Welcome to Your Digital Edition of Tech Briefs and Motion Design

Welcome to your Digital Edition of Tech Briefs and Motion Design

Included in This August 2018 Edition:

Tech Briefs Motion Design

August 2018 www.techbriefs.com Vol. 42 No. 87 August 2018

2D Material Enables On-Chip Optical Communication Machine Vision Can Do More Than You Think Drive Technology for Precise Actuator Control Testing Technologies for Mission-Critical IoT SPECIAL SECTION: Conical, Floating-Piston Isolation Valve Imager Tracks Cancer and Technology Leaders in Power/Power Management IMTS Show Preview Stem Cells

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2D Material Enables On-Chip Optical Communication

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Free Info at http://info.hotims.com/69509-704 August 2018 • Vol. 42 No. 8

Contents Features 14

10 Products of Tomorrow

14 Key Technologies Needed to Advance Mission-Critical IoT

20 Optimized Imager Tracks Cancer and Stem Cells in Medical Research

50 Application Briefs

55 Facility Focus 60 NASA Spinoff: Space Fertilizer Grows Plants on Earth 52 Solutions 24 Power & Energy 24 Graphene Oxide Nanosheets for Lithium-Metal Batteries 24 Water-Based Battery Stores Solar and Wind Energy 25 Electrode Design Boosts Supercapacitor Performance 26 Chemical Heat Battery Material Releases Energy on Demand 55 28 Electrical/Electronics 28 Ultra-Low Power Consumption for Data Recording 28 Integrated Inverter for Controlling Multiple Electric Machines 29 Power Outlet Analyzes Electrical Current Usage 30 Linear Resonators Make Electronics More Resistant to Damage and Defects 30 Microcontroller Altimeter (uCA)

31 Thermally Conductive Crystals Dissipate Electronics Heat 31 Advances in Spintronic Devices 32 Built-In Temperature Sensing Method in a Microheater Departments 33 Supersonic Waves Enable Heat Management in Electronics Devices 8 UpFront 12 Q&A 34 Optics 13 5 Ws 34 Hyperfine Interpolated Range Finding for CW Lidar, Radar, and Sonar Using Repeating Waveforms and Fourier 59 Advertisers Index Transform Reordering 34 Crystal-Free Formation of Non-Oxide Optical Fiber New for Design Engineers 35 Hybrid Optics for Color Imaging 52 IMTS Product Preview 36 Material Brings Optical Communication onto Silicon Chips 54 New Products/Software 38 Materials & Coatings 38 Hardface Coating Systems for Wear and Corrosion Resistance 38 Artificial “Blubber” Protects Divers in Frigid Water Special Section 39 Rubber-Like Adhesive Film Sticks to Highly Deformable Areas Technology Leaders in Power/Power Management

(Solutions continued on page 6) 22 Auxiliary Power Solutions for 1500 VDC Photovoltaic Systems

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Free Info at http://info.hotims.com/69509-705 Contents

40 Water-Repellent Nanotextures Possess Anti-Fogging Capability 49 Location Awareness Algorithm for Internet of Things Devices 41 Modified, 3D-Printable Alloy for Flexible Electronics and Soft Robots 49 Simulation Technique Models Material-Aging Process 42 Manufacturing & Prototyping 42 3D Printing of All-Liquid 3D Structures Product of the Month

42 Diamond Pellet Grinding Tool Pepperl+Fuchs (Twinsburg, OH) introduced the R200 and R201 photoelectric sensors 43 Printing Flexible, Stretchable Silver Nanowire Circuits that connect via smart sensor profiles for easy integration. 44 Method 3D-Prints Marine-Grade Stainless Steel 45 Health & Biotech 52 45 Non-Invasive Diabetes Monitoring Patch 45 Ingestible Sensors Powered by Stomach Acid 46 Self-Powered Paper Patch Measures Glucose On the cover 47 Portable Brain Imaging System An increase in computing performance has been achieved by squeezing more and more transistors into a 47 Mobile Phone Detection of Atrial Fibrillation tighter space on microchips, leading to an “interconnect bottleneck” that slows down communication between 48 Software different parts of the chip. MIT (Cambridge, MA) developed a semiconductor material device that uses light, 48 Information Sharing Protocol VCR (ISPVCR) rather than wires, to communicate between different parts of a chip, eliminating the interconnect bottleneck. 48 Modification of SURFICE Code Learn more about this technology on page 36. 48 Comprehensive Software Simulation on Ground Special Power (MIT image by Sampson Wilcox) at Kennedy Space Center

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6 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -7 0 6 Tech Briefs, August 2018 MICROHYDRAULICS. MACRO CAPABILITIES.

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Free Info at http://info.hotims.com/69509-707 UP Linda Bell FRONT Editorial Director NASA to See Plant New Science Arrives at Space Station Stress from Space A new batch of science was delivered to the International Space NASA’s Ecosystem Spaceborne Ther - Station (ISS) that studies the use of mal Radiometer Experiment on Space artificial intelligence, gut health in Station (ECOSTRESS) is designed to space, more efficient drug develop- study how plants respond to heat and ment, and the formation of inor- water stress by measuring the tempera- ganic structures without the influ- ture of Earth’s vegetation at all times of ence of Earth’s gravity. day with an accuracy of a few tenths of a Mobile Companion, a joint degree. It will monitor rapid changes in European Space Agency and crop stress, enabling earlier estimates of Airbus investigation, explores the how yields will be impacted. Elevated CIMON, a mobile and autonomous assistance system, is use of artificial intelligence (AI) temperature measurements are an early designed to help astronauts with their everyday tasks on as a way to mitigate crew stress indicator of potential droughts. the International Space Station. and workload during long-term Visit www.nasa.gov/ecostress spaceflight. CIMON (Crew Inter - active Mobile CompanioN) is a mobile and autonomous assistance system that aids What’s New on Techbriefs.com astronauts with their everyday tasks on the ISS. CIMON is a free flyer fueled with AI, which helps it create a feeling of talking to a crewmate. Here’s an Idea: Spaceflight has an impact on many bodily systems. Rodent Research-7 takes a look Sponges! After a disas- at how the microgravity environment of space affects the community of microorgan- ter like the 2010 Deep - isms in the gastrointestinal tract, or microbiota. The study also evaluates relationships water Horizon oil spill between system changes, such as sleep-wake cycle disruption and imbalance of micro- in the Gulf coast, what bial populations, to identify contributing factors and support development of coun- if a giant sponge could termeasures to protect astronaut health dur- clean up the area and ing long-term missions, as well as to improve the wildlife around it? What if a bunch of the treatment of gastrointestinal, immune, tiny sponges could quickly save gunshot metabolic, and sleep disorders on Earth. victims? In the latest episode of our Cardiovascular diseases and cancer are the Here’s an Idea™ podcast series, three leading causes of death in developed coun- researchers show how simple sponges tries. Angiex Cancer Therapy examines aren’t simple at all — in fact, they’re solv- whether microgravity-cultured endothelial ing some of today’s most complex, mod- cells represent a valid in-vitro model to test ern problems. effects of vascular-targeted agents on normal Contact me at [email protected] blood vessels. Results could help create a with your comments and suggestions. model system for designing safer drugs, tar- Find us every month on iTunes, geting the vasculature of cancer tumors, and Results of Angiex Cancer Therapy experiments helping pharmaceutical companies design could create a model system for designing or subscribe and listen at safer cancer drugs. techbriefs.com/podcast safer vascular-targeted drugs. Chemical Gardens are structures that grow during the interaction of metal salt solutions with silicates, carbonates, or other selected anions. Their growth character- Next Month in Tech Briefs istics and attractive final shapes form from a complex interplay between reaction-diffusion processes and self-organization. On Earth, gravity-induced flow due to buoyan- The September issue highlights sensors cy differences between the reactants complicates our understanding of the physics and their role in the Industrial Internet of behind these chemical gardens. Conducting this experiment in a microgravity envi- Things (IIoT). Find out how wireless sen- ronment ensures diffusion-controlled growth and allows researchers a better assess- sors are bringing together machines and ment of initiation and evolution of these structures. people to enable smart manufacturing. Visit https://www.nasa.gov/mission_pages/station/research/index.html

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8 www.techbriefs.com Tech Briefs, August 2018 Simulated NVH testing you can see and hear.

Visualization of the noise pressure level outside the gearbox and vibration- induced von Mises stress in its housing.

The most eff ective approach for reducing the noise radiation from a gearbox is to perform a vibroacoustic analysis to learn how the design can be improved. Noise, vibration, and harshness (NVH) testing is an important part of the design process, and it can be simulated with multiphysics software. The COMSOL Multiphysics® software is used for simulating designs, devices, and processes in all fi elds of engineering, manufacturing, and scientifi c research. See how you can apply it to modeling gearbox vibration and noise. comsol.blog/NVH-simulation

Free Info at http://info.hotims.com/69509-708 This column presents technologies that have applications in commercial areas, possibly creating the Products of products of tomorrow. To learn more about each technology, see the contact information provided for Tomorrow that innovation.

► Pressure Sensor Mechanism NASA Johnson Space Center developed the Pressure Sensor ► Electronic Skin for Mechanism to measure or monitor tactile pressure. Prosthetics Based on passive Radio Frequency Identification (RFID) sensor tags, it is applicable to a variety of Amputees often experi- systems. In operation, this RFID-enabled patented ence the sensation of a technology reacts to a pressure change, causing the “phantom limb” — a feel- passive tag to generate an electromagnetic field. ing that a missing body part is still there. Johns The sensor has the potential to be easily integrated Hopkins University has created an electronic into mechanical systems to wirelessly and au - skin that, when layered on top of prosthetic tonomously communicate pressure changes back hands, brings back a real sense of touch through to a monitoring system without an external power the fingertips. Made of fabric and rubber laced supply. Potential applications for this technology with sensors to mimic nerve endings, the e-dermis include remote patient mobility monitoring, robot- recreates a sense of touch as well as pain by sens- ic control systems, pressure-sensing gloves, and ing stimuli and relaying the impulses back to the security systems. Older devices may also be outfit- peripheral nerves. The skin sends information ted with these sensors to add pressure-monitoring to the amputee by stimulating peripheral nerves functionality while avoiding the cost of a total sys- in the arm, making the so-called phantom limb tem replacement. come to life. Inspired by human biology, the e- dermis enables its user to sense a continuous Contact: Johnson Space Center spectrum of tactile perceptions, from light touch Phone: 281-483-3809 to noxious or painful stimulus. E-mail: [email protected] https://technology.nasa.gov/patent/MSC-TOPS-56 Contact: Tracey Reeves, Johns Hopkins University Phone: 443-997-9903 E-mail: [email protected]

► Sensor Combination Detects People by Smell Trained rescue dogs are the best disaster workers — their sensitive noses help them track down people buried by earthquakes or avalanches. But dogs need breaks, so ETH Zurich researchers developed a device that detects people by smell. It consists of small and extremely sensitive gas sensors for acetone, ammonia, and isoprene — all metabolic products that people emit in low concentrations via breath or skin. The sensors are combined with two commercial sensors for CO2 and moisture. While there are electronic devices for searching after earthquakes, these work to locate trapped people who are capable of making themselves heard or are visible beneath ruins. These resources would be complemented with the chemical sensors. Drones and robots could also be equipped with the gas sensors, allowing difficult-to-reach or inaccessible areas to also be searched.

Contact: Fabio Bergamin, ETH Zurich Phone: +41 44 632 42 44 E-mail: [email protected]

10 www.techbriefs.com Tech Briefs, August 2018 10 MHz Dis ib i mpliifi

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Dr. Sara Tech Briefs: Where do you start Abdollahi, when researching a new material that can be 3D-printed? 2.25” Carnegie Mel - lon University Dr. Abdollahi: There are three stages: College of the expert, the algorithm, and then again, Engineering, the expert. The expert chooses the Pittsburgh, PA parameter search space and decides which factors are important; for example, esearchers in Carnegie Mellon bath concentration, pH, printer speed, RUniversity’s College of Engineering layer height, acceleration, or nozzle diam- have developed a novel approach to eter. We start with a random combination optimizing soft-material 3D printing. of the parameters and assess the print. We The Expert-Guided Optimization (EGO) then take the parameters that gave the method combines expert judgment with best print and start a hill climb — itera- an optimization algorithm that efficient- tively varying one factor at a time, while ly searches combinations of parameters keeping the others constant. We look to relevant for 3D printing. see which direction we should move towards to get a higher score. Finally, it’s Tech Briefs: What was the problem up to the experts to judge the results. you sought to solve with this They can choose to change the factors, - brushed or bldc motors technology? the factor levels, or the entire parameter. - 5 amps per axis Dr. Sara Abdollahi: I was looking to Tech Briefs: How do you analyze the - 16 analog inputs create soft material with 3D printing quality at each iteration? - 16 on/off drivers because I was trying to make a conform- able cuff that I could integrate with Dr. Abdollahi: We used two different cal- - home and limit in small electronic sensors. I wanted to ibration structures: a hollow cylinder and a - live tech support create a medical device that would five-sided cube. We then defined variables measure things like heart rate and we thought were important; for example, - made in the USA blood oxygen content, like the clunky for the cylinder, it was layer adhesion, or oximeter they put on your finger when stringiness, and if it was well fused with the you go to the hospital. My goal was to rest of the print. For the cylinder, an impor- See the make a wearable version of that. tant parameter is “infill,” or whether the I soon realized that there are a lot of cylinder is completely hollow or if some EZQUAD SERVO parameters involved in 3D-printing soft material protrudes into the interior. I then in action! materials, especially since the material created a scoring system. For layer fusion, starts as a liquid. For example, it zero means the print is a big mess and 10 is requires a temporary sacrificial support when the layers are fully fused. I anticipate bath. There’s a lot of trial and error that at some point, we could integrate some involved to align the parameters. I had form of physical evaluation. taken some courses on policy analysis where I learned about the expert inter- Tech Briefs: What are the next steps? WWW.ALLMOTION.COM vention that’s used for policy decision- making. We decided to implement that Dr. Abdollahi: I would like to see this (510) 471-4000 approach for our engineering problem. technique used with other objects and other We were still able to benefit from the additive manufacturing processes. Ideally, it 30097 Ahern Avenue systematicity provided by an algorithm, would be nice if it could be standardized, Union City, CA 94587 but we could also utilize intervention scaled, and used in industry as a tool to get from an expert to change the parame- a desired product without the random trials Technical Support ters and factor levels of the variables in that often lead to a lot of product waste. (408) 460-1345 order to escape when the model could To learn more, read a full transcript, or lis- not converge. We call this process ten to a downloadable podcast, visit Expert-Guided Optimization (EGO). www.techbriefs.com/podcast.

Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -7 10 www.techbriefs.com Tech Briefs, August 2018 Ws of the 5 PHADE Addressing System

Who PHADE could be used by government agencies to enhance public safety; for example, the government can deploy cameras in high-crime or high-accident areas, and warn specific users about potential threats. PHADE also can be used in places such as museums, where visitors can receive messages with information about the artifacts or exhibits they are viewing. It could be implemented in shopping malls to provide consumers with digital product information or coupons.

What PHADE technology allows public cameras to send personalized messages to people without compromising their privacy, a process called private human addressing. While traditional data transmission protocols need to first learn the destination’s IP or MAC address, this system uses motion patterns as the address code for communication. The smartphones then locally make their own decisions on whether to accept a message. The PHADE system works using a server to receive video streams from cameras to track people. The camera builds a packet by linking a message to the address code and broadcasts the packet. Upon receiving the packet, a mobile device of each of the targets uses sensors to extract its owner’s behavior and follow the same transformation to derive a second address code. If the second address code matches with the address code in the message, the mobile device automatically delivers the message to its owner. PHADE keeps the users’ personal sensing data within their smartphones, and transforms the raw features of the data to blur partial details. The creators named the system PHADE because the blurring process “fades” people’s motion details out. PHADE has advantages over Bluetooth-based beacons, which have difficulties in adjusting for ranges of transmission, and do not allow for context-aware messaging.

Where Purdue University, West Lafayette, IN

When Patents have been filed, and the Office of Technology Commercialization is seeking partners to license the PHADE technology.

City governments will be able to use PHADE to send alerts to distracted pedestrians when cars are approaching. (Purdue University)

Why The system allows surveillance cameras to “talk” to the public through individual smartphones; for example, it can be used to send alerts to distracted pedestrians when cars are approaching.

Contact: Office of Technology Commercialization at [email protected], Phone: 765-588-3475, or visit www.prf.org/otc/

Tech Briefs, August 2018 www.techbriefs.com 13 Enabling the future of the mission-critical IoT requires more than just the right design. It requires the right tools to build a strong foundation.

y 2028, virtually all major sensing mance, ultra-high reliability, and securi- The IoT is no longer just about con- and feedback systems benefiting ty, it will be an entire mission-critical sumer-based smart appliances for the Bfrom continuous monitoring will ecosystem designed and hardened to home or wearable fitness watches for connect to devices currently known as withstand the rigors of the real world. personal use. More and more, it is weav- the Internet of Things (IoT). As that That ecosystem will enable functionality ing its way into industries and applica- connectedness becomes a given, the and deliver efficiencies that just a few tions that were never connected. It will need to label anything as IoT will years ago might have seemed impossible. be used to automate energy distribution become unnecessary, in much the same in smart grids, to enable remote machin- way that referring to a smartphone today The Time for Change is Now ery and remote surgery, and in auton - as an Internet-connected device seems There are literally billions of IoT omous vehicles for things like automatic redundant. As the pervasiveness of the devices around the world today, and emergency detection and autonomous IoT spreads, it will change completely hundreds more are coming online each vehicle accident prevention. It is hap- how the world interacts with informa- second. Cisco predicts that by 2020, pening already. tion. And, it will have a dramatic impact there will be 50 billion connected There are many factors today driving on mission-critical IoT devices and the devices. The tremendous growth poten- this proliferation, not the least of which is applications they enable. tial for IoT in the coming years is simply automation. As the cost of automation Forget Industry 4.0 and think more in undeniable. A big part of that growth has declined, its use throughout the mis- terms of Mission-Critical IoT 2.0. Rather will come from mission-critical IoT sion-critical IoT has gone up dramatical- than just devices optimized for perfor - devices. ly. Nowhere is this change more visible

14 www.techbriefs.com Tech Briefs, August 2018 MANUFACTURING HEALTHCARE POWER SYSTEMS AUTOMOTIVE

Manufacturing will no Healthcare will become Power systems will evolve to more Autonomous vehicles and vehi- longer revolve around large- proactive, rather than reac- closely match supply and demand, cle-to-vehicle communication will scale production, instead tive, as medical wearables rather than just providing a supply become typical, making trans- morphing into manufactur- alert patients and health- once a demand has been made. This portation more efficient and ing as a service (MaaS) with care professionals to health evolution will enable cheaper energy safer. As a result, insurance com- 3D printing enabling mass irregularities and begin storage and a more stable power panies may even begin offering customization. As the transi- predicting potentially sig- grid. With fewer energy fluctuations better premiums to those vehi- tion takes hold, production nificant incidents before on the grid, the carbon footprint of cles with the ability to operate in batch sizes of a single unit they have the chance to the electricity generation will also autonomous or autopilot driving will become typical. occur. decrease. modes.

The IoT will have a dramatic impact on mission-critical IoT devices and the applications they enable. than on the factory floor. In a true smart applicable industry or government regu- IoT ecosystem. And, it will require factory, this automated system will be able lations — they are non-negotiable. designers, manufacturing engineers, to harness all the information at its dis- In the consumer-based IoT world, a network operators, and service providers posal to learn and adapt to new demands. failed weather sensor or a dropped to address several key challenges. Significant technological advances of audio stream is an inconvenience. Device Layer: A basic IoT module the past 10 years are also driving the pro- Likewise, a smart coffeemaker that mal- con sists of a battery, power management gression of the mission-critical IoT. Many functions might make the consumer circuit, microcontroller, RF module, and IoT devices now carry the processing unhappy, require an expensive service other key components. Within each power of early supercomputers and are call, or even result in a costly product component, there are design and test sometimes powered by coin cells expect- recall, but it is not life-threatening. challenges that confront the designer. ed to last more than ten years. IoT In the mission-critical IoT world, the Challenge 1. The module’s battery and devices and gateways now contain high- consequences of an unreliable device or power management circuit must be opti- performance radios that use cutting- device failure can be catastrophic. A mized to ensure a long-lasting battery edge protocols, all competing for band- failed pacemaker could result in a life. Many mission-critical IoT devices width. Modern networks often have patient’s death. A lost boiler sensor con- are not connected to power and often thousands of connection points and nection might cause the boiler’s tubes to operate using a single battery for several must maintain constant uptime, ensure overheat and fail, resulting in an explo- years without maintenance or battery adequate data rates, and protect the sion. A down network in a hospital could replacement. security of data and devices. These interrupt a remote surgery in process or Challenge 2. The RF module must advances — coupled with breakthroughs fail to deliver an alert to a healthcare conform to the appropriate wireless in the cost of sensors, the rise in cloud professional about a patient’s health cri- standard and meet the data transmis- computing, and continued progress in sis. Such extreme outcomes are a key sion throughput and range. Such con- connectivity technologies — are not only reason why strict adherence to require- formance can be challenging for mis- proliferating the mission-critical IoT ments like reliability are so essential in sion-critical IoT applications where an around the world, but forcing it to evolve the mission-critical IoT. It is also part of ever-increasing number of wireless into a new, more robust, feature-rich why designing for the mission-critical standards (Bluetooth®, ZigBee, Z- generation: the mission-critical IoT 2.0. IoT is so challenging. Wave, Wi-Fi, NFC, and LPWA technologies such as NB-IoT, Cat-M1) have Mission-Critical IoT Advancing Mission-Critical IoT emerged to support IoT applications. Requirements Success in the mission-critical IoT To ensure interoperability within the Mission-critical IoT is not the same as requires innovation. To advance it to the ecosystem, all devices need to pass IoT. They both share common technolo- next level, that innovation will need to wireless certification test before gain- gies like sensors, cloud platforms, con- take place across the three layers of the ing market entry. nectivity, and analytics; however, the similarities end there. Likewise, mission-critical IoT will not be the same as mission- critical IoT 2.0. As the ecosystem evolves, so too will its requirements. Yet many of the existing specialized requirements will remain intact. Today’s mission-critical IoT requires rock-solid security, unfailing reliability — even in harsh environments — and the ability to operate with little or no human intervention. These requirements are dictat- ed by the industry in which the mission- A down network in a hospital could fail to deliver an alert to a healthcare professional about a critical IoT device will operate and any patient’s health crisis.

Tech Briefs, August 2018 www.techbriefs.com 15 MISSION-CRITICAL IOT

Challenge 3. Interference and crosstalk Maximizing battery life for IoT EMI compliance and wireless between each of the module’s blocks smart devices conformance -How long can my battery last? Battery -How confident am I that my design must be identified and eliminated. In IoT -Is my device drawing unnecessary can pass the conformance test? power? devices, the demand for more functional- -Is my device creating excessive emissions? ity in a small form factor is forcing circuit -How well can my device tolerate design to become more compact and unwanted emissions? Power driving traces closer together. Thus, Management mutual inductance has become more Signals prevalent. At the same time, the drive MCU toward lower-power electronics has Actuator/Display Interface caused DC supply voltages and tolerances RF to be reduced. Ripple, noise, and tran- Analog sients riding on these low-voltage rails can Sensor Front End adversely affect clocks and digital data. Challenge 4. Electromagnetic interfer- Signal and power integrity issues -How do I resolve issues involving Interference due to multi-format wireless connectivity ence (EMI) issues must be identified and interference, cross-talk, excessive -Is my device communicating at the right speed and covering the dealt with early in the design process to losses, impedance mismatch, right range? power rail ripples? -Is my device able to work under dense signal environment with ensure electromagnetic compatibility multiple wireless signals operating at the same spectrum? (EMC) compliance. EMI can be especially problematic in scenarios where large A basic IoT module consists of a battery, power management circuit, microcontroller, RF module, numbers of IoT devices operate simulta- and other key components. neously near one other. Avoiding EMI requires designers to not create unwant- ly in mission-critical IoT, where highly Network and System Layer: In the mis- ed emissions in their designs, and to complex and dense device deployment sion-critical IoT, network infrastructure ensure those designs remain robust environments are commonplace. is a critical ecosystem component. To sur- against unwanted emissions. Challenge 1. Wireless equipment must vive and thrive in the real world, it must Wireless Communications Layer: In the be able to perform in the presence of be accurate, robust, secure, and stable. IoT, the wireless communications layer is multiple users, with different wireless Challenge 1. A network must be able to essential to enabling the flow of informa- technologies, in the same spectrum. In handle erratic devices and the potential tion to and from the device and the net- mission-critical environments like a security concerns they may enable. work. For some designers, that communi- large hospital, the density of connected Roughly 50% of all IoT devices come cation presents a new challenge, especial- devices can easily reach 50,000+, without from companies less than three years even factoring in the devices on the old. While many have been thoroughly Mission-critical IoT requirements patients themselves or their visitors. tested, some are not. These devices may often include some combination of With all of these devices operating in the behave erratically and even allow mali- the following: same environment, wireless technolo- cious agents to bring a network down. In gies that share similar frequency bands the mission-critical IoT, such a scenario • Robust performance to withstand can cause co-channel and adjacent chan- is unacceptable. harsh and/or remote environments nel interference with one another. This Challenge 2. Service quality and per- • Precision and accuracy to work in is especially true in the unlicensed 2.4- formance must not be disrupted by net- manufacturing processes synchro- GHz Industrial, Scientific and Medical work changes. Continuous updates and nized to milliseconds (ISM) frequency band, commonly used upgrades to network equipment keep • Low latency to enable real-time by cordless phones, wireless video cam- networks in constant flux. Whether exist- communication eras, microwave ovens, and an increasing network devices can support a new • Programmability to support new ing number of wearables like medical service is a question often left to chance. manufacturing processes monitoring devices and smart meters. As Verifying that the deployed network is • Scalability to support large-scale net- the 2.4-GHz ISM band gets even more reliable and can provide the best possible works with tens of thousands+ con- overcrowded, the ability for these quality of experience (QoE) is essential. trollers, robots, machinery, etc. devices to co-exist peacefully and contin- • Security and resiliency to protect ue operating as usual will become Building A Strong Foundation both end-point devices and networks severely challenged. Innovating the mission-critical IoT for from disruption, and against threats Challenge 2. Any issues that can impede success demands two things: the right and attacks the network’s readiness or cause a disrup- design and the right test and measure- • Interoperability to ensure operation tion in its quality or performance must be ment tools on which to build a strong with legacy devices and operations identified and eliminated. Because IoT foundation for that design. In the mis- • Ultra-high reliability so that devices devices support a broad range of wireless sion-critical IoT, those tools are critical can operate 20-30+ years in harsh communications technologies, networks to helping designers, manufacturing environments and remote locations must also support these technologies. process engineers, network operators, And, they must be able to provide that and administrators to address the chal- Mission-critical IoT is not the same as IoT. They support in a range of different environ- lenges they face throughout the entire both share common technologies like sensors, cloud platforms, connectivity, and analytics; ments and locations where RF conditions IoT ecosystem. Fortunately, there are however, the similarities end there. may differ dramatically. many. In the device ecosystem, the best

