

About the cover: An automotive student testing a vehicle’s exhaust system. Cover design by Sharon K. Miller.

14 techdirections X MARCH 2018 Home, James

Your autonomous chauffeur could be here sooner than you think

By Jeff Bogue

HAVE to admit that trying to keep several excursions, but Tesla, always How does all of this technology up with the throngs of technology thumbing their nose at conventional work together and where will it end? bombarding the automotive in- automotive ideals, had one of their What are Telematics and what do dustry is like trying to juggle cats. vehicles cross the U.S. in just 58 they do? Well, Telematics is a term It seems like every other day an hours while being “driven” mostly to describe the connectivity of the Iengineer says something completely autonomously. vehicle (think OnStar and others) outrageous and then some company “Mostly” is the key word here, and they are increasing that expo- puts it in a new car. Active Vehicle but cars are parking themselves, and nentially each year. (in 2010 less than Tracking, Heads Up Displays (HUD), even finding their own parking spots. 10% of vehicles had factory installed Remote Vehicle Shutdown, and Bio- On top of that they are overriding telematics. We are looking at about metric Access are just a few. active human control to apply the 62% for the 2016 model year). The Autonomous Vehicle and brakes in accident avoidance situ- The last couple of years at the Driver Override Systems are the two ations. I do believe that “mostly” is Consumer Electronics Show (CES) that have me most intrigued. These going to get smaller and smaller very have proven themselves as automotive showcases. In 2016, Audi sent an A7 from San Francisco to Las Vegas fully autonomously. BMW had a car Google self- that could roam a parking lot by it- driving cars self looking for a parking spot. Nvidia begin tests on (all you gamers know these guys, and city roads this Tesla has a partnership with them) summer. developed two computer systems specifically designed to handle the information generated by self-driving systems. In January 2017, it became even more abundantly clear that tech in From http://wot.motortrend. vehicles was going to be a format to com/1505_google_self_ driving_cars_begin_tests_ be reckoned with. BMW debuted a on_city_roads_this_summer. new user interface concept for the html/photos/#3 interior of the car called the HoloAc- are a pair that, and I love this, were quickly, and I am excited. Now don’t tive Touch system at the show. The touted just a few years ago as be- get me wrong, I love my four-wheel system features a virtual “free float- ing “in cars within the next 10 to 20 drive pickup truck with the manual ing” display that’s controlled via fin- years”. Well, that was the quickest transmission, crank windows, and ger gestures, not a touchscreen, and ten years I have seen yet. Google smell of hound dog, but sometimes it also features haptic feedback. It uses has sent their self-driving car out on is just not universally practical. sensors to detect where your finger I remember just six or so years is pointing and then a vent shoots air Jeff Bogue is an electronics special- ago reading that most people owned to that location to provide the haptic ist focused on research and develop- phones that had more computing feedback (which tech services that?). ment. He works at ATech Training as a power than what was used to put a That is just touching the surface product representative and contributor man on the moon. Now that rough es- (pun intended) of all of the other to ATech Educator News. This article timate seems grossly understated and vehicles that were capable of com- is reprinted from the December 2017 modern vehicles are making modern plete autonomous operation and/or issue of ATech Educator News. phones seem like weak little cameras. incorporating artificial intelligence

www.techdirections.com AUTOMOTIVE TECHNOLOGY 15 to entertain and chauffer. The 2018 5. GPS—integrated global posi- These sensors have a basic range of CES was not any less automotive- tioning 30' or less and take care of the light centric either with multiple speakers 6. Vehicle to vehicle (V2V) and duty work like Park Assist, but their in- from the automotive industry and Vehicle to infrastructure (V2I) com- put is deemed no less signiﬁcant than manufacturers on high alert to be jaw munication. the others and is added to the fray dropping or go home with a partici- It may seem a little redundant, but when the vehicle is in motion. pation trophy. all of these sensors work in conjunc- The automobile has seen this tion with each other to give the vehi- The Front and Rear Radar transitioning into a giant computer cle and occupants a full moving pic- Systems support adaptive cruise control, pre-crash protection, and collision warning systems with and without automatic steering and braking intervention. They also take care of the medium- and long-range New vehicles can activity. These systems can range contain infotainment, from wide angle (up to 80° and 30 m connectivity, driver range) to multi-mode and long-range assistance, and (60° and 18° respectively and out to autonomous driving 200 m). These give the vehicle a bet- technologies ter view front and back out to some distance. This better situates the vehicle in its surroundings and supplies early warning of trouble ahead.

The Lidar System is for the final From http://infotreeservice.com/ brush strokes. Laser sensors (Lidar) infotainment-and-telematics- consulting/ gather detailed distance measurements of a vehicle’s surroundings become more and more prevalent ture of their active surroundings and at a frame rate that matches video’s every year. These technological mar- V2V is set to complete the picture. 30 frames a second. This informa- vels employ a vast array of sensors, tion comes from a vertical array of cameras, and inputs that generate The Long- and Short-Range spinning and/or scanning lasers and an amount of data that is absolutely Ultrasonic Sensors mirrors that send and receive pulses amazing. This data is handled pri- Long-range ultrasonic sensors are of light at more than a million times marily by multiple bus systems, de- primarily used for vehicle-positioning a second. This forms a complete 3D pending on the sensor, but CAN and and tracking in the lane adjacent to detailed dot matrix picture (down to FlexRay are predominant with Media Oriented Systems Transport taking care of the video and GPS. When behind The computing power alone to the wheel handle and process this data stream of a vehicle is truly astounding. The modern powered with vehicle has the equivalent of several radar, LIDAR, computers just to run the vehicles’ camera, and motor in the most efficient way pos- ultrasound sible. Now add a couple more com- technologies, puters to monitor and respond to drivers can feel the non-engine inputs. These inputs more relaxed. consist of several different types that From https://e2e.ti.com/blogs_/b/behind_the_wheel/ From archive/2014/06/10/sun-fun-and-technology-ti- technology-heats-up-the-summer work in conjunction with each other to survey the automobiles’ surround- the host vehicle in order to identify the centimeter) of the vehicle's imme- ings and driving conditions. free areas around the vehicle and diate surrounding area. Here is just a tentative list of sen- provide information to an automatic sors for a modern vehicle. avoidance collision system that can The Front and Rear Camera 1. Long- and short-range ultra- perform autonomous braking and lane Systems monitor and assist low- sonic sensors change maneuvers. Short-range ul- speed maneuvering and situational 2. Front and rear radar systems trasonic sensors have a limited range awareness for parking assist, active 3. Lidar—laser imaging systems and are more specifically relegated to avoidance, and enhanced visual 4. Front- and rear-facing cameras the close-in work around the vehicle. dashboard displays for the modern

16 techdirections X MARCH 2018 Technology’s Past Posters From http://wot.motortrend.com/1402_nhtsa_announces_plans_ From to_submit_v2v_communications_proposal.html/photos/

NHTSA plans to submit V2V communications proposal

“driver.” (Note: These can also be O Level 3: The driver can fully infrared, added to the HUD, etc.) cede control of all safety-critical functions in certain conditions. The car The GPS assists in high-speed senses when conditions require the situational awareness and tells you driver to retake control and provides where you are, how fast you are go- a “sufficiently comfortable transition ing, and when to turn. time” for the driver to do so. O Level 4: The vehicle performs all V2V and V2I—Vehicle to Vehicle safety-critical functions for the entire and Vehicle to Infrastructure com- trip, with the driver not expected to munications. This last piece of the control the vehicle at any time. As puzzle is one that is very important, this vehicle would control all func- yet a few years out. The Federal Gov- tions from start to stop, including all ernment has started the ball rolling parking functions, it could include D on this and it could potentially be the unoccupied cars. ress up your classroom “golden ticket” as far as autonomous It all sounds mind-blowingly com- with the faces of American driving is concerned. This would give plicated, and it is, from the engineer- history! Stunning posters give the vehicle the ability to basically ing point of view, but most of these your students a glimpse of see around corners, spotting and tag- systems are modularly designed. the people and the inventions ging other vehicles, road signs, and There would be no real troubleshoot- that changed our lives forever. traffic signals that it cannot yet get a ing of failed systems. Most of that The men and women whose visual on for better situational aware- would be taken care of by the host visions and strong will pro- ness and active avoidance. computers before it ever gets to the vided the groundwork for our Tesla, BMW, Google, and others shop. The technician would be uti- modern-day comforts leap off are going all in and Cadillac an- lized to take care of bad connections, the pages of history and into nounced V2V would be standard in swapping bad components, and the lives of your students! 2017 and have “Super Cruise” avail- adjusting sensors for optimum field able too. Things are going to get of view. interesting quick. That being said, In reality, what the technician ~ ÛpÛÛÝÛ~Û]Y[` the National Highway Traffic Safety will see is answers on his scan tool. Administration has proposed a for- These systems together give the SAVE! Set of 12 mal classification system: automobile and driver a better grasp only $109.95! O Level 0: The driver completely of what is going on in and around the controls the vehicle at-all-times. vehicle, more so than what a human O Level 1: Individual vehicle con- could gather alone, but there is still To view all 12 and to order, trols are automated, such as traction work to be done. Computers cannot visit control, electronic stability control, yet react to certain situations in a and automatic braking. way that a human could, but then www.techdirections. O Level 2: At least two controls again, over 80% of all highway acci- com/posterstech.html can be automated in unison, such as dents are caused by driver error. I’m Tech Directions Books/Media adaptive cruise control in conjunc- looking forward to getting in my car 800-530-9673 x300 tion with lane assist. and saying “Home, James.” www.techdirections.com AUTOMOTIVE TECHNOLOGY 17 Five Ways 3D Printing Is Transforming the Automotive Industry

By Stratasys, Inc.

N the span of a decade, 3D print- with Stratasys since 2012, but even wheel rims to grilles, and then move ers have moved from an optional in that relatively brief period of time, to the Objet500 to create one-third piece of equipment for produc- Lindner has seen significant changes scale and even life-size parts. In a ing relatively simple prototypes across the industry. single printing session, both mul- to an absolute necessity—one “We are moving away from tradi- tiple clear and opaque materials are Ithat is transforming the automo- tionally thinking (only) about rapid seamlessly integrated to craft a scale tive industry in fundamental ways. prototyping, and going into ques- model without assembly. Now fixtures in automotive design tions like: How does 3D printing or “The accuracy of the Objet30 3D studios, factory assembly lines, and additive manufacturing contribute to printer enables us to take a full-size test tracks, 3D printers are creating productivity? How does it optimize part and scale it down to produce a complex parts, speeding up tooling costs, or even improve workflow?” one-tenth scale model,” David Hay- cycles, enhancing measurement and said Lindner. ward, operations and projects man- testing, and providing customization Here are five key ways 3D printing ager at the Bentley Design Studio, solutions across all aspects of the is changing the automotive industry, explained in a case study. “Once we vehicle development process. both today and in the near future: have approval at this scale, we can Davide Ferrulli, Stratasys® Italy- move on to our larger Objet500 Con- based territory manager, who has 1. From Small to Big: nex 3D printer to produce one-third been employed at Stratasys for more Flexible, Optimized Design scale models, full-sized parts, as well than 10 years, has seen the shift One of the key benefits of early- as parts that combine different mate- toward 3D printing, firsthand. “Ev- stage vehicle design with ery single day, I’m surprised to find the assistance of a 3D a new application discovered by a printer is the ability to customer.” start small and scale up Whether using fused deposition rapidly, well before assess- modeling (FDM®) to create new ment or the part reaches tooling for short-run testing or pro- the assembly line. duction parts, customizing vehicle One example of that interiors, or making measurement capability can be found at and production devices such as jigs, Bentley Motors Ltd. Nearly the automotive industry is increas- every detail of a future ingly turning to 3D printing to man- production vehicle is first age tight production cycles and cut created in miniature using costs. Stratasys PolyJet™ tech- “We’re going more and more into nology. The 3D process em- assembly plants of large OEMs (origi- powers designers to test Bentley Motors designers print miniature scale nal equipment manufacturers) and multiple forms and a vari- models of vehicle interiors and exteriors. discussing how these tools can sup- ety of practical functions, port them in overcoming long rollout bringing them closer to a final design rial properties, without assembly.” cycles,” said Christoph Lindner, Stra- much more quickly than in the past. PolyJet technology also allows tasys territory manager GSC. “We are The studio uses two machines, companies to print translucent pro- exploring how rapid tooling contrib- the Objet30 Pro™ and Objet500 totypes. “This is an application world utes to productivity in their plant or Connex™ multi-material 3D print- for itself,” Lindner said. “Anything even on the assembly line.” Lindner, ers, in tandem. Designers rely on the that has to do with glass, interiors, who is based in Germany, has been Objet30 to model anything from tiny overmolding materials, such as mir-