16 www.techbriefs.com Tech Briefs, August 2018 COMSOL CONFERENCE 2018

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Free Info at http://info.hotims.com/69509-711 MISSION-CRITICAL IOT

tem, through a power distribution net- Network Performance Assessment and work (PDN). Monitoring for verifying, quantifying, and Wireless Conformance Test for design verifi- troubleshooting network performance cation and pre-conformance of the device and reliability from pre- to post-deploy- to the appropriate wireless standard. ment. EMI Simulation and Modeling to simu- Network Infrastructure Performance Test to late the radiated emission of electronic test the peak network performance and circuits and components to determine reliability under realistic conditions to whether emissions are within levels spec- get a deeper understanding of its realis- ified by common EMC standards, and tic operation under challenging condi- estimate emission levels before hard- tions and scaling bottlenecks. ware is developed, respectively. Network Validation to validate protocol What once was a sea of people working on a EMC Compliance Test to ensure products compliance and interoperability during traditionally automated production line push- ing a product to completion has now become are compliant to EMC standards. a device’s lifecycle to gain visibility into a system heavily dominated by robots — fully In the wireless communications how well it will handle traffic. connected, flexible, and with access to a con- ecosystem, the best tools of choice for Applications and Network Security Test to stant stream of data from a range of sources. designers and manufacturers to ensure harden the performance of network and devices communicate effectively include: security devices by emulating real-world tools of choice during the early research Wireless Connectivity Test for receiver application protocols and modeling and development stage include: test and troubleshooting during devel- security attacks/malware, and validating Simulation and Design Tools to gain a bet- opment and to verify, during manufac- network and data center performance as ter understanding of a device’s operation turing, that wireless IoT devices can well as service provider networks. and expected perfor mance, and deter- interoperate and are able to handle mul- mine what tradeoffs to make to achieve tiple standards concurrently. Success Demands Innovation the best real-world performance and Co-Existence Test to ensure IoT devices To succeed in the mission-critical IoT, functionality. and systems can perform their critical designers, manufacturing engineers, net- Battery Drain Analysis to accurately functions in the presence of multiple work operators, and service providers measure the device’s dynamic current users, with different wireless technolo- alike must take a proactive approach to range over a period of time to more fully gies in the same spectrum. dealing with the challenges they face understand its current use and the dura- Network Simulation to test the real- within each segment of the ecosystem. tion of each of its operating modes. With world performance of IoT devices by Advancing the mission-critical IoT this information, designers can find the verifying their compliance to a carrier’s de mands innovation. That innovation optimal balance among battery, protocol, test plan in the integration, interoper- is only possible using the right test and and software functionality, and realize ability, and carrier acceptance testing measurement solutions to create a excellent performance and service life. phases. solid, reliable, robust, and secure foun- Signal Integrity Test to evaluate high- Network Readiness to verify coverage dation of device functionality, wireless speed serial interconnect and quickly from the wireless communication net- communication, and network infra- validate and correlate signal integrity work to ensure high-quality networks structure. simulation with actual measurement. and a high QoE. This article was written by Cheryl Ajluni, Power Integrity Test to analyze how effec- In the network and system ecosystem, IoT Solutions Lead at Keysight Technologies, tively power is converted and delivered the best tools for network operators and Santa Rosa, CA. For more information, visit from the source to the load within a sys- service providers include: http://info.hotims.com/69509-121.

In the mission-critical IoT, network infrastructure is a critical ecosystem component. To survive and thrive in the real world, it must be accurate, robust, secure, and stable.

18 www.techbriefs.com Tech Briefs, August 2018 Find MetalNot Metal

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Free Info at http://info.hotims.com/69509-712 Help from an electro- optical engineer at Glenn Research Center let BioInVision make its CryoViz imaging device more sensitive, more efficient, and cheaper to manufacture.

Optimized Imager Tracks Cancer and Stem Cells in Medical Research

fter earning his doctorate, ponents and get the best performance,” electro-optical engineer, had recently Debashish Roy set about creating he recalled. The task of selecting and taken charge of the optics lab for A a business from the biological configuring optical and robotic parts Glenn’s Research and Engineering imaging device he’d helped invent as a required a high level of expertise. “We Directorate when he met Roy in 2012. graduate student. The system held prom- didn’t have a lab to try out all the possi- “We’d mainly been dealing with diag- ise for cancer and stem cell research, ble scenarios. We didn’t even have the nostic imaging systems for combustion among other possible applications. But equipment we needed.” and fluid physics that are usually flown he soon realized he could use some help. NASA’s Glenn Research Center, locat- on the space station,” Lewis said, adding “In the first-generation system, we ed just on the other side of Cleveland that optical communications, custom weren’t sure if it was the best possible from Roy’s business, had the lab, equip- sensors, and light-based metabolic configuration or how to verify the com- ment, and expertise. Michael Lewis, an analysis have also been high on the lab’s

20 www.techbriefs.com Tech Briefs, August 2018 priorities list for supporting NASA mis- solved quickly, could result in a signifi- Now BioInVision has clients across the sions. The facility is full of optical tables, cant payoff for the company. In the case United States and in Canada, Europe, cameras, and other imaging systems; of BioInVision, that specialist was Lewis. and Asia. The company offers both a laser illumination systems; spectrome- “I was unfamiliar with the microtome product and a service: a larger, busier ters; and electronics equipment. initially,” said Lewis, but once he knew lab might purchase a CryoViz device, The system Roy had developed was what the device was and what Roy was while a smaller one might send in spec- what he called an imaging cryomicro- trying to achieve with it, it wasn’t diffi- imens for the company to analyze on its tome, a device t hat could take a frozen cult to come up with some ideas. behalf. block containing a biological sample — “In its basic form, a microtome is The Case Center for Imaging Research typically a mouse — and repeatedly slice high-resolution imaging, and we cer- of Cleveland in University Hospitals has off extremely thin sections while taking tainly have the cameras and the optics purchased a device, opening up research multiple high-resolution images of the in the lab to do that,” he said. Since the possibilities in area institutes like the block face to capture any cells tagged idea was to create a smaller, cheaper Cleveland Clinic and Case Western with a fluorescent marker. This process version that wouldn’t require quite the Reserve University. ultimately reconstructed a digital three- performance level of the original, Lewis The company was also chosen as a dimensional version of the specimen said, “I took the approach of trying to partner in the European Union’s MER- with locations and counts of all the fluo- utilize existing commercial compo- LIN Project, which aims to develop stem rescent cells within the specimen. nents put together in a way that would cell-based therapies for liver disease. The goal is to track the movement of optimize the system.” Roy says BioInVision has found the particular cells, especially cancer and For example, the imager has to pick most traction in stem cell research. Stem stem cells, through a lab mouse’s body. up on dim signals without being over- cells can morph into different cell types, “If I want stem cells to do cardiac repair, whelmed by bright ones, so choosing the giving them the potential to treat or pre- are my stem cells going to the heart?” right sensors, lenses, and other optical vent a variety of conditions. But scien- Roy asked. “Are micrometastases going components is crucial, especially to tists still have a limited understanding of to other parts of the body and starting achieve a size reduction. how and why a stem cell becomes a new tumors?” Lewis ultimately gave Roy a spread- nerve cell or a muscle cell, for example, To answer these questions, researchers sheet detailing four or five different com- or how it travels through the body. tag cells grown in petri dishes with fluo- binations of parts. “He looked at that as a While the academic community might rescent labels and inject them into a really nice way to keep the cost of the sys- use the CryoViz system for basic research mouse. At some point, the mouse is tem down, but still give him a higher to advance this understanding, drug frozen to preserve cellular structure, level of performance than he was expect- companies are using it in attempt to cre- and Roy’s device turns it into thin slices ing,” Lewis recalled. Roy and his team ate new therapeutic products. Cancer while taking thousands of images at cel- started applying Lewis’ optimized optics researchers, meanwhile, use it to track lular resolution. The machine can be designs to their original product almost the behavior of cancer cells. Other med- programmed to do all this with no assis- immediately. ical imaging techniques, such as MRI or tance from the user. CT scans, don’t offer the kind of resolu- The Final Product tion that can track individual cells Technology Transfer The updated CryoViz is more sensi- through the body. By 2012, Roy’s startup, BioInVision, tive, more efficient, and cheaper to Roy said he aims to make the smaller, had made its CryoViz device commer- make than the original design. Using more affordable version of the CryoViz cially available, but hadn’t yet made any Lewis’ designs, BioInVision was also available in the near future, increasing sales. In addition to optimizing his exist- able to eliminate a component that smaller labs’ access to the technology. ing system, Roy wanted to develop a reduced manufacturing time, and cut In the longer term, he hopes the smaller, cheaper version, and it was with out a possible point of failure, as well as research it enables will lead to new stem this desktop version in mind that he a vendor. cell therapies and breakthroughs in the applied to participate in Glenn’s first Anne Richie, the company’s vice pres- search for a cure for cancer. With fur- round of the Adopt a City Program. ident of administration and finance, ther development and regulatory Adopt a City, one of the programs said the assist from Glenn saved approvals, it could also be used in hospi- under NASA’s Regional Economic BioInVision development money up tals for clinical procedures like biopsies, Development initiative, grew out of the front, as well as the potential costs of he said. White House’s Strong Cities, Strong any design errors and the cost of mov- For more information, visit http:// Communities initiative, announced in ing forward with a more expensive info.hotims.com/69509-124. 2011, that sought to partner federal product. agencies with local businesses and gov- “As a startup, you can make a lot of ernments. Under Adopt a City, Glenn mistakes and lose a lot of money. For a joined forces with Cleveland, Cuyahoga smaller company, it can really hinder County, and the Manufacturing Ad- your process,” she said. Instead, the vocacy and Growth Network, and select- money saved was invested in speeding ed small- and mid-sized manufacturers up development. “It was the right to receive 40 free hours of technical expertise, and it was available locally, expertise from its specialists to resolve and that really accelerated the process,” specific technical challenges that, if she added.

Tech Briefs, August 2018 www.techbriefs.com 21 TECHNOLOGY LEADERS Power/Power Management Auxiliary Power Solutions for 1500 VDC Photovoltaic Systems

hotovoltaic systems are continually evolving to improve their effi- Monitoring System ciency and financial viability. One Photovoltaic Photovoltaic Dc Power trend is to move to larger strings Arrays Combiner Distribution Box Cabinet P RS485 of cells giving higher dc voltages to be converted to ac voltage for the grid. Cost Photovoltaic RS485 savings result, but auxiliary power sup- Inverter plies for monitoring and control need to accept these higher voltages as inputs.

0.4/10 kV The PV Market Boosting Transformer Despite the waxing and waning of government support for photovoltaic (PV) power generation systems, growth is still strong with installed global capacity Figure 1. Typical PV arrangement. increasing from 178 GW in 2014 to a projected 540 GW in 2019, according to combiners, for the same 15 MW of potential deployment savings of a report by Solar Power Europe. Europe power, current drops to 66.6% of the $400,000. (Figure 2). leads the way with an expected increase 1000 V value and resistive cable losses to It certainly looks advantageous to to 158 GW in 2019, but other countries 44.4% because of the I2 in I2R. This gain move to higher string voltages, but are experiencing much higher growth means higher system efficiency or lower there are some potential downsides: rates. China, for example, expects a cost of installation with smaller cables insulation all down the line must be four-fold increase over the same period and connectors. Because there are fewer uprated for the higher operating volt- and the United States a three-fold strings to achieve 15 MW, there are 31% age, as do the combiner boxes and grid increase. The solar industry also has a sig- fewer combiner boxes; for example, 94 inverters. This is not necessarily an nificant economic impact, with around compared with 137, assuming each box issue, though, as inverter technology 55 million people directly employed in handles 20 strings. Of course, associated commonly operates at high voltage in the sector globally in 2014. combiner cabling, connector, and main- other areas such as traction. The latest PV has always fought to justify itself in tenance costs are lower, too. GTM techniques that make use of wide terms of $/watt of generated power, and research has analyzed the system cost bandgap semiconductor devices are still is hampered by the initial low efficiency per watt comparing 1000 V and 1500 V applicable at 1500 V, further improving of the panels themselves. Currently, lev- systems in a 10-MW plant showing a conversion efficiency. els of monocrystalline cells at around 25% efficiency would be market-leading, Component Component Unit Cost System Cost (per W) and theoretical maximum values are not Count much higher. Designers therefore continually strive to squeeze the last drop of PV Modules Same +1~2% +$0.02 energy from systems by minimizing losses in connections and the conversion Cables, Conduits, process from panel dc output to ac for Trenching -40~45% Same -$0.03 the grid. One way to do this is to connect panels in series so that power is Combiner Boxes -33% +10~20% -$0.005 processed at high voltages where currents and consequent I2R losses are lower. For example, grid-connected sys- PV Inverters -40% +80~100% +$0.01 tems typically have blocks of 22 panels with cells connected in strings to give Ac Subsystem Reduced -10~15% -$0.005 1000 V producing 5.5 kW per string; 2,727 strings might then be combined for a 15 MW installation. (Figure 1). Direct Labor N/A -$0.03 If, however, panel numbers in strings are increased to deliver 1500 V to the Figure 2. Potential deployment savings for a 10-MW solar plant.