18 techdirections X MARCH 2018 rors and panels—these applications design before creating a steel version injection molding. However, such a are the main drivers behind the clear for a final mold. Designing tooling low-volume is well within reach of 3D material.” with additive manufacturing from printing technology, both in terms of At Jaguar Land Rover, the Ob- the very beginning removes multiple costs and materials. jet500 Connex 3D printer was tasked steps and untold costs compared Customizing interiors, particularly with producing a complete fascia with traditional tooling methods. for commercial customers, is another air vent assembly for a Range Rover “And this can only be done with major need that’s being addressed Sport. It used rigid materials for the additive manufacturing,” Lindner with 3D printing, Ferrulli said. That housing and air-deflection blades, said. A prime example of shrinking includes creating low-volume, spe- the tooling process can be found in cialized instrument panels that add the 2011 Lamborghini Aventador, the features such as compartments for sports car brand’s flagship model. tools and instruments, as well as flex- The $400,000 Aventador clocks in at ible dashboard features, such as GPS 230 mph and owes many of its perfor- and satellite navigation systems. mance attributes to its carbon-fiber- And while electric vehicles still reinforced composite monocoque, represent a low-volume segment, the which makes up the core of the inte- market is growing rapidly, and 3D grated body-chassis. It weighs 324.5 printing could play a more promi- pounds, and the entire body and nent role. These vehicles require chassis weigh just 505 pounds. lightweight, highly specialized com- A team used a Fortus 3D printer ponents and parts that must be pro- with a build envelope large enough duced in lower quantities—a perfect to produce a complete one-sixth place for FDM. scale prototype of the Jaguar Land Rover used the body and chassis in Objet500 Connex 3D printer to print one piece in just two a complete fascia air vent. months, including the time to print and as- and rubber-like materials for the semble the parts. control knobs and air seal. In a single Under traditional process, they printed the complete manufacturing pro- fascia air vent as a working part. cesses, it would have Once printed, the model was taken taken an estimated four from the printer, cleaned, and tested, months and $40,000 to proving that the hinges on the blades build the tooling for the all worked, and the control knob had scaled part. But with 3D the right look and feel. printing, total build and A carbon-fiber reinforced monocoque is key processing time was 20 to the Lamborghini Aventador’s light weight. 2. Rapid Tooling with days, with a total cost Additive Manufacturing Cuts of $3,000. Lindner noted one recent project the Steps, Cuts the Time in which Stratasys worked with a A recent survey conducted by 3. Fast Customization via producer of a small commercial elec- Stratasys found that 60% of Italian 3D Printing tric vehicle (EV). The team produced customers use Fortus® 3D printers Customizing vehicles, especially the tools for thermoforming the roof to perform at least one manufactur- when it comes to interiors, is a costly of the vehicle. When the pieces of ing task. Some Stratasys customers endeavor for automakers. Mass the roof were glued together and at- exclusively use Fortus 3D printers for production of a particular automo- tached to the vehicle, the lighter roof manufacturing, according to Ferrulli. tive feature in low-volume vehicles helped achieve a nearly 5% overall And rapid tooling has become the often proves too expensive for OEMs weight reduction. major focus for many automotive to justify. But 3D printing offers an While this is an early-stage proj- customers, a trend that is only ex- economical solution to carmakers ect, and some technical obstacles pected to grow in coming years. looking to provide an array of trims remain, it shows the potential for 3D “We see a huge adoption around and options for consumers. printing in the growing EV sector. having, for example, pre-series molds For example, Stratasys worked produced with a 3D printer and then with a German automaker to create 4. Validation and Advanced doing the first 50 to 200 design itera- a driver-friendly feature in the cabin Measurement on Demand tions for the tooling,” Lindner said. of the car. This option was available When it comes to measurement Engineers can then evaluate the on just 10,000 vehicles—too few and parts assembly, Lindner also molds to determine the optimal units to justify the cost of tooling and sees 3D printing playing an increased www.techdirections.com AUTOMOTIVE TECHNOLOGY 19 role on the factory floor. He provided technologies cannot produce parts the original design. However, that the example of a supplier that worked as large without warping. But FDM original design, mounted as a proto- with Stratasys engineers to develop a parts hold their shape over time, type in a cockpit mockup and con- multi-functional tool that can measure Ferrulli said. nected to sub-assemblies, contained several points on a headlight or tail- “When Fiat saw the capability of 27 flaws that would have added cost light prior to final assembly. FDM technology, they were surprised and time delays, or could have ham- “We came up with a triangle- because they were finally able to pered fit and finish. shaped tool that marries three dif- do something with the technology The automotive sector has long ferent processes into one tool, and they were not able to do before,” he been one of the most fast-paced and it’s printed with FDM technology,” he said. “They are able to build com- complex industries. But the industry said. The tool measures the edges, plex parts (for the engine such as where the rubber connects compartment) that would to a taillight, to validate accuracy of withstand the functional the parts and fixtures. tests … (for) resistance to It also replaces tools made with chemicals and heat,” Fer- steel or aluminum that have less rulli said. functionality, reducing costs by two- One of the most popular thirds at the same time. The FDM- thermoplastics, ULTEM™ produced tool is light and mobile 9085 resin, a flame-retar- and can be carried to any station, or dant, high-performance anywhere along the assembly line. thermoplastic, is the go-to “It can serve as an assistant in the material for complex parts zero-tolerance car process, to assure that go in the test vehicles, quality control,” Lindner said. “And including inside engine that’s something no one considered compartments. The weight- Hyundai Mobis 3D printed an instrument panel before in the measuring process.” to-performance ratio is in ABS plastic to measure component fit. The tool will be produced by a similar to some aluminum supplier serving the plant, which alloys used in these applications, and arguably has never faced more chal- produces several hundred thousand it is resistant to temperatures up to lenges—or very promising opportu- cars per year, Lindner said. 186° C. Another popular material for nities—as it does today. automotive parts is ULTEM™ 1010 A host of obstacles, from the 5. Rea-World Functional resin, which has higher resistance to demand for vehicle electrification, Testing: Discovering What temperature than ULTEM 9085 resin, to diverse consumer preferences, to Works as well as increased rigidity, and can tighter environmental regulations, Nearly 10 years ago, experts at withstand temperatures as high as all have contributed to tightened 214° C. vehicle production schedules and But using FDM shortened vehicle life cycles. These technology isn’t just a pressures directly affect every OEM way to confirm what and every supplier throughout the designers believe will value chain. They require creative work; it can also reveal approaches to speed up the design what isn’t working process, increase quality, and cut well before a part or a costs—all at the same time. whole assembly goes 3D printing technology is proving into production. For vital in the design studio and factory example, original and floor alike. As a cost-effective solu- aftermarket equipment tion for improving measurement, maker Hyundai Mobis functional testing, vehicle custom- relies on prototyping ization, optimized design, and rapid for design verification tooling, adopting and optimizing Fortus 3D printers on a factory floor and functional testing, 3D printing is critical for engineers, using a Fortus FDM plant workers, and designers of all Stratasys showed Fiat how to cre- system to help evaluate components kinds, wanting to stay ahead of the ate door and body panels with FDM such as instrument panels. Spe- competitive field. And with new ap- technology. Ferrulli recalls that man- cifically, Hyundai Mobis produced a plications being discovered, tested, agers at the Italian automaker were prototype instrument panel in ABS and implemented virtually every day, impressed by how large, yet thin, the plastic for Kia’s Spectra and precisely 3D printing technology’s potential panels were, as well as how easily scanned it with a coordinate measur- to impact the industry is just begin- the parts fit together. SLA and SLS ing machine to ensure accuracy to ning.