22 www.techbriefs.com Tech Briefs, August 2018 TECHNOLOGY LEADERS Materials/Coatings/ Adhesives

Auxiliary dc-dc converters working in this environment must have specific per- Wide Input Dc-Dc PV COMBINER 24 V formance. The very wide input range is difficult to achieve with standard flyback

Dc-Dc or forward converter topologies, espe- PV Array To cially with the high maximum input volt- Inverter Fusing, Gating ages. With variation in pulse width to PV Array & Monitoring 1500 V 3.3 V +/-5 V regulate the output, internal peak volt-

Dc-Dc ages and currents can be extreme, Hall Processor Comms necessitating a more complex topology PV Array Sensors 5 V that limits peak stress. Protection is key as well — the converters need to operate with frequent Figure 3. Typical solar combiner box internal power architecture. “brown-outs” as the input dips below the minimum under different illumination There is an area in the system that 1500 Vdc operating voltages. Partial dis- conditions. The converter must not be requires attention. PV combiners and charge is the gradual breakdown of damaged by this or other fault conditions inverters need low-voltage isolated power microvoids in insulation at high voltage, that might be seen in a typical remote for monitoring and control derived from leading to degradation and eventually installation such as overloads, short cir- the 1500 V line, and small dc-dc convert- complete failure. Partial discharge is cuits, and over-voltages. Environmental ers that operate at these levels are not required to be absent during tests and conditions are tough as well — you really common. The lower-voltage end is necessitates particular construction of want your PV system to be in full sun, so important, too, as the supply could dip to the isolation barrier in a dc-dc converter. temperatures in control cabinets are like- 200 V under particular conditions, so the As in all safety standards, insulation ly to be high. With the agency-specified converter needs to provide at least a 7.5:1 requirements depend on the system volt- isolation ratings presenting another chal- input range — again, not a common age, installation over-voltage (OV) cate- lenge, dc-dc converter design for PV specification. Figure 3 shows a typical gory, and pollution degree (PD) of the applications is not a minor task. solar combiner unit illustrating the environment. For PV systems with a 1500 power architecture: a 200–1500 Vdc Vdc bus, OV II is used for the PV panel Off-the-Shelf Solutions input dc-dc converter with a 24 Vdc out- circuits with minimum impulse with- Fortunately, there are ready-made solu- put feeding additional isolated and non- stand of 6000 V, whereas OV III is used tions available on the market to address isolated converters for communications for the grid-connected inverter stage these design challenges. A range of dc-dc and processor/sensor power. The main and requires 8000 V impulse withstand. converters specifically designed for 1500 high-voltage dc-dc converter needs fully As the installations are considered Vdc photovoltaic systems is available that reinforced safety isolation and would typ- industrial-grade with some environmen- includes the required 200-1500 V input ically be specified as 4000 Vac-rated. tal protection, PD 2 is generally applica- with variants available at 5, 10, 15, and 40 ble, which allows only non-conductive W ratings. Outputs available are 5, 9, 12, PV Standards pollution with occasional condensation. 15, or 24 V, depending on series. The parts The standard that relates to the safety Designing to meet standards such as IEC are approved to EN-62109-1, the European of PV systems is IEC 62109-1 Safety of 62109-1 is not trivial, with many more version of IEC 62109-1, with 4000 Vac isola- Power Converters for use in Photo - considerations required than men- tion up to 5,000 m altitude; some also meet voltaic Power Systems. Part 1 specifies tioned. Another standard relevant to UL 1741. The parts are encapsulated in a general requirements and Part 2 defines the US PV market is UL 1741, which is choice of board-mount, chassis-mount, or specific requirements for inverters. The for the more general application of DIN-rail formats with an operating tem- standard is relevant to systems up to Distributed Energy Resources, but perature up to 70 °C with no derating. 1500 V, and its scope outlines the design includes requirements for converters PV systems are all about efficient ener- and construction methods required to and controllers. gy conversion up to the GW level, but ensure protection against common haz- require comprehensive control and ards such as electrical shock, mechani- monitoring to get the best performance. cal, temperature, fire, chemical, and Auxiliary power supplies are not an more. Of particular relevance to dc-dc insignificant part of the system and need converters is the reference to IEC 60664, special characteristics to withstand the Insulation Coordination for Equipment high operating voltages while complying within Low-Voltage Systems. Unlike with reliability and safety standards. some older standards, IEC 60664 does This article was written by David Carroll, include requirements for operating at Director of Product Management at CUI Inc., altitudes above 2,000 m, and partial dis- Figure 4. CUI’s AE series of dc-dc converters ranging Tualatin, OR. For more information, visit charge testing, which is very relevant to from 5 W to 40 W. http://info.hotims.com/69509-123.

Tech Briefs, August 2018 www.techbriefs.com 23 Power & Energy

Graphene Oxide Nanosheets for Lithium-Metal Batteries These sheets improve battery function and make the battery safer. University of Illinois, Chicago, Illinois

ithium-metal batteries — which can graphene oxide — can help regulate lithi- In lithium-ion batteries, a separator is Lhold up to ten times more charge than um deposition in such a way that extends placed in the electrolyte. Usually made of lithium-ion batteries — haven’t been com- the life of lithium-metal batteries. a porous polymer or glass ceramic fibers, mercialized because of a fatal flaw: as the Lithium-metal batteries are useful the separator allows lithium ions to flow batteries charge and discharge, lithium is because of their high energy density and through while keeping the other compo- deposited unevenly on the electrodes. relatively light weight compared with nents blocked to prevent electrical shorts This buildup cuts the lives of these batter- conventional batteries. Over the course that can lead to fires. ies too short to make them viable, and of many charge-discharge cycles, howev- A modified separator was used in a lithi- more importantly, can cause the batteries er, lithium builds up unevenly on the um-metal battery to modulate the flow of to short-circuit and catch fire. battery’s lithium metal electrode in a lithium ions to control the rate of lithium A graphene-oxide-coated nanosheet was branching, or dendritic pattern, and ul - deposition and prevent dendrites from developed that, when placed in between timately causes the battery to go dead. If forming. A fiberglass separator was the two electrodes of a lithium-metal bat- the dendrites grow through the elec- sprayed with graphene oxide, producing a tery, prevents uneven plating of lithium trolyte solution and make contact with nanosheet. Using scanning electron and allows the battery to safely function for the other electrode, the battery may microscopy and other imaging tech- hundreds of charge/discharge cycles. Two- experience a catastrophic event — an niques, it was shown that when the dimensional materials — in this case, explosion or fire. nanosheet was used in a lithium-metal battery, a uniform film of lithium formed on the lithium electrode’s surface, which actually improves battery function and GO makes the battery much safer. Molecular simulations suggested that

N2 the lithium ions become temporarily bonded to the graphene oxide, and then Dendritic Li Uniform Li diffuse through areas of nanoscopic defects in the sheet. This delays the passage of lithium ions enough to prevent the

Bare Li formation of dendritic deposition of lithi-

GO Coated Li um on the electrode. Results of phase-field modeling computations indicated that 3 μm μ 3 m graphene oxide can also mechanically suppress the growth of lithium dendrites. Left: Dendrites forming on a lithium electrode. Right: Lithium plates uniformly on a lithium elec- For more information, contact Sharon trode in a battery with a graphene oxide nanosheet separator. (Reza Shahbazian-Yassar) Parmet at [email protected]; 312-413-2695.

Water-Based Battery Stores Solar and Wind Energy The battery can inexpensively store wind or solar energy for use when it is needed. Stanford University, Palo Alto, California

ind and solar energy generation energy generated when the Sun is shin- could charge and recharge up to 10,000 Wcreates challenges, since the Sun ing and wind is blowing so it can be fed times, creating a grid-scale battery with a only shines by day, and sometimes the back into the electric grid and be redis- useful lifespan well in excess of a decade. wind doesn’t blow. Another variability is tributed when demand is high. Given the water-based battery’s expected surges of demand on the grid. On a hot The prototype manganese-hydrogen lifespan, it would cost a penny to store day when air conditioning is in use, util- battery generates a mere 20 milliwatt enough electricity to power a 100-watt ities must have load-balancing strategies hours of electricity, which is on par with lightbulb for 12 hours. to meet peak demand. A water-based the energy levels of LED flashlights; how- The battery uses a reversible electron battery was developed that could pro- ever, the researchers can scale up the bat- exchange between water and man- vide a cheap way to store wind or solar tery to an industrial-grade system that ganese sulfate, a cheap, abundant indus-

24 www.techbriefs.com Tech Briefs, August 2018 trial salt used to make dry cell batteries, fertilizers, paper, and other products. To mimic how a wind or solar source might feed power into the battery, the researchers attached a power ENABLING YOUR INNOVATION source to the prototype. The electrons flowing in reacted with FROM CONCEPT TO PERFORMANCE the manganese sulfate dissolved in the water to leave particles of manganese dioxide clinging to the electrodes. Excess electrons bubbled off as hydrogen gas, thus storing that energy for future use. The prototype uses platinum as a catalyst to spur the cru- SOFTWARE THAT LIVES UP TO cial chemical reactions at the electrode that make the recharge process efficient, and the cost of that component THE POWER OF YOUR IDEAS would be prohibitive for large-scale deployment. Researchers are working on cheaper ways to coax the manganese sulfate and water to perform the reversible electron exchange. More than 10,000 recharges of the prototypes were conducted; it will be necessary to test the battery under actual electric grid storage conditions in order to truly assess its lifetime performance and cost. For more information, contact Tom Abate at [email protected]; 650-736-2245.

Electrode Design Boosts Supercapacitor Performance The device design was inspired by the structure and function of leaves on tree branches. University of California, Los Angeles, California

upercapacitors are rechargeable energy storage devices Sthat deliver more power for their size than similar-sized batteries. They also recharge quickly, and they last for hundreds COMPETITIVE ADVANTAGES to thousands of recharging cycles. Today, they are used in • hybrid cars’ regenerative braking systems and for other appli- New! “Smart Workspace” • cations. Advances in supercapacitor technology could make Search-based design simulation their use widespread as a complement to, or even replacement • Program your own applications with API for batteries used in household electronics. • Precise ﬁeld calculations using our proprietary The challenge has been producing more efficient and BEM and FEM solvers durable electrodes. Electrodes attract ions to the surface of the • Intuitive and easy-to-use interface supercapacitor, where that energy becomes available to use. Ions in supercapacitors are stored in an electrolyte solution. An electrode’s ability to deliver stored power quickly is deter- “For our purposes, ‘ELECTRO’ is actually the mined in large part by how many ions it can exchange with that preferred software tool for every-day engineering. It solution; the more ions it can exchange, the faster it can deliv- is important to have software that is very quick and er power. easy to learn and this product is more than capable A long-lasting electrode for supercapacitors was developed of handling the large models we require.” that is more than ten times more efficient than other designs. The electrode design provides the same amount of energy stor- Dr. Beriz Bakija, Siemens AG’s Energy Sector, Germany age, and delivers as much power as similar electrodes, despite being much smaller and lighter. In experiments, it produced ASK FOR AN ONLINE DEMONSTRATION 30 percent better capacitance — a device’s ability to store an electric charge — for its mass compared to the best available electrode made from similar carbon materials, and 30 times better capacitance per area. It also produced ten times more power than other designs, and retained 95 percent of its initial capacitance after more than 10,000 charging cycles. [email protected] / (204) 632-5636 The electrode was designed to maximize its surface area, creating the most possible space for it to attract electrons. integratedsoft.com The device design was inspired by the structure of trees,

Tech Briefs, August 2018 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -7 13 25 Power & Energy which absorb ample amounts of carbon tures, about 100 nanometers wide, made ance between the electrolyte and the sur- dioxide for photosynthesis because of of graphene — ultra-thin sheets of car- face to deliver energy than they would if the surface area of their leaves. To cre- bon. The leaves are then arranged on the electrode surfaces were flat. ate the branch-and-leaves design, the the perimeter of the nanotube stems. The electrode also performs well in researchers used two nanoscale struc- The leaf-like graphene petals also give acidic conditions and high temperatures, tures composed of carbon atoms. The the electrode stability. both environments in which supercapac- “branches” are arrays of hollow, cylindri- The engineers then formed the struc- itors could be used. cal carbon nanotubes, about 20 to 30 tures into tunnel-shaped arrays; the ions For more information, contact Matthew nanometers in diameter, and the that transport the stored energy flow Chin at [email protected]; 310-206- “leaves” are sharp-edged, petal-like struc- through the arrays with much less resist- 0680

Chemical Heat Battery Material Releases Energy on Demand This chemical composite could store heat from the Sun or any other source, and release the heat when needed. Massachusetts Institute of Technology, Cambridge, Massachusetts

new chemical composite could be Aused to store heat from the Sun during the day in a thermal battery, and release the heat when needed. A common approach to thermal storage is to use a phase change material (PCM), where input heat melts the material, and its phase change — from solid to liquid — stores energy. When the PCM is cooled back down below its melting point, it turns back into a solid, at which point the stored energy is released as heat. There are many examples of these materials, including waxes or fatty acids used for low-temperature applications, and molten salts used at high temperatures. But all current PCMs require a great deal of insulation, and they pass through that phase change temperature uncontrollably, losing their stored heat relatively rapidly. Instead, the new system uses molecular switches that change shape in response to light. When integrated into With the new composite, an energy barrier is installed so the stored heat cannot be released imme- the PCM, the phase-change tempera- diately. In its chemically stored form, the energy can remain for long periods until the optical trig- ture of the hybrid material can be ger is activated. (MIT) adjusted with light, allowing the thermal energy of the phase change to be releases its energy. The hybrid material In its chemically stored form, the maintained even well below the melting melts when heated, and after being energy can remain for long periods point of the original material. exposed to ultraviolet light, it stays melt- until the optical trigger is activated. The composite serves as an add-on ed even when cooled back down. Next, Stored heat can remain stable for at for traditional phase change materials when triggered by another pulse of least 10 hours, whereas a device of sim- — molecules that undergo a structural light, the material resolidifies and gives ilar size storing heat directly would dis- change when light shines on them. back the thermal phase-change energy. sipate it within a few minutes. In the ini- Integrating the molecules with conven- The system could make use of any tial proof-of-concept system, the tem- tional PCM materials to release the source of heat, not just solar. The avail- perature change or supercooling stored energy as heat, on demand, was ability of waste heat is widespread — achieved for the thermal storage mate- accomplished by combining the fatty from industrial processes, to solar heat, rial can be up to 10 ˚C (18 ˚F), but acids with an organic compound that and even the heat coming out of vehi- could go higher. The material can store responds to a pulse of light. With this cles — and is usually wasted. Har - about 200 joules per gram. arrangement, the light-sensitive compo- nessing some of that waste could pro- For more information, contact Karl-Lydie nent alters the thermal properties of the vide a way of recycling that heat for use- Jean-Baptiste at [email protected]; 617- other component, which stores and ful applications. 253-1682.

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Ultra-Low Power Consumption for Data Recording Tohoku University, Miyagi, Japan ew phase change material was devel- The principle of PCRAM operation The Cr2Ge2Te6 can achieve a reduction Noped that has electrical characteristics relies on the change in electrical resis - of more than 90% in power consumption that behave differently than those of con- tance between high-resistance amor- for data recording compared to using a ventional materials. This new material pro- phous and low-resistance crystalline states conventional GST memory cell. vides a drastic reduction in power con- in phase change material. Ge-Sb-Te Simultaneously, Cr2Ge2Te6 was found sumption for data recording in non- (GST) is well known as a phase change to combine a faster operation speed (~30 volatile random access memory (RAM). material for PCRAM application. GST ns) and a higher data retention property Phase change random access memory can operate at high speed, but has poor (over 170 °C) than conventional materi- (PCRAM) has attracted attention as a data retention at high temperatures als. Comparison with other reported next-generation, practical, non-volatile (~85 °C), and needs a large amount of materials indicates that Cr2Ge2Te6 can memory. PCRAM is expected to not only power for data recording. break the tradeoff relationship between replace flash memory, but also to be used The new material, Cr2Ge2Te6 phase data retention and operation speed. for storage-class memory, which can miti- change material, exhibits an inverse resis - For more information, contact Yuji Sutou, gate the difference in latencies between tance change from low-resistance amor- Department of Materials Science, at DRAM and flash memory. phous to high-resistance crystalline states. [email protected].

Integrated Inverter for Controlling Multiple Electric Machines Potential uses include electric and hybrid electric vehicles, and other applications that require multiple electric engines. Oak Ridge National Laboratory, Oak Ridge, Tennessee

here are applications that require or generator to run in either a motoring reduces the number of components Tmultiple electric machine drives, mode or a generating mode. A conse- required in an electric engine, lowering such as electric or hybrid electric vehi- quence of this design is that each vehicle the total component cost. It also sup- cles, where there is a main traction requires a number of inverters and ports the design of smaller engines. motor and one or more accessory inverter controllers, plus the engine vol- The integrated inverter control per- motors or generators. To control the ume to house them all. mits each inverter to share one or more speed or power of these multiple motors To improve options for motor design, of the following: a common DC bus, a or generators independently, each mo- an integrated inverter control was devel- DC bus filtering capacitor, a gate drive tor or generator requires an inverter. oped for directing multiple inverters circuit, a process control circuit, voltage The use of an inverter enables the motor with a single processer. This invention sensors, current sensors, speed sensors, or position sensors. With a proper con-

Three-Phase Two-Phase trol algorithm, the motors/generators Electric Machine Inverter Inverter can be run in either a motoring mode Drive D8 Three-Phase (providing power to the motor shaft) or D1 D2 D7 Current Motor/ in a generating mode (power is trans- S1 S2 S3 S7 S8 Sensor Generator ferred from the motor shaft to the Vdc D3 C a 0 N inverter direct current source). The dc 1 b Source c 0 invention can be used in synchronous α 0 β machines, induction machines, or per- D D D D 0 dc 4 5 6 9 D10 manent magnet machines. Bus Tα Tcom S4 S5 S6 S9 S10 The invention provides advantages of Tβ lower cost and a smaller volume for Two-Phase drive systems in specific applications Motor/ Gate Driver such as the electric or hybrid vehicle. In Generator this application, one machine serves as a Voltage Sensor main traction machine while other Processor Control machines are used to power accessory Circuit (DSP) devices on the vehicle. For more information, contact David L. The internal short placed within a pouch cell. (Dirk Long, NREL) Sims at [email protected]; 865-241-3808.

28 www.techbriefs.com Tech Briefs, August 2018 Power Outlet Analyzes Electrical Current Usage This “smart” outlet learns to identify plugged-in appliances and distinguish dangerous electrical spikes from benign ones. Massachusetts Institute of Technology, Cambridge, Massachusetts

lectrical interruptions, or “nuisance without actually touching it, sensing the After training the network, the hard- Etrips,” occur when a detector installed passing current as a changing magnetic ware and software were run on new data behind the wall trips an outlet’s electrical field. Between the current clamp and from the same four devices, and found it circuit when it senses something that the microcomputer, a USB sound card was able to discern among the four types could be an arc-fault — a potentially dan- was connected, which was used to read of devices (for example, a fan versus a gerous spark in the electric line. The the incoming current data. computer) with 95.61 percent accuracy. problem with today’s arc-fault detectors is that they often err on the side of being overly sensitive, shutting off an outlet’s power in response to electrical signals that are actually harmless. WebDAQ A smart power outlet was developed that can analyze electrical current usage from a single outlet or multiple Internet Enabled Data Loggers from MCC outlets, and can distinguish between benign arcs — harmless electrical spikes such as those caused by common household appliances — and danger- Remote Conﬁ guration and Monitoring ous arcs, such as sparking that results from faulty wiring and could lead to a Virtually Unlimited Storage fire. The device can also be trained to identify what might be plugged into a particular outlet, such as a fan versus a desktop computer. The design comprises custom hardware that processes electrical current Integrated HW and SW data in real time, and software that analyzes the data via a neural network — a set of machine learning algorithms that are inspired by the workings of the human brain. In this case, the machine- learning algorithm is programmed to Flexible Triggers, Built-in Web Server, determine whether a signal is harmful Alarms, Emails, and Easy-to-Use or not by comparing a captured signal SMS Texts to others that previously were used to train the system. The more data the network is exposed to, the more accurately it can learn characteristic “fingerprints” used to differentiate good from bad, or even to distinguish one appliance from another. Buy with Conﬁ dence with a 30-Day Money-Back Guarantee The smart power outlet is able to connect to other devices wirelessly as part MODEL INPUTS SAMPLE RATE RESOLUTION DIGITAL I/O of the Internet of Things. A pervasive WebDAQ 316 16 Thermocouple 75 S/s Max 24-Bit 4 network could be developed in which Temperature Logger customers can install not only a smart WebDAQ 504 power outlet in their homes, but also an 4 IEPE 51 kS/s/Ch Max 24-Bit 4 Vibration/Acoustic Logger app on their phone through which they can analyze and share data on their electrical usage. MCCDAQ.COM/WebDAQ The hardware setup consists of a Raspberry Pi Model 3 microcomputer Contact us — a low-cost, power-efficient processor that records incoming electrical cur- 1.800.234.4232 rent data — and an inductive current ©2018 Measurement Computing Corporation, 10 Commerce Way, Norton, MA 02766 • [email protected] clamp that fixes around an outlet’s wire

Tech Briefs, August 2018 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -7 15 29 Electrical/Electronics

In identifying good from bad signals, the A neural network could be run over These new definitions would then get system achieved 99.95 percent accuracy the Internet where other users can con- shared wirelessly to users’ outlets, — slightly higher than existing AFCIs. nect to it and report on their electrical improving their performance and The system was also able to react quickly usage, providing additional data to the reducing the risk of nuisance trips with- and trip a circuit in less than 250 millisec- network that helps it to learn new defi- out compromising safety. onds, matching the performance of con- nitions and associate new electrical pat- For more information, contact Abby temporary, certified arc detectors. terns with new appliances and devices. Abazorius at [email protected]; 617-253-2709.

Linear Resonators Make Electronics More Resistant to Damage and Defects This innovation overcomes signal disruption when electronic circuits are broken or damaged. Advanced Science Research Center, GC/CUNY, New York, New York

obile phones, tablets, and other the signal traveling in the circuit, and this provided direct evidence of a topological Mportable devices are prone to fail- robustness can be achieved using suitably transition in the circuitry that translated ure caused by small defects in their com- tailored nonlinearities in circuit arrays. into a self-induced robustness against plex electronics that can result from reg- Nonlinear resonators were used to defects and disorder. ular use. An innovation provides robust mold a band-diagram of the circuit array. As soon as the higher-voltage signal protection against circuitry damage that The array was designed so that a change was applied, the system reconfigured affects signal transmission. in signal intensity could induce a change itself, inducing a topology that propagat- Particular properties of matter (such as in the band diagram’s topology. For low ed across the entire chain of resonators, electrical conductivity) can be preserved in signal intensities, the electronic circuit allowing the signal to transmit without certain materials, despite continuous was designed to support a trivial topolo- any problem. Because the system is non- changes in the matter’s form or shape. This gy, and therefore provide no protection linear, it is able to undergo an unusual concept is associated with topology — a from defects. In this case, as defects were transition that makes signal transmission branch of mathematics that studies the introduced into the array, the signal robust, even when there are defects or properties of space that are preserved transmission and the functionality of the damage to the circuitry. under continuous deformations. The inno- circuit were negatively affected. Similar ideas can be applied to nonlin- vation showed that the science of topology As the voltage was increased beyond a ear optical circuits, and extended to two- can be used to facilitate robust electromag- specific threshold, however, the band- and three-dimensional nonlinear meta- netic-wave propagation in electronics and diagram’s topology was automatically materials. circuit components. In addition, the inher- modified, and the signal transmission For more information, contact Paul ent robustness associated with these topo- was not impeded by arbitrary defects McQuiston at [email protected]; logical phenomena can be self-induced by introduced across the circuit array. This 212-413-3300.

Microcontroller Altimeter (uCA) Goddard Space Flight Center, Greenbelt, Maryland

raditional altitude switch designs for The Microcontroller Altimeter (uCA), tions. The output of the sensor and Tharsh environments are mechanical developed by engineers at NASA’s switches is provided to the user for real- in nature and operate by means of an Goddard Space Flight Center, over- time altitude determination as well as inflatable bladder or bellows that me- comes these limitations by combining discrete altitude trip point knowledge. chanically depresses a pushbutton the robust and cost-effective nature of Updates to the altitude trip points are switch. The altitude trip point is set by modern printed circuit board (PCB) facilitated through USB programming, mechanically adjusting the distance of and solid-state technology to deliver a which allows for in-field adjustment, the switch to the bellows. The mechani- system that is one-third the size of cur- and provides added flexibility late dur- cal action of the switch results in a loss rent systems while still maintaining the ing integration and testing. of accuracy on the order of several thou- same switch channel density, and also NASA is seeking partners to further devel- sand feet, forcing engineers to design providing auxiliary user outputs. op this technology through joint cooperative interfacing systems with an extremely The uCA combines a high-accuracy research and development. For more infor- high error tolerance. Furthermore, integrated silicon pressure sensor with mation about this technology and to explore these types of systems are typically large MOSFET technology to provide tradi- opportunities, please contact techtransfer@ and unreliable, difficult to manufac- tional normally open and normally gsfc.nasa.gov; 301-286-5810. Follow this ture, and prone to failure under certain closed switches capable of high-power link for more information: https://technology. operating conditions. switching for a wide variety of applica- nasa.gov/patent/GSC-TOPS-184.

30 www.techbriefs.com Tech Briefs, August 2018 Thermally Conductive Crystals Dissipate Electronics Heat The thermal properties of boron arsenide crystals can be used to keep electronic devices cool. University of Illinois Urbana-Champaign, Champaign, Illinois, and University of Texas, Dallas

he inner workings of high-power Most of today’s high-performance com - phase, and then cool and condense into Telectronic devices must remain cool puter chips and high-power electronic small crystals. Materials characterization to operate reliably. High internal tem- devices are made of silicon, a crystalline and trial-and-error synthesis were com- peratures can make programs run slow- semiconducting material that does an bined to find the conditions that produce er, freeze, or shut down. To address this adequate job of dissipating heat. But in crystals of high enough quality. issue, researchers have optimized the combination with other cooling technol- Electron microscopy and a technique crystal-growing process of boron ogy incorporated into devices, silicon called time-domain thermoreflectance arsenide — a material that has excellent can handle only so much. Diamond has were used to determine if the lab-grown thermal properties and can effectively the highest known thermal conductivity crystals were free of the types of defects dissipate the heat generated in electron- — about 15 times that of silicon — but that cause a reduction in thermal con- ic devices. there are problems when it comes to ductivity. The result of this optimization marks using it for thermal management of Dozens of the boron arsenide crystals the realization of a previously predicted electronics. The cost of natural dia- were tested. It was found that the ther- class of ultra-high-thermal-conductivity monds and structural defects in man- mal conductivity of the material can be materials. Boron arsenide is not a natu- made diamond films make the material three times higher than that of the best rally occurring material, so it must be impractical for widespread use in elec- materials being used as heat spreaders synthesized in the lab. It also needs to tronics. today. have a very specific structure and low The boron arsenide crystals were syn- For more information, contact David defect density for it to have peak ther- thesized using a technique called chemi- Cahill, Professor, Department of Materials mal conductivity, so its growth happens cal vapor transport. Elemental boron and Science and Engineering, at d-cahill@ in a very controlled way. arsenic are combined while in the vapor illinois.edu; 217-333-6753.