20 techdirections X MARCH 2018 Helping Students Understand Automotive Electricity

By Rob Thompson

DOUBT I’m alone in finding that reversing the order of the bulbs and resistance and current flow as shown automotive students often strug- then assuming the 1157 bulb is "bad." in Photos 2 and 3, students can see gle the most when learning basic I give the students spare bulbs and that the circuit is complete and electricity. To address this issue, sockets so they can replace the "bad" neither bulb is "bad." Checking the I created a series of articles with bulbs with little effect. voltage drop of the 1157, shown in Iideas for helping teach fundamen- After some more testing, circuit Photo 4, begins to show why the cir- tal electrical concepts using some simple classroom lab activities. The first part of this series appeared in Fig. 1—Series circuit 194 1156 or 1157 the March 2017 issue of techdirec- Battery voltage ______tions (www.techdirections.com/ past-issues.html), which starts with Circuit resistance ______making sure students understand Voltage drop 1 ______Voltage drop 2 ______basic terms, such as volts, amps, and Ohm’s Law predicted amperage ______Measured amperage ______watts. We then talk about measure-

ments, meters, and circuits. 2014 Learning Cengage © Drawing Previously, I mentioned having students use automotive bulbs to build and test basic circuits. Performing lab activities gives the students practice using a DMM, in- specting and testing bulbs, sockets, and wiring, and introduces troubleshooting procedures. And, because of my sadistic nature, I mix blown bulbs and faulty sockets into the selection of parts the students use to build and test these circuits. One of my favorite circuits uses Photo 1 Photo 2 an 1157 and a 194 bulb in series, Fig. 1. The students are told the 1157 bulb represents the brake or turn signal light and it is supposed to illuminate. Of course the problem is the 1157 won't light up (Photo 1). This usually makes the students try

Rob Thompson is a high school automotive technology instructor, South- Western City Schools, Grove City, OH. He is the author of several automotive Photo 3 technology books. Reprinted from his newsletter, www.rob-thompson.net. Photo 4

www.techdirections.com AUTOMOTIVE TECHNOLOGY 21 and creates a visual image in their heads about what voltage drop looks like. Another benefit of using circuits and components such as those shown here is that as the connections and wires break, it automatically provides a supply of items that need repairing. This gives students practice cutting and stripping wire, installing terminals, and soldering pieces back together. Continuing the theme, here are some more examples of using a scope to Photo 5 Photo 6 teach electricity. Figure 2 shows a three-bulb series cuit acts the way is does. I find this circuit is particularly circuit with a PICO scope connected to show each voltage effective in helping to teach voltage drop and the effect drop and the current flow. While not earth-shattering, this of unwanted resistance on circuit operation. set up does provide a good visual of how current remains Another way to reinforce how voltage drops affect constant in the circuit relative to the voltage drops. a circuit is to have students set up a series circuit with Figure 3 shows a turn signal circuit using an old 552 DMMs connected, to show each voltage drop (Photos 5 flasher unit connected to an 1157 and a 194 bulb wired and 6). Photo 5 shows the voltage drop of each bulb, and in an alternating-flash circuit found on many older GM Photo 6 shows each referenced to the battery. Again, products. In both Figs. 2 and 3, it is clearly visible that the having students set up and measure voltage drop this bulbs require a small amount of time to heat up, which way can really reinforce what is going on in the circuit, affects the current flow in the circuit.

Fig. 2 Fig. 3

Fig. 4

Fig. 5

22 techdirections X MARCH 2018 Figures 4 and 5 show the current flow through two different types of windings. Figure 4 shows current flow through a generator field coil that has been removed from a generator. This type of demonstration is great when discussing electromagnetism and CEMF. Also, it's fun to toss small tools at a charged field coil to impress students with the strength of the magnetic field that is created. Figure 5 shows current flow through a fuel injector. This type of image is nice because it shows how the movement of the core affects the magnetic field. Figures 6 and 7 show two different power window circuits. Figure 6 is a passenger window, and Figure 7 is the driver's side window with the auto up and down feature. Fig. 6 Figure 8 shows battery voltage and current during cranking and starting on a known-good vehicle. With this one capture, you can show battery, cranking motor, and generator condition. Figure 9 shows the same vehicle during extended cranking to perform a relative compression test. Once students have built and tested a variety of circuits, they take a pass/fail test. They have to build and test a series-parallel circuit of their own design, diagram the circuit, test resistance, current flow, and voltage drops correctly with me watching them work. Once complete, they begin performing tests on school vehicles using lab worksheets (Figs. 10-12) to guide them. The main purpose of the circuit building is to get students Fig. 7 used to using meters and taking measurements. A second

Lab DMM worksheet Perform the following measurements and record your readings.