Advances in Spintronic Devices Applications include faster, energy-efficient spintronic computers and ultra-high-capacity data storage. University of California, Riverside, California

pintronic devices promise to solve Smajor problems in today’s computers, which use massive amounts of electricity to generate heat. This requires expending even more energy for cooling. By contrast, spintronic devices generate little heat and use relatively minus- cule amounts of electricity. Spintronic computers would require no energy to maintain data in memory. They would also start instantly and have the potential to be far more powerful than today’s computers. While electronics depend on the charge of electrons to generate the binary 1s or 0s of computer data, spintronics depends on the property of electrons called spin. Spintronic materials register binary data via the “up” or “down” spin orientation of electrons — like the north and south of bar magnets — in the materials. A major barrier to development of spintronic devices is generating and detecting the infinitesimal elec- Methods were developed to detect signals from spintronic components made of low-cost metals tric spin signals in spintronic materials. and silicon. (UC Riverside)

Tech Briefs, August 2018 www.techbriefs.com 31 Electrical/Electronics

Advances in spintronic devices could electrical voltage in the bi-layer. The the neighboring atoms are magnetically lead to new technology for computing voltage was due to a phenomenon oriented in opposite directions. These and data storage. One advance is a known as the spin-Seebeck effect. The “magnetic moments” are due to the spin method to detect signals from spin- resulting “spin current” in the bi-layer of electrons in the atoms, and are cen- tronic components made of low-cost could be detected due to another phe- tral to the application of the materials in metals and silicon, which overcomes a nomenon known as the inverse spin-Hall spintronics. major barrier to wide application of effect. More efficient magnetic switch- Antiferromagnetism was detected in spintronics. Previously, such devices ing in computer memories could lead to the two types of silicon — n-type and p- depended on complex structures that development of such devices. type — used in transistors and other used rare and expensive metals such as A key property for spintronics materi- electronic components. N-type semicon- platinum. als — called antiferromagnetism — ductor silicon is doped with substances A new technique detects the spin cur- could be generated in silicon, opening that cause it to have an abundance of rents in a simple two-layer sandwich of an important pathway to commercial negatively charged electrons; p-type sili- silicon and a nickel-iron alloy called Per- spintronics, given that silicon is inexpen- con is doped to have a large concentra- malloy. All three components are both sive and can be manufactured using a tion of positively charged holes. Com- inexpensive and abundant, and could mature technology with a long history of bining the two types enables switching of provide the basis for commercial spin- application in electronics. current in such devices as transistors tronic devices. They also operate at Ferromagnetism is the property of used in computer memories and other room temperature. magnetic materials in which the magnet- electronics. One side of the Permalloy-silicon bi- ic poles of the atoms are aligned in the For more information, contact Sarah layer sandwich was heated to create a same direction. In contrast, anti- Nightingale at [email protected]; temperature gradient that generated an ferromagne tism is a property in which 951-827-4580.

Built-In Temperature Sensing Method in a Microheater This cost-effective temperature sensing method harnesses an inherent mechanism. Ames Research Center, Moffett Field, California

ASA Ames Research Center has de - Nveloped an innovative built-in temperature sensing method for microheaters. The temperature sensing of Temperature Control Engine chip-based microheaters is conventional- ly done with the aid of a separate sensor, Temperature which typically adds to the production Heating module sensing module cost and can cause inaccuracy. These have been widely used in many applications including gas sensors, flow meters, polymerese chain reaction chambers and the hot-stage in transmission electron microscopes where accurate monitoring of temperature is critical. NASA has developed a novel resistor-based micro- Power for heating Resistance for monitoring heater that relies on a Joule heating mechanism. The resistance is dependent on the body temperature, which means Microheater that the microheater has an inherent sensing mechanism and eliminates the need for embedded sensors. The operation scheme of the temperature sensing technology. The physical structures of both the Joule heater and the thermistor are tem. Second, the interrupt period for built-in temperature sensing is attrib- equivalent in principle, i.e., a resistor, the temperature sampling should be suf- uted to the electrical time constant which implies that the resistor pattern ficiently short so as to avoid temperature being few orders of magnitude smaller can offer dual functions of heating and perturbations. than the thermal time constant. The temperature sensing simultaneously; It is found that an intermittent tem- temperature estimation results using the however, two assumptions need to be perature sampling in the middle of the built-in method show excellent agree- confirmed in order to assure the dual heating cycle does not disturb the body ment with the benchmark measure- functions. First, the parasitic power dur- temperature if the temperature sam- ments from an infrared pyrometer. ing the temperature sensing operation pling voltage and pulse width are suffi- Intermittent inter ruption for the tem- should not heat up or cool down the sys- ciently low and short, respectively. The perature sampling is found to be allow-

32 www.techbriefs.com Tech Briefs, August 2018 able during the heating period as long as the sampling is made required to drop 1 °C. Therefore, this method enables body at very low voltages lasting short duration. The electrical time temperature sensing at low cost with negligible self-heating constant of the order of tens of picoseconds is nine orders of and interruption of cooling effects. magnitude smaller than the thermal time constant in the order NASA is actively seeking licensees to commercialize this technology. of tens of milliseconds. In addition, a clock frequency of 10 Please contact the Ames Technology Partnerships Office at ARC- megahertz is easily affordable since low-cost electronics can [email protected] to initiate licensing discussions. Follow sample pulses of 100 nanoseconds. This results in temperature this link for more information: http://technology.nasa.gov/ sampling within six orders of magnitude faster than the time patent/TOP2-271.

Supersonic Waves Enable Heat Management in Electronics Devices These phasons could improve heat transport in insulators and enable new strategies for heat management in future electronics devices. Oak Ridge National Laboratory, Oak Ridge, Tennessee

esearchers have observed waves of atomic rearrangements, Phase differences accumulate in a lattice of wrinkles called soli- Rknown as phasons, propagating supersonically through a tons. Solitons are solitary waves that propagate with little loss of vibrating crystal lattice — a discovery that may dramatically energy and retain their shape. They can also warp the local envi- improve heat transport in insulators and enable new strategies ronment in a way that allows them to travel faster than sound. for heat management in future electronics devices. It provides Next, the researchers will explore other crystals that, like a shortcut through the material — a way to send the energy of fresnoite, can rotate phasons. Strain applied with an electric pure atomic motion at a speed that’s higher than what is field may be able to change the rotation; changes in tempera- achievable with phonons (atomic vibrations). The shortcut ture also may vary properties. may open possibilities in heat management of nano scale For more information, contact Dawn Levy at [email protected]; 865- materials. 576-6448. Neutron scattering was used to measure phasons with veloc- ities about 2.8 times and about 4.3 times faster than the natural “speed limits” of longitudinal and transverse acoustic waves, respectively. Insulators are necessary in electronic devices to prevent short circuits, but without free electrons, thermal transport is limited to the energy of atomic motion. Hence, understanding the transport of heat by atomic motion in insulators is important. The neutrons were scattered in fresnoite, a crystalline min- eral so named because it was first found in Fresno, California. It is promising for sensor applications through its piezoelectric property, which allows it to turn mechanical stress into electrical fields. Fresnoite has a flexible framework structure that develops a competing order in the structure that does not match the underlying crystal order, like an overlay of mis- matched tiles. Phasons are excitations associated with atomic rearrangements in the crystal that change the phase of waves describing the mismatch in the structure.

Neutron scattering studies of lattice excitations in a fresnoite crystal revealed a way to speed thermal conduction. (Image: ORNL graphic artist Jill Hemman)

Tech Briefs, August 2018 Free Info at http://info.hotims.com/69509-7 1 7 33 Optics

Hyperfine Interpolated Range Finding for CW Lidar, Radar, and Sonar Using Repeating Waveforms and Fourier Transform Reordering Langley Research Center, Hampton, Virginia

ASA’s Langley Research Center has the reordering of an array used in the This technique can be applied broadly Ndeveloped a novel fine interpola- Fourier transform to obtain results with any repeating waveform, and not tion technique that is useful in signal much more rapidly and with greater confined to PN code and PSK modula- processing for applications in lidar, accuracy. By applying certain nonlinear tion. In addition, it allows use of continu- sonar, radar, and similar modalities. The deconvolution techniques to single or ous wave (CW) lasers rather than the cost- interpolation technique uses repeating multiple pulses, the pulses can be lier, bulky pulsed lasers. Potential applica- waveforms, Fourier transform reorder- sharpened, allowing measurement of tions include range finding, differential ing, and Richardson-Lucy deconvolu- objects that are actually smaller than absorption studies, and cloud and tree tion to obtain faster and more accurate the resolution of the lidar. This is then canopy thicknesses determination. results. The prime target application is enhanced further using Richardson- NASA is actively seeking licensees to range finding, but the technique is Lucy deconvolution. The resulting res- commercialize this technology. Please equally suitable for differential absorp- olution and pulse width can be contact The Technology Gateway at tion studies, such as determining CO2 enhanced by about two orders of mag- [email protected] concentrations in the atmosphere. nitude using these techniques, thus to initiate licensing discussions. Follow Compared to standard methods such breaking the fundamental resolution this link for more information: http:// as fitting, which tend to be slow, this limit for BPSK modulation of a particu- technology.nasa.gov/patent/TB2016/ technology uses a simple technique of lar bandwidth and bit rate. LAR-TOPS-219.

Crystal-Free Formation of Non-Oxide Optical Fiber Applications include surgical and cutting lasers, radiation-resistant optical fibers, and remote optical sensing in harsh environments. Marshall Space Flight Center, Alabama

esearchers at NASA’s Marshall Space RFlight Center have devised a method for the creation of crystal-free non-oxide optical fiber preforms. Non-oxide fiber optics are extensively used in infrared transmitting applications such as communication systems, chemical sensors, and laser fiber guides for cutting, welding, and medical surgery. Some of these glasses, however, are very susceptible to crystallization. Even small crystals can lead to light scatter and a high attenuation coef- ficient, limiting their usefulness. NASA has developed a new method of non- oxide fiber formation that uses axial mag- SEM images of ZBLAN fibers: at left, processed in unit gravity, forming visible crystals; at right, netic fields to suppress crystallization. processed with magnetic, eliminating crystal formation. The resulting non-oxide fibers are crystal- free and have lower signal attenuation glasses (e.g. ZBLAN) are highly trans- Theoretical estimates for signal attenu- rates than silica-based optical fibers. parent from near ultraviolet to mid- ation losses for non-oxide fibers yield val- Signal propagation through tradition- infrared wavelengths, and have lower ues of approximately 0.001 dB/km for a al silica-based optical fibers is limited to theoretical signal attenuation rates, transmitted wavelength of 2.55 microme- visible and near-infrared wavelengths. In resulting in the ability to transmit wide- ters. The theoretical loss for the state-of- contrast, non-oxide glasses such as band signals over significant distances the-art fused silica is two orders of magni- chalcogenide and heavy metal fluoride with minimal losses. tude higher at 0.12 dB/km at 1.55

34 www.techbriefs.com Tech Briefs, August 2018 micrometers. There are a number of crys- heated in the 0.1-T magnetic field did not perature will ensure that no crystals are tals and defects that can serve as scattering show evidence of crystallization under present in the preform after processing. centers in non-oxide glass preforms and optical microscopy or Scanning Electron NASA is seeking partners to further devel- fibers. These include ZrF4, LaF3, AlF3, Microscopy (SEM). op this technology through joint cooperative ZrO2, platinum particles from crucible As seen in the figures, an axial mag- research and development. For more infor- reactions, carbon from organic impuri- netic field has the effect of suppressing mation and to explore opportunities, please ties, and crucible reactions and bubbles crystallization in ZBLAN. The experi- contact Clark Darty at ronald.c.darty@ due to contraction, cavitation, and gas ments indicate that the combination of a nasa.gov. Follow this link for more informa- precipitation. Using this patented pre- vertical magnetic field and a rapid cool- tion: https://technology.nasa.gov/patent/ form formation technology, the fibers down from the crystallite melting tem- TB2016/MFS-TOPS-44.

Hybrid Optics for Color Imaging These metalenses can be used in ultrathin cameras or tiny microscopes. University of Washington, Seattle, Washington

oday’s glass-based lenses are bulky that are manufactured materials with images with very low levels of aberra- Tand resist miniaturization. To address physical and chemical properties not tions across the visual spectrum. the problem, two different imaging normally found in nature. A metasur- Instead of manufactured glass or sili- methods — a type of lens designed for face-based lens (metalens) consists of cone, metalenses consist of repeated nanoscale interaction with lightwaves, flat, microscopically patterned material arrays of nanometer-scale structures, and robust computational processing — surfaces designed to interact with light- such as columns or fins. If properly laid were combined successfully to create waves. To date, images taken with meta - out at these miniscule scales, the struc- full-color images. lenses yield clear images for only small tures can interact with individual light- The ultrathin lens is part of a class of slices of the visual spectrum. The new waves with precision that traditional engineered objects known as metasur- metalens — in conjunction with compu- lenses cannot. Since metalenses are also faces — 2D analogs of metamaterials tational filtering — yields full-color so small and thin, they take up much less

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Tech Briefs, August 2018 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -7 19 35 Optics

image across all visible wavelengths, the Conventional Metalens Image researchers thought to resolve the aberrations for all wavelengths afterward using Final Reconstructed Image computational filtering algorithms. For the rose in the blue vase, this type of meta - lens would capture an image of the red rose, blue vase, and green stem — all with similar types of chromatic aberrations that could be tackled later using computational filtering. Extended Depth of Focus Metalens Image A metalens was constructed whose surface was covered by tiny, nanometers-wide Postprocessing columns of silicon nitride. These columns Software were small enough to diffract light across the entire visual spectrum, which encompasses wavelengths ranging from 400 to 700 nanometers. The arrangement and size of the silicon nitride columns in the The metalens consists of arrays of tiny pillars of silicon nitride on glass that affect how light interacts metalens were designed so that it would with the surface. A traditional metalens (top) exhibits shifts in focal length for different wavelengths exhibit a spectrally invariant point spread of light, producing images with severe color blur. The modified metalens design (bottom) interacts function. Essentially, this feature ensures with different wavelengths in the same manner, generating uniformly blurry images that enable simple and fast software correction to recover sharp and in-focus images. (Shane Colburn/Alan that, for the entire visual spectrum, the Zhan/Arka Majumdar) image would contain aberrations that can be described by the same type of mathe- room than the bulky lenses of cameras mal range, such as an all-green image or matical formula. Since this formula would and high-resolution microscopes. Meta- an all-red image. For scenes that include be the same regardless of the wavelength lenses are manufactured by the same colors outside of that optimal range, the of light, the researchers could apply the type of semiconductor fabrication proc ess images appear blurry, with poor resolution same type of computational processing to that is used to make computer chips. and other defects known as chromatic correct the aberrations. In experiments producing images with aberrations. For a rose in a blue vase, for Unlike many other metasurface-based metalenses, the optimal wavelength range example, a red-optimized metalens might imaging systems, the new approach isn’t so far has been very narrow — at best pick up the rose’s red petals with few aber- affected by the polarization state of light, around 60 nanometers wide with high effi- rations, but the green stem and blue vase which refers to the orientation of the elec- ciency. But the visual spectrum is 300 would be unresolved blotches with high tric field in the 3D space in which light- nanometers wide. levels of chromatic aberrations. waves are traveling. Today’s metalenses typically produce If a single metalens could produce a For more information, contact Arka accurate images within their narrow opti- consistent type of visual aberration in an Majumdar at [email protected]; 206-616-5558.