Vehicle ______1. Bat ter y voltage at the bat ter y ______2. Bat ter y voltage at underhood fuse ______Dif ference _____ 3. Bat ter y voltage at an interior fuse ______Dif ference _____ 4. Bat ter y voltage at headlight connector ____ Dif ference _____ 5. Bat ter y voltage at tail light connector _____ Dif ference _____

Vehicle ______1. Bat ter y voltage at the bat ter y ______Fig. 8 2. Bat ter y voltage at underhood fuse ______Dif ference _____ 3. Bat ter y voltage at an interior fuse ______Dif ference _____ 4. Bat ter y voltage at headlight connector ____ Dif ference _____ 5. Bat ter y voltage at tail light connector _____ Dif ference _____

Fig. 10 Fig. 9 www.techdirections.com AUTOMOTIVE TECHNOLOGY 23 ence with using a DMM usually do not transition easily to making measurements on vehicles and still confuse taking a voltage reading with measuring voltage drop. Additionally, students still may not have a good grasp of how voltage drops affect circuits on the car. To help visualize an actual circuit, I put together a brake light circuit that approximates how it would be on the vehicle. In Photo 7, the brake light circuit initially is wired up to work normally. As a class, we go through each part of the circuit, discuss the functions Photo 7 and operation of the components, and use a meter to make measurements. Once familiar with how the circuit works, I introduce several "bugs." Included in the bugs are damaged wires at the switch, two resistors wired in after the switch, and several poor connections at various points (Photo 8). With the circuit taped to the board, students can easily visualize the circuit and then perform tests at various points to try out diagnosing and fixing various concerns. This usually starts some of the students on developing diagnostic techniques and thinking about Photo 8 how to find and repair electrical problems. I've found that providing a circuit like this, and one benefit is they can see how series, parallel, and series that is removed from the car, allows students to get a parallel circuits operate. much better idea of how a circuit is constructed, how it Transitioning to working on a vehicle is often where a operates, and how to perform tests before being expected stumbling block occurs. Students who have little experi- to tackle real problems on vehicles.

Voltage Drop Testing Resistance Tests Measure the voltage drop of the following components in operation. Measure the resistance of the following components.

Vehicle ______Vehicle ______1. Bat ter y voltage at the bat ter y ______1. Headlight bulb ______2. Voltage drop of headlight ______Dif ference _____ 2. Tail light bulb ______3. Voltage drop of parking light ______Dif ference _____ 3. Brake light switch open ______closed ______4. Voltage drop of brake light switch ______Dif ference _____ 4. Negative battery cable (disconnected from battery) ______5. Voltage drop of bat ter y ground cable _____ Dif ference _____ 5. Speaker ______

Fig. 11 Fig. 12

24 techdirections X MARCH 2018 Continued from page 12. software and run the machines with bottom. They were able to route out Transforming the shop and learn- no problems. The possibilities are an entire stage lighting template. ing the equipment was a challenge endless.” “If we had to do these by hand, it for the school, at first. The trans- MHS recently created an entire would have taken months. We had to formation was a huge commitment, robotics team. Smith states, “The create six of these and I was able to but overall, was a necessity for the CNC equipment has been tremen- program it all within minutes, letting school to further their knowledge dously beneficial for our new robot- the router do the rest,” said Woolsey. The tech teachers were also able to design and route perfect (and huge) theater props for the play. Another eager- “The students are taught to-learn student the software, but are given who just freedom to think out of the successfully box, challenging their young completed his minds,” says Sommer. He uses final project on online tools available to him the class CNC and the students for learning router and finding quick solutions to immediate challenges. Sommer believes this is a great tool for students to use at home or in the shop, as a secondary way to master Aspire and AutoCAD software. and better their classes. MHS now ics team, as well. We are able to The program at MHS has com- has grades 8-12 students flowing manufacture our own parts, and pletely transformed the learning pro- through the shop for all nine periods we can customize any of our parts. cess from conventional hand tools to of the day. It has also helped us with our alli- now being able to design, program, “We are still learning how to in- ances with other robotics clubs. We and route whatever they imagine, tegrate the new equipment into our are now able to help other schools as well as cut metals with their new teaching curriculum. It is a work in manufacture their own progress, but very much worth it. We robotics parts.” also spend more time on designing Not only is the Fab and learning the Aspire, AutoCAD, Lab used for classes and Inventor CAD/CAM programs. As and manufacturing ro- a result, the types of projects have botic team parts, but it changed tremendously. Before, we is also used for many used a lot of hard and soft woods, other activities that the and now, we are using more plywood. entire town requires. “We are getting the students to Sommer explained how solve more real-world problems such the CNC equipment has as seating, flat pack furniture, and completely transformed space organizers.” Sommer stated the theater clubs in the that, “The biggest challenge to add- elementary, middle, and ing CNC into our program was that high schools of Mineola. we were given two high-end CNC “Once word got out that machines and high-end computer we could manufacture design programs all at once. This was pretty much anything, overwhelming in the beginning, espe- we were getting requests cially since we had little to no experi- from everyone asking ence with these types of machines if we could create their and software. designs.” “Thanks to the training and excep- Paul Sommer and Metal cutting project in the works on the class- tional tech support from Techno CNC Andrew Woolsey, tech- room’s Techno CNC plasma cutter Systems, we were able to get through nology teachers at MHS, the first few months and begin to de- were also asked to help with theater CNC plasma metal cutting machine. velop a curriculum for our students. design. They were given the project “We had trouble cutting thick mate- Now, our students are able to use the to create stage lighting from the rial so I had wanted to research a www.techdirections.com CNC 25 projects. Not only has the CNC equipment benefited the tech students, but it has also made it possible for business students to practice marketing, Tech student, Sareem, design, and advertising, while having works closely with an idea come to life,” said Smith. Business Ownership and The lab is designed to let the kids Marketing student, Tara, design whatever they want. “Basical- to design these wooden ly, if you can draw it, you can route plaques to sell at their it,” Sommer explained. The students school store. are taught to create, design, program, and route, and have their visions come to life. The Business Ownership & Mar- keting class at MHS works closely with the students from the Tech class to design and create a finished plasma cutter. It has changed the and with the possibility of getting a product. The Business Ownership & welding class by allowing us to cut job that they love after school. We Marketing class students are respon- thick plate steel accurately. In the are really focused on getting kids to sible for designing the product to past, we used a torch or hand-held pursue a pathway for their future here hopefully be sold in their new school plasma,” said Sommer. at MHS and we concentrate on having store. The students then bring their The students have developed a electives that pave that pathway. ideas to the Tech students who bring passion for CNCs, and are even con- “We are using this CNC equipment their concepts to life. sidering manufacturing as a future. not only in tech classes but in our “I first started to think of a prod- “As a high school, it is our job to pre- business classes, as well. The CNC uct that I could sell at local events, pare our students for the real world. equipment has allowed us to cre- like our musical events, or at our We want our students to leave high ate a school store where students school store. I came up with a pic- school with an idea and direction, can actually showcase and sell their Continued on page 29.