Material Brings Optical Communication onto Silicon Chips Ultrathin films of a semiconductor that emits and detects light can be stacked on top of silicon wafers. Massachusetts Institute of Technology, Cambridge, Massachusetts

n increase in computing perform- ferent parts of a microchip; however, sili- 2D molybdenum ditelluride can be Aance has been achieved by squeezing con — the material used to build chips — mechanically attached to any material. ever more transistors into a tighter space does not emit light easily. Another difficulty with integrating on microchips. This downsizing has also A light emitter and detector were other semiconductors with silicon is that meant packing the wiring within micro- developed that can be integrated into sil- the materials typically emit light in the vis- processors ever more tightly to gether, icon CMOS chips. The device is built ible range, but light at these wavelengths leading to effects such as signal leakage from a semiconductor material called is simply absorbed by silicon. Molyb- between components, which can slow molybdenum ditelluride. This ultrathin denum ditelluride emits light in the down communication between different semiconductor belongs to an emerging infrared range, which is not ab sorbed by parts of the chip. This delay, known as the group of materials known as two-dimen- silicon, meaning it can be used for on- “interconnect bottleneck,” is becoming sional transition-metal dichalcogenides. chip communication. an increasing problem in high-speed Unlike conventional semiconductors, To use the material as a light emitter, it computing systems. the material can be stacked on top of sili- first had to be converted into a P-N junc- One way to solve the interconnect bot- con wafers. In contrast to materials such tion diode, a device in which one side tleneck problem is to use light rather as gallium arsenide that is used for optics, (the P side) is positively charged, while than wires to communicate between dif- but cannot be grown easily on silicon, the the other side (the N side) is negatively

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Extreme precision A molybdenum ditelluride light source for silicon photonics. A new light emitter and detector can be integrated into silicon CMOS chips. (Image: Sampson Wilcox) Modular – up to 4 synchronized channels charged. In conventional semiconduc- optical communication. Most telecom- Easy set up and configuration tors, this is typically done by introducing munication systems operate using light via WEB interface chemical impurities into the material. with a wavelength of 1.3 or 1.5 microme- Math functions for thickness or With the new class of 2D materials, it can ters; however, molybdenum ditelluride differential calculations be done by simply applying a voltage emits light at 1.1 micrometers. This across metallic gate electrodes placed makes it suitable for use in the silicon side-by-side on top of the material. chips found in computers, but unsuitable Once the diode is produced, a current for telecommunications systems. To this is run through the device, causing it to end, the researchers are exploring anoth- emit light. The device can also be er ultrathin material called black phos- switched to operate as a photodetector by phorus that can be tuned to emit light at reversing the polarity of the voltage different wavelengths by altering the applied to the device. This causes it to number of layers used. They hope to stop conducting electricity until light develop devices with the necessary num- shines on it when the current restarts. In ber of layers to allow them to emit light at www.micro-epsilon.com this way, the devices are able to both the two wavelengths while remaining transmit and receive optical signals. compatible with silicon. MICRO-EPSILON The researchers are investigating other For more information, contact Abby Raleigh, NC 27617 / USA materials that could be used for on-chip Abazorius at [email protected]; 617-253-2709. Phone +1/919 787 9707 [email protected] Tech Briefs, August 2018 www.techbriefs.com Free Info at http://info.hotims.com/69509-720 Materials & Coatings

Hardface Coating Systems for Wear and Corrosion Resistance Applications include rotor and turbine blades, power-generating surfaces, military hardware, and sports equipment. Y-12 National Security Complex, Oak Ridge, Tennessee

etal alloys, such as titanium alloys nificantly different between the substrate strate metal alloys may be accomplished Mand steels, are known to have a and a ceramic or cermet surface coating. by depositing a slurry, suspension, good combination of mechanical proper- Hardface coating systems for metal blend, or mixture of selective materials ties for many structural applications, but alloys and other materials provide wear onto a surface using a number of meth- these metal alloys do not meet the wear and corrosion resistance to overcome ods such as painting, spraying, thermal and corrosion resistance requirements for some of these attendant shortcomings. A spraying, dipping, powder coating, etc., some structural applications. Titanium titanium boron coating is applied as a liq- and then reactively forming the surface alloys, for example, have many attractive uid to the surface of another metallic by heating using laser radiation, plasma properties such as high specific strength object. As the liquid cools, it bonds to the radiation, infrared radiation, electron and stiffness, relatively low density, and surface and undergoes a chemical reac- beam radiation, microwave radiation, excellent corrosion resis tance, but have tion that provides superior wear and induction, welding, etc. poor resistance to wear and oxidation at thermal stress properties. The metallic The surface coatings formed by this high temperatures. Conventional surfac- coating combines the performance of approach change the surface characteris- ing (such as nitriding), coating deposition heat treatment and alloys, bonded to the tics of a component or structure to pro- (such as plasma spraying and sputtering), surface of the substrate. vide properties of high hardness, high and plating have significant shortcomings The coatings are applied by deposition temperature strength, wear and corrosion that in clude potentially providing distort- processes including thermal spraying, resistance, and strong adherence to the ed substrates, deteriorated surfaces, physical vapor deposition (PVD), powder substrate without significantly changing and/or weak interfacial bonding. coating followed by post-heat treatment, as the bulk material properties. Layers or To overcome these shortcomings and well as by slurry coating. The reinforced functional grading may be employed to provide high wear- and corrosion-resis- composite structure in the coatings is increase bonding strength and adherence, tant surfaces on metal alloy substrates, preferably formed during the thermal or to mitigate differences in the CTE, surface alloying and reactive surface spray or PVD processes, whereby the whether or not post-heat treatment is uti- modification have been developed — process heat provides the inherent energy lized. The surface may be applied to fin- depositing and post-heat-treating a to facilitate the reaction for the formation ished components by portable field tech- unique combination of materials, select- of the desired composition. In such cases, niques, or fabricated onto sheet materials ed based upon the substrate material post-heat treatment is not necessary; how- prior to the final manufacturing steps. and specific application environment. ever, in some cases, such post-heat treat- For more information, contact the Office Functionally graded or layered interfaces ment may increase the percentage of rein- of Technology Commercialization and are used to overcome interfacial bond- forcement in the matrix. Partnerships at [email protected], 865- ing weaknesses, especially when the coef- Surface engineering, surface modifi- 241-5981, or visit www.y12.doe.gov/ ficient of thermal expansion (CTE) is sig- cation, or surface alloying of the sub- technologies.

Artificial “Blubber” Protects Divers in Frigid Water This treatment of standard neoprene triples the survival time for swimmers. Massachusetts Institute of Technology, Cambridge, Massachusetts

hen Navy SEALs carry out dives in gas for about a day. The treatment then The material that has become stan- WArctic waters, or when rescue teams lasts for about 20 hours — far longer dard for wetsuits is neoprene, an inex- are diving under ice-covered rivers or than anyone would spend on a dive. The pensive material that is a mix of synthet- ponds, the survival time even in the best process could also be done in advance, ic rubber materials processed into a kind wetsuits is very limited — as little as tens with the wetsuit placed in a sealed bag to of foam, producing a closed-cell struc- of minutes. Researchers have discovered be opened just before use. The process ture similar to styrofoam. Trapped with- a process to triple that survival time. essentially combines a blubber-like insu- in that structure, occupying more than The process works by placing a stan- lating material that also makes use of two-thirds of the volume and accounting dard neoprene wetsuit inside a pressure trapped pockets of gas; namely, xenon for half of the heat that gets transferred tank autoclave filled with a heavy inert or krypton. through it, are pockets of air. If the

38 www.techbriefs.com Tech Briefs, August 2018 1 ISO 1 900 34 O 85 S I

Holes in a wetsuit reveal the thickness of the neoprene material. The treatment could provide the AS 9100 same amount of insulation with just half the thickness. (Photo: Susan Young) trapped air is replaced with xenon or case, a failure of the pump or a cut or Perfection krypton, the material’s insulating prop- tear in the suit can result in a quick loss erties increase dramatically. The result is of insulation that can be life-threatening a material with the lowest heat transfer within minutes. But the xenon- or kryp- in Tubing of any wetsuit ever made. This could ton-infused neoprene requires no such You may think that improve survivability in water colder support system and has no way of quickly than 10 °C, raising it from less than one losing its insulating properties, and so since our name is Eagle hour to two or three hours. does not carry that risk. One next step is Currently, the only viable cold-water to look at ways of making a long-term, Stainless that we only alternatives to wetsuits are dry suits, stable version of a xenon-infused neo- which have a layer of air between the suit prene, perhaps by bonding a protective work with stainless and the skin that must be maintained layer over it. steel. However, Eagle using a hose and a pump; or a warm- For more information, contact Karl-Lydie water suit, which similarly requires a Jean-Baptiste at [email protected]; 617- is also a distributor of hose and pump connection. In either 253-1682. aluminum tubing in a variety of alloys. Rubber-Like Adhesive Film Sticks to Highly Deformable Areas Cutting kirigami-style slits in stretchy films could make for bandages, heat pads, and wearable electronics that adhere to flexible surfaces. Massachusetts Institute of Technology, Cambridge, Massachusetts

dhesives used for common pain- mi as a way to develop new functional Arelieving bandages often do not stick materials. properly when attached to places that A thin, lightweight, rubber-like adhesive encounter large, inhomogenous bending film was developed that can stick to highly motion, like elbows and knees. To solve deformable regions of the body, such as this problem, kirigami was considered as a the knee and elbow, and maintain its hold Eagle Stainless Tube & Fabrication, Inc. possible solution. Originally an Asian folk after 100 bending cycles. The key to the Franklin, Massachusetts art, kirigami is the practice of cutting intri- film’s clinginess is a pattern of slits that the cate patterns into paper and folding this researchers have cut into the film, similar Phone (800) 528-8650 paper, much like origami, to create three- to the cuts made in kirigami. www.eagletube.com dimensional structures. More recently, When placed on the knee, the film slits some scientists have been exploring kiriga- open at the center in the region of the

Tech Briefs, August 2018 www.techbriefs.com Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -72 1 Materials & Coatings

mi film threaded with heating wires, also was developed. With the application of a 3- Volt power supply, the pad maintains a steady temperature of 100 °F. The bandage can function and stick to the skin even after 100 knee bends. Kirigami-patterned adhesives may enable products such as everyday medical bandages, and wearable and soft electronics. Three main parameters give kirigami films their adhesive properties: shear-lag, in which shear deformation of film can reduce the strain on other parts of the film; partial debonding, in which the film segments around an open slit maintain a partial bond to the underlying surface; and inhomogenous deformation, in which Kirigami-patterned adhesives may enable products from everyday medical bandages, to wearable a film can maintain its overall adhesion, and soft electronics. (MIT) even as parts of its underlying surface may bend and stretch more than others. knee with the most pronounced bend- The cuts that open release tension that Future work involves changing the elas- ing, while the slits at the edges remained would otherwise cause the entire film to tomer film to gel material, which could closed, allowing the film to remain bond- peel away from the skin. directly diffuse medicine into the skin. ed to the skin. The kirigami cuts give the A kirigami-patterned adhesive bandage, For more information, contact Sara film not only stretch, but also better grip: as well as a heat pad consisting of a kiriga- Remus at [email protected]; 617-253-2709.

Water-Repellent Nanotextures Possess Anti-Fogging Capability Cone-shaped nanotextures could prevent fog condensation on surfaces in humid environments in the power generation and transportation industries. Brookhaven National Laboratory, Upton, New York

ome insect bodies have evolved the conical impacted materials’ ability to droplets to spontaneously jump off their Sability to repel water and oil, adhere repel water. Cone-shaped nanotextures surface — a phenomenon caused by the to different surfaces, and eliminate light proved much better at forcing water efficient conversion of surface energy to reflections. Scientists have been studying droplets to roll off, carrying dirt particles kinetic energy when two droplets com- the physical mechanisms underlying away and leaving surfaces completely dry. bine. The team investigated how reduc- these properties found in nature and Further work has demonstrated that ing texture size and changing texture mimicking them to design materials for the optimized nanotextures have excel- shape impacts the anti-fogging ability of use in everyday life. lent anti-fogging abilities, which could a model surface. Several years ago, Brookhaven National be applicable for condensing coils of To simulate fogging conditions, the Laboratory developed a nanoscale sur- steam turbine power generators, car and scientists heated water and measured face-texturing method for imparting com- aircraft windshields, and other materials the adhesion force as warm water plete water repellency to materials — a prone to fogging. droplets cooled upon contacting the property inspired by insect exoskeletons Fog forms when warm, moist air hits a nanotextured surfaces. These measure- that have tiny hairs designed to repel cooler surface (such as a window or wind- ments revealed that droplet adhesion water by trapping air. Their method lever- shield) and forms water droplets. When was significantly affected by the type of ages the ability of materials called block water droplets are similar in size to the surface nanotexture, with warm drops copolymers (chains of two distinct mole- structural features of a textured hydro - strongly sticking to those with large tex- cules linked together) to self-assemble phobic surface, they can get inside and tures, and hardly sticking to surfaces into ordered patterns with dimensions grow within the texture, instead of with the smallest ones. The droplets measuring only tens of nanometers in remaining on top. Once the texture fills remain on top, essentially floating on size. The scientists used these self-assem- up, water landing on the material gets the cushion of air trapped beneath. bled patterns to create nanoscale textures stuck, resulting in the appearance of fog. The scientists next used an optical in a variety of inorganic materials, includ- Scientists previously observed that the microscope connected to a high-resolu- ing silicon, glass, and some plastics. wings of cicadas, which are covered by tion video camera to view droplet conden- Initially, they studied how changing the nanosized cone-shaped textures, have sation on different textures during dew shape of the textures from cylindrical to the ability to repel fog by causing water formation, when atmospheric moisture

40 www.techbriefs.com Tech Briefs, August 2018 condenses faster than it evaporates. While all textures are initially are so lightly adhered to the surface that when two drops join covered by large numbers of microdroplets, over time, textures together, they gain enough energy to spontaneously jump off the with a cylindrical shape become covered in water, while the ones surface, similar to the mechanism observed in cicada wings. with a conical shape spontaneously dry themselves. Conical- For more information, contact Avijit Sen at [email protected]; shaped textures resist dew formation because the water droplets 631-344-3752.

Modified, 3D-Printable Alloy for Flexible Electronics and Soft Robots The physical structure of liquid metal is altered by incorporating a conductive nano- or micro-nickel filler. Oregon State University, Corvallis, Oregon

iquid metal printing is integral to the flexible electron- cation that uses sonication — the energy of sound — to mix the Lics field. Additive manufacturing enables fast fabrication of nickel particles and the oxidized gallium into the liquid metal, intricate designs and circuitry. The field features a range of prod- the alloys’ printability was restricted to two-dimensional. Struc- ucts including electrically conductive textiles; bendable displays; tures up to 10 millimeters high and 20 millimeters wide were sensors for torque, pressure, and other types of strain; wearable printed using this method. sensor suits, such as those used in the development of video The gallium alloy paste demonstrates several features new to the games; antennae; and biomedical sensors. Soft robots, flexible field of flexible electronics; namely, it can be made easily and computer screens, and other stretchable electronic devices also quickly. Also, the structural change is permanent, the electrical can be created. properties of the paste are comparable to pure liquid metal, and Additive manufacturing (3D printing) of tall, complicated the paste retains self-healing characteristics. structures can be accomplished with a highly conductive galli- For more information, contact Steve Lun deberg at steve.lundeberg@ um alloy. Nickel nanoparticles were added into the liquid metal oregonstate.edu; 541-737-4039. (galinstan) to thicken it into a paste with a consistency suitable for additive manufacturing. The runny alloy was impossible to layer into tall structures, but with a paste-like texture, it can be layered while maintaining its capacity to flow and to stretch ISOTROPIC inside rubber tubes. Gallium alloys are already being used as the conductive mate- Silver Conductive rial in flexible electronics. The alloys have low toxicity and good Silicone Adhesive conductivity, plus they are inexpensive and “self-healing” — able to attach back together at break points. Prior to this new modifi- MasterSil 973S-LO

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Tech Briefs, August 2018 Free Info at http://info.hotims.com/69509-722 41 Manufacturing & Prototyping

3D Printing of All-Liquid 3D Structures The reconfigurable material could be used to construct liquid electronics that power flexible, stretchable devices. Lawrence Berkeley National Laboratory, Berkeley, California

method was developed for printing A3D structures composed entirely of liquids. Using a modified 3D printer, Water flow threads of water were injected into silicone Nanoparticle oil, sculpting tubes made of one liquid Supersoap Layer within another liquid. Threads of water between 10 microns and 1 millimeter in diameter were printed, as well as a variety of spiraling and branching shapes up to several meters in length. What’s more, the material can conform to its surroundings and repeatedly change shape. The material owes its origins to two advances: learning how to create liquid tubes inside another liquid, and then Oil automating the process. First, a method was developed to sheathe tubes of water These schematics show the printing of water in oil using a nanoparticle supersoap. Gold nanoparti- in a special nanoparticle-derived surfac- cles in the water combine with polymer ligands in the oil to form an elastic film (nanoparticle super- tant that locks the water in place. The soap) at the interface, locking the structure in place. (Berkeley Lab) surfactant, called a supersoap, prevents the tubes from breaking up into like glass, which stabilizes the interface inject water in a predetermined pattern. droplets. The supersoap was achieved by between oil and water and locks the liquid Liquid can be squeezed from a needle, dispersing gold nanoparticles into water structures in position. This stability means and threads of water can be placed any- and polymer ligands into oil. The gold that the water can be stretched into a tube, where in three dimensions. The material nanoparticles and polymer ligands want and it remains a tube. The water also can also can be “pinged” with an external to attach to each other, but they also be shaped into an ellipsoid, and it remains force that momentarily breaks the super- want to remain in their respective water an ellipsoid. soap’s stability, and changes the shape of and oil mediums. An off-the-shelf 3D printer was modified the water threads. In practice, soon after the water is inject- by removing the components de signed to Watch a video demo of the method on ed into the oil, dozens of ligands in the oil print plastic, and replacing them with a Tech Briefs TV at www.techbriefs.com/tv/ attach to individual nanoparticles in the syringe pump and needle that extrudes liquid_structures. For more information, water, forming a nanoparticle supersoap. liquid. The printer was programmed to contact Dan Krotz at [email protected]; 510- These supersoaps jam together and vitrify, insert the needle into the oil substrate and 486-4019.

Diamond Pellet Grinding Tool Applications include optics, semiconductors, medical devices, and integrated photonic devices. Marshall Space Flight Center, Alabama

ASA Marshall Space Flight Center — either flat, curved, or aspheric — as makes use of a template fabricated via Nhas developed a numerically con- well as other precision surfaces such as 3D printing that encapsulates diamond trolled grinding tool that eliminates orthopedic joint replacements. pellets and fits over a CNC tool head. undesirable periodic variations in sur- Because the tool can be integrated The unique design solves the problems face contours in optical and other sur- with CNC machining, it eliminates the associated with similar, commercially faces — such as mid-spatial frequency tedious and imprecise hand polishing available designs where other types of errors — that result from polishing. It that has often been relied upon, while fixtures articulated, or gave way too can also be used to eliminate any unde- avoiding added errors due to over-pol- much, rendering those previous tools sirable irregularities in optical surfaces ishing. The NASA Marshall invention ineffective. By encapsulating the dia-

42 www.techbriefs.com Tech Briefs, August 2018 mond pellets in a 3D-printed template The tool was originally developed to precision finishing, whether curved, whose stiffness and articulation can be address recurring issues in fabricating flat, or aspheric. This could include controlled by air pressure and thickness, UV and X-ray optical surfaces, but can medical devices like artificial joints, as mid-spatial frequency errors are elimi- be used for visible-range optical sur- well as semiconductor wafers, sap- nated at their source. faces or for any surface that requires phire windows, and many others. By reducing the processing time in polishing complex surfaces by as much as half, the NASA invention can also reduce costs. Using the NASA tool, very low arc- second-resolution mirrors can be fabricated on a robotic polisher. The tool can be set up and used in less than one day, and can be rebuilt quickly, with few components requiring replacement. The tool can be used on glasses, metals, and other materials used for optics and precision surfaces. NASA is actively seeking licensees to commercialize this technology. Please contact Sammy Nabors at [email protected] to initiate licensing discussions. Follow this (Left) The grinding/polishing tool with rubber bladder (black) and template (white). (Right) The link for more information: https://technology. grinding/polishing tool with diamond pellets assembled into the template. nasa.gov/patent/MFS-TOPS-83.

Printing Flexible, Stretchable Silver Nanowire Circuits The size of the printing area is limited only by the size of the printer. North Carolina State University, Raleigh, North Carolina

ilver nanowires have drawn signifi- Scant interest in recent years for use in many applications ranging from prosthetic devices to wearable health sensors due to their flexibility, stretchability, and conductive properties. While proof-of-concept experiments have been promising, there have been significant challenges to printing highly integrated circuits using silver nano - wires. Silver nanoparticles can be used to print circuits, but the nanoparticles produce circuits that are more brittle and less conductive than silver nano - wires. Conventional techniques for printing circuits don’t work well with 5 mm silver nanowires; the nanowires often clog the printing nozzles. Two printed silver nanowire patterns, horseshoe and Peano curve, with high resolution. A new technique was developed that allows circuits to be printed on flexible, ging while retaining very fine printing The size of the printing area is limited stretchable substrates using silver nano- resolution. only by the size of the printer, meaning wires. The advance makes it possible to The “ink” consists of a solvent con- the technique could be easily scaled up. integrate the material into a wide array taining silver nanowires that are typical- The new technique was used to create of electronic devices. ly more than 20 micrometers long. The prototypes that make use of the silver The approach uses electrohydrody- resulting circuits have the desired con- nanowire circuits, including a glove with namic printing, which relies on elec- ductivity, flexibility, and stretchability. an internal heater and a wearable electrostatic force to eject the ink from the In addition, the solvent is both nontox- trode for use in electrocardiography. nozzle and draw it to the appropriate ic and water-soluble; once the circuit is For more information, contact Matt site on the substrate. This allows use of printed, the solvent can simply be Shipman at [email protected]; 919- a very wide nozzle, which prevents clog- washed off. 515-6386.

Tech Briefs, August 2018 www.techbriefs.com 43 Manufacturing & Prototyping

Method 3D-Prints Marine-Grade Stainless Steel This stainless steel is used for welding, medical implants, engine parts, and oil pipelines. Lawrence Livermore National Laboratory, Livermore, California

arine-grade stainless steel is valued Mfor its performance under corrosive environments, and for its high ductility — the ability to bend without breaking under stress. But conventional techniques for strengthening this class of stainless steels typically come at the expense of ductility. A method of 3D printing one of the most common forms of marine grade stainless steel — a low- carbon type called 316L — promises an unparalleled combination of high- strength and high-ductility properties for the ubiquitous alloy. Components were 3D-printed with 316L stainless steel, and the material’s performance was better than those made with the traditional approach. The methodolo- gy could lead to widespread 3D printing of such stainless steel components, particularly in the aerospace, automotive, and oil and gas industries, where strong and tough materials are needed to tolerate extreme force in harsh environments. To successfully meet and exceed the necessary performance requirements for 316L stainless steel, researchers first had to overcome a major bottleneck limiting the potential for 3D printing high-quality metals: the porosity caused during the laser melting (or fusion) of metal pow- ders that can cause parts to degrade and fracture easily. Researchers addressed this through a density optimization process involving experiments and computer modeling, and by manipulating the materials’ underlying micro structure. Using two different laser powder bed fusion machines, researchers printed thin plates of stainless steel 316L for mechanical testing. The laser melting technique inherently resulted in hierarchical cell- like structures that could be tuned to alter the mechanical properties. When 316L is additively manufactured, it creates a grain structure that resembles a stained-glass The ability to 3D-print marine-grade, low-carbon stainless steel (316L) could have implications for window. The grains are not very small, but industries such as aerospace, automotive, and oil and gas. the cellular structures and other defects inside the grains that are commonly seen blocking some others to provide the microstructure, and discover how to in welding control the properties. strength. The stainless steel is a “surro- make high-performance steels in cluding Deformation of metals is mainly con- gate material” system that could be used corrosion resistance. Researchers will trolled by how nanoscale defects move for other types of metals. then look at employing a similar strategy and interact in the microstructure. This The eventual goal is to use high-perfor- with other lighter-weight alloys that are cellular structure acts as a filter, allowing mance computing to validate and predict more brittle and prone to cracking. some defects to move freely, and thus future performance of stainless steel For more information, contact Jeremy providing the necessary ductility while using models to control the underlying Thomas at [email protected]; 925-422-5539.

44 www.techbriefs.com Tech Briefs, August 2018 Health & Biotech

Non-Invasive Diabetes Monitoring Patch This adhesive patch measures glucose levels through the skin without a finger-prick blood test. University of Bath, Bath, United Kingdom

n effective, non-invasive way of Amon itoring blood glucose could help both diabetics and those at risk of developing diabetes make the right choices to either manage the disease well, or reduce their risk of developing the condition. To address this need, an adhesive patch was developed that measures glucose levels through the skin without a finger-prick blood test, potentially removing the need for millions of diabetics to frequently carry out the painful and unpopular tests. The patch does not pierce the skin. Instead, it draws glucose out from fluid between cells across hair follicles that are individually accessed via an array of miniature sensors using a small electric current. The glucose collects in tiny reservoirs and is measured. Readings can be taken every The device can measure glucose levels without piercing the skin. 10 to 15 minutes over several hours. Crucially, because of the design of the vidual hair follicle. This significantly mentally friendly. In addition, the design array of sensors and reservoirs, the patch reduces inter- and intra-skin variability in can be implemented using high-through- does not require calibration with a blood glucose extraction, and increases the put fabrication techniques like screen sample, meaning that finger