26 techdirections X MARCH 2018 Physics/Engineering Mash-Up Piques Student Interest

By Douglas Ripka [email protected]

TEM is a widely used lege, PA. As a comprehensive high changes. The student received two term, not only in edu- school with a full Career and Techni- separate grades, one for each class. cation but in the news cal Center, as well as a Technology In the first year, we had a cohort media whenever jobs of Education Department, there were of students enrolled for both classes. the future are discussed. plenty of opportunities for collabora- The standard Physics 1 curriculum SWhile we all know what the letters tion in the past, so a pairing of a sci- already in use in the school was used, of STEM stand for, there are as many ence course with a technology class with a few additions of topics such ways to implement it as there are made sense. as torque that future engineers might people trying to do so. After talking to faculty and ad- see in later engineering studies. The After many years involved in ministration, we decided to take physics curriculum is algebra based. STEM learning, I have come to be- two existing courses, Physics 1 and I was paired with a physics teacher lieve that the classes that best repre- Advanced Engineering Technology who has an undergraduate degree in sent what STEM can be contain three and “nest” or pair them together. A engineering science. Our duty for the elements: student signing up for one would last several years has been to assist 1. Interdisciplinary—since STEM have to register for the other class in the other’s class. has science, technology, engineering, as well. Only one section of Physics In the first year, the curriculum and math in the name, any course 1 was treated this way. Using exist- centered on VEX robotics (culminat- must incorporate at least two to live ing courses allowed us to fast track ing in a regional Sumo-Robot compe- up to the name. the process. Otherwise, we would tition), CAD/CAM, and designing and 2. Project based—students must be challenged with assignments that are not canned or have a predictable outcome. The struggle builds confi- dence in their ability to solve prob- Photo 1—Ben lems without relying on the teacher Rudnik and Nathan or other authority for validation Schweitzer test 3. Team oriented—students work- and video record ing in teams learn to trade ideas, their golf ball negotiate outcomes, and trust oth- launching machine. ers while meeting their goals. While Another machine some projects can be individual, in the foreground even those do not occur in a vacuum- clearly shows the students can see what other students photogates and are doing around them and learn, LabQuest unit. and improve on the ideas of others. The nested Physics/Engineering Technology course was first taught in the 2009-2010 school year at State College Area High School, State Col- have had to wait a year to implement building a Rube Goldberg machine. Douglas Ripka is an engineering new classes as the proposals worked For that, students had to present technology teacher in the State College their way through the system. We their designs to a panel of engineers (PA) Area High School Career and were able to use the curriculum for for a design review. Technical Center. the existing courses with minimal Like all good teaching vehicles, we www.techdirections.com STEM 27 construction, materials processing (formerly wood shop), and computer graphics courses. With such Photo 2—Daniel a diverse population, it is inevitable Briscoe and Jea- that some differentiated instruction nette Felmlee- occurs, for example in the CAD unit. Gartner working on Some students have never touched taping their boat CAD before, some have never used Inventor before, and some have used SolidWorks or Inventor. Each student is challenged to learn new, or add to existing, skills. We are piloting a STEM lab this year, in preparation for moving to a new/renovated high school. Students can go to the STEM lab to work on building all, or parts, of their engineering projects for which we don’t have equipment. Students must be certified by the STEM lab teachers as Photo 3—Chloe Melnick passing safety tests and demonstra- paddling her team’s boat tions before they can work in the lab. to the finish line Currently, we are using the Materials Engineering Processing lab. The golf ball launcher project is new this year, and we used the STEM lab to help create all or part of the machines. Each team was tasked to design a golf ball launcher, powered by heavy rubber bands. The angle of launch had to be adjustable between 30° and 60° inclusive, and students have evolved the curriculum to pres- O Complex machines (simple had to incorporate photogates to ent new challenges to students. The machines) measure time of passage of the golf Engineering Technology class had a O Electrical project-creating a volt- ball, and calculate velocity. They also weighted grade associated with it, meter or ammeter- (Circuit theory had to measure the distance the ball so after two years, a weighted grade and Ohm’s Law) traveled and account for the launch physics curriculum was created to O Musical instrument project height (Photo 1). put both classes on an equal footing. (sound and waves, vibrations in air Using the STEM lab allowed the The enhanced curriculum includes and matter) students to access a wider array of engineering-related topics of torque, O Final Exam—use NSPE Code of hand and power tools than those simple machines, thermodynamics, Ethics to identify possible conflicts found in the engineering lab. Many and rotational motion, while cover- between the code and actual actions teams did part of their work in the ing other topics such as kinematics taken during engineering accidents in STEM lab, then completed construc- to greater depth. the last 50 to 60 years. tion in the engineering lab, where In the current year, the curriculum Students interested in taking the we were better set up to mill slots in for the Advanced Engineering Tech- nested classes can apply to take the PVC pipe and do final assembly and nology course is as follows: (related class during their junior or senior test. physics concepts in parentheses) year. They must have passed our The next building project for the O Safety, hand and power tool use College Prep Algebra 2 and com- students is the cardboard boat proj- O CAD/CAM including laser, CNC, pleted two science credits. About ect (Photos 2 and 3). Students learn and 3D printing half of the students are returning about buoyancy and center of mass O Golf ball launcher (2D kinematics) engineering students, but there is with this project; they also practice O Cardboard boats (buoyancy and no pre-requisite engineering course brainstorming, modeling, CAD, and center of mass) they must take. While the rest may building skills. After a team has done O Rube Goldberg machines with have not taken engineering courses a rough sketch of their design, they design review (work, energy, force, before, they may have taken courses calculate the displacement of the momentum, circular motion, kine- that provide related skills and knowl- boat with the pilot/navigator/power matics) edge such as architecture, building source on board, along with checking

28 techdirections X MARCH 2018 the center of mass for their design. swimming pool and timed as it goes front of a group of engineers from the After these calculations have across. If it survives the crossing, it local community. The presentation been checked, the students draw is pulled out and put back in to see must address cost and schedule as up the design in CAD and add final how long before it sinks, So, boats well as the “tricks” or steps of the dimensions to guide them during have to be designed for two tasks, Rube Goldberg machine. Students the building process. Then a scale speed and endurance. gain insight into how real-world model is made at 2" equal to 1' out The highlight for many students engineers go about designing some- of thin cardboard such as cereal is the Rube Goldberg machine chal- thing, as well as learn some soft skills boxes, which is tested in a tub for lenge (Photo 4). Put simply, a Rube such as making a good impression, stability and tolerance to off-center Goldberg machine does a simple task communicating clearly, and meeting loads. With this hurdle is crossed, in a complex way. Before students goals. students can proceed to create a full- can start building, they have to pre- When we first proposed creating size version of their boat. The com- pare a set of documents that will the nested course, one piece of feed- pleted boat is placed in the school be presented at a design review in back we received was that we were going to create an elite class, which would discourage some from par- ticipating. This has not turned out to be so. While many students who Photo 4—Part of have a strong interest in engineering one Rube Goldberg as a career have taken the classes, machine showing others who were unsure have taken dominoes and a the class and found their passion. Newton’s Cradle Others have indicated that they have no intention of pursuing a career in engineering, but have gone on to college in majors as diverse as stage management, English, and business, or directly into the military. Since we started the nested Physics/Engineering class, over 250 students have taken the class. Many have benefited from the close coor- Photo 5—One of dination of curriculum between the the many musical two classes. By regularly looking at instruments made curriculum outcomes and standards, in class we have been able to keep the class new and interesting to the students as well as relevant to their postsec- ondary careers.

Continued from page 26. Just like that, I am able to cut out all tagious, making more and more ture frame that has an adjustable of the products for the shop. I am so students want to enroll in the tech picture frame in the center, where impressed with how precise every- classes offered at MHS. “We have you can easily take the photo in and thing is. The text is sharp and the always had good enrollment. But we out of the heart shape. We came up corners are crisp, and everything ﬁts are deﬁnitely getting more students with our ideas based on what people together perfectly,” says Jabar. coming in who were intimidated by would be most inclined to purchase,” The students at MHS were excit- the traditional machinery in the past. said Tara, 17-year-old student at ed to speak about their projects and Once they see that they can pretty MHS. new passions for CNC. Amazed at all much rapid prototype anything that Tara then brought her idea to the machines can do, the students they can draw and design on the Sareem Jabar, intern and student at bragged about being able to learn computer, they immediately want MHS, who was able to bring her idea using such advanced equipment at a to take the class,” says Sommer. He to life. The two worked together to high school level. Most importantly, ended with saying, “CNC is absolute- make a design into a tangible prod- the students could explain and teach ly a necessity for any high school, uct. “The business class pretty much other students what they did, how and we are so happy and proud to feeds me the ideas. My job is to then they programmed it, and what tools have invested in such quality equip- put it on paper. Once I am able to do they used to complete the project. ment for our students to learn and that, I program it into the machine. The students’ energy is con- prosper.” www.techdirections.com STEM 29 professional development The Time is Ripe for Tech Apprenticeships

By Eric Larson

HE U.S. Bureau of Labor ally positive view of apprenticeships, sSkilled workers in other fields Statistics predicts by 2024 with most of the remaining respon- —Consider the field of cybersecu- there will be more than 1.2 dents holding a neutral perception rity as a case study. A 2017 study million open jobs in infor- (38%) and a minute group expressing shared by the Wall Street Journal mation technology due negative opinions (2%). Regarding IT showed about 87 % of professionals Tto a combination of industry growth now working in cybersecurity did and Baby Boomer retirements. This not start there. Nearly a third (30 %) trend has troubling implications for 67% came to their positions from fields the entire U.S. economy, because Two-thirds of outside technology, such as market- employer demand for tech talent organizations expect ing, finance, and the military. Fully already routinely outstrips the avail- filling openings with a third of chief information security able supply. Analysts estimate at the right candidate officers and other upper levels in cy- least half a million open IT positions to be challenging bersecurity today started with roles already go unfilled in the U.S. during over the next outside IT departments, research- any given calendar quarter. two years. ers reported. These findings sug- This looming IT skills gap is forc- gest many companies need look no ing many organizations to rethink farther than their own ranks to find approaches to recruiting, training apprenticeships, eight in 10 manag- viable cybersecurity talent, so long and talent management. ers polled believe the concept has as they are willing to look beyond the For example, for CompTIA’s latest merit. Furthermore, a large group IT department. IT research brief—“Employer Percep- (83 %) could envision their company sGroups currently under- tions of IT Apprenticeships”—we exploring a formal IT apprenticeship represented in IT—Our organiza- asked more than 550 U.S. hiring man- program. agers about issues they face. More As advocates than two thirds (67%) expect filling for the IT indus- Top Hiring Challenges openings with the right candidate to try, we find this Finding candidates with the be challenging during the next two new openness right level of experience 57% years. Moreover, nearly all (99%) to the classical Finding candidates with the note at least one specific challenge apprenticeship right “hard” skills 43% they currently endure, such as find- model refreshing ing candidates with the right level of and encouraging. Pool of quality candidates locally 42% experience, finding candidates with Why? Because the right “hard” technical skills and apprenticeship Filling openings in a timely 38% identifying candidates with the right is a time-tested manner “soft” business skills. technique for Finding candidates with the 37% Our recent study revealed that six rapid skills de- right “soft” skills in 10 hiring managers have a gener- velopment which Finding candidates in the can begin closing right salary range 37% Eric Larson is senior director of Cre- the tech talent Images © 2018 CompTIA Properties, LLC. CompTIA.org Properties, LLC. CompTIA 2018 © Images ating IT Futures’ signature initiative, gap in com- IT Futures Labs, which discovers and paratively short order. Specifically, tion’s pre-apprenticeship training develops research, projects, programs, apprenticeships enable employers program, IT-Ready, offers eight weeks and best practices for charting new to tap three potential sources of IT of intensive, classroom-based educa- pathways to tech careers. talent: tion and training free of charge. We

30 techdirections X MARCH 2018 seek participants from groups cur- Top Apprenticeship Program Benefits rently under-rep- Organizations Could Realize or Have Realized resented in the IT 1 Opportunity to train workers to suit needs (63%) Want to get industry, including: unemployed, 2 Opportunity to address skills gaps early in a published? under-employed worker's career (50%) and displaced 3 Opportunity to engage with local schools, workers, women, community colleges & other feeders (44%) Want your ethnic minorities, 4 Opportunity to hire an employee loyal to the company (43%) and veterans and their spouses. 5 Opportunity to hire a worker ready to contribute students on from day one (43%) IT-Ready stu- 6 Opportunity to attract a more diverse pool of dents learn skills candidates (41%) the cover? that include building a computer from parts, installing software, trou- graduation. This approach lends a bleshooting problems, and setting real-world immediacy to cybersecu- We are looking up and managing networks. We also rity awareness and other technology instill softer professional skills, such training often lacking in classroom for articles about as effective communication, custom- settings. what is going on er service, and job interviewing. At In Chicago, our home market, we in the career-technical the end of the eight-week program, collaborate on this approach with IT-Ready students take our A+ certi- Accenture, Cisco, and IBM. To add and STEM education fication exam and are encouraged to greater weight to our argument, fields! pursue other CompTIA credentials, yet another of our recent studies— such as Security+, free of charge after “Youth Opinions of Careers in In- Articles should be graduating. formation Technology”—indicates We connect the graduate to local apprenticeships are a viable means 1,000-2,000 words companies with whom we have close of interesting teenagers in IT jobs. in length, and should relationships. The students are ready About four in 10 teens we canvassed for paid work, be it a full-time tech recognized apprenticeships as a be accompanied support role or an apprenticeship credible source of career guidance. by photos that leads to a specialization such as We believe that today’s college stu- cyber-security. Our experience over dents—not to mention tomorrow’s and/or drawings, the past five years has convinced us high school graduates—are open to if appropriate. that non-traditional students can be apprenticeships as their entry into viable candidates for IT apprentice- tech careers. ships. So, whether focusing on talent sStudents under-trained in inside or outside an organization, ap- Also, we are looking college—In one of our other stud- prenticeships can supply companies for high-res quality ies, “Assessing the IT Skills Gap,” with a more predictable, sustainable 87 % of the 600 U.S. IT and business pipeline of applicants, while provid- photos for cover use. executives surveyed across a variety ing new technology workers with industries agreed with the statement necessary experience, education, “Colleges are not sufficiently prepar- and mentorship. Through apprentice- If you have an idea ing students for today’s jobs” includ- ships, businesses can overcome the ing cybersecurity, which ranked current scarcity of tech profession- you want to pitch to among our poll’s top five IT skills gap als and prepare their workforce for make sure it would areas. today’s—and tomorrow’s—IT chal- be a good fit, either Companies can apply the appren- lenges, such as cybersecurity. ticeship solution to this channel, too, There’s no shortage of evidence: send Vanessa an by creating what we call “sustained Today’s workforce and employers email, vanessa@ internship” programs. In short, col- say they are ready for apprentice- lege students (and sometimes quali- ships. The question remains: Will techdirections.com, fied high school candidates) work companies bite the bullet and deploy or give her a call, as interns for the same organization this powerful model to bridge the IT summer after summer with the skill gap? The economy is waiting for 734-975-2800 x306. promise of a full-time position upon an answer. www.techdirections.com PROFESSIONAL DEVELOPMENT 31 Teacher Training Opportunities

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More Than Fun Answers Time for Change 2 miles, it took her 1 hour to walk Phone Button Boggle® 15 Sickles and 14 Knuts. home. Therefore she got home at Word Reason Yes, I know that Harry shouldn’t 3:30 PM. pi number have given the three Knuts because four number he got them right back in change but Social Security BeneFits! two number he didn’t really understand the mon- The answer is 78 years, 0 couple two etary system, so he just gave all the months.At that age, the total of all plane undefined term in geometry change that he had in his pocket. the reduced monthly benefits will half fraction equal the total of all the full monthly sum addition School’s Out! benefits. bit binary digit They were dismissed from school To solve, let x = Full monthly cent hundred at 2:30 P.M. and walked 2 miles. benefit. dot dot-product Sally got home at 3:30 PM. Let n = number of months from rule a ruler or algorithm To solve this problem, let x = the age 66 until the two totals are equal. slant slant height of solids in geometry number of hours for Dick to walk Then the reduced monthly ben- fair in game theory or statistics (dice) home. Then Dick traveled 4x miles efit is .75x. fairly in game theory home. There are 4 years or 48 months unfairly in game theory? This word uses Jane must have traveled for x + between age 62 and age 66, and if ALL 8 buttons!!!! 1/6 hours, so she walked 3x + 1/2 he retired at age 62, he would be flow as in flow chart? miles home. Since they lived at the getting the reduced rate for that plot on a coordinate system same house, set 4x = 3x + 1/2 and many months. loci plural of locus (location) solve for x. So, 48(.75x) + n (.75x) = nx foci plural of focus x = 1/2 hour. Solving this equation, x will divide trial in statistics Since Dick arrived home at 3:00 out, and you obtain n = 144 months. flip in probability (coin tossing) PM, he must have been dismissed So, the two totals will be equal in nu Greek letter used in statistics at 2:30 PM. So, the distance from 144 months from age 66. box box plots in statistics home to school is 2 miles. (it checks Since 144 months = 12 years, the If your students find any others, please in both expressions above). age that Mr. P is looking for is 78 let us know! Since Sally walked at 2 mph for years 0 months.

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Phone Button Boggle® How many math words can you find on Time for Change a phone keypad by starting on one of the In Harry Potter and the Sorcerer’s Stone by J.K. Rowling, Hagrid eight lettered buttons (2 through 9) and explains the monetary system of the wizards to Harry: picking one of the letters on it, then moving The gold coins are Galleons one button in any direction (horizontally, 17 Silver Sickles = 1 Galleon vertically, or diagonally) to a new button and picking one of its letters, and so on? 29 Knuts = 1 Sickle. You may use a button only once in each How much change should Harry get if he buys a broomstick that word, and words must be two to eight let- costs 1 Galleon, 5 Sickles, and 18 Knuts? He gives the cashier all ters in length. Abbreviations do not count. the money that he has in his pocket: 2 Galleons, 4 Sickles, and 3 Knuts. ABC DEF 1 2 3 School’s Out! Dick, Jane, and Sally, all siblings who live together, left GHI JKL MNO school at the same time and walked home. Dick walked at 4 mph, Jane walked at 3 mph, and Sally 4 5 6 walked at 2 mph. Dick got home at 3 p.m. and Jane got home at 3:10 p.m. PQRS TUV WXYZ What time were they dismissed from school, how far did 7 8 9 they walk, and when did Sally get home? Social Security BeneFits! # Mr. P was born between 1943 and 1954, so his full retire- * 0 ment age for social security monthly payments is age 66. However, he can begin receiving a reduced monthly benefit at age 62. The monthly retirement benefit is reduced by 25% and he would continue to receive that reduced amount for the rest of his life. Mr. P wants to know what age he would be (year and month) when the total amount of the reduced monthly benefits from age 62 to this age would equal the total of all the full monthly benefits from age 66 to this age. Please give your answer in years and months (for example, 67 years 2 months).

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See answers on page 32.

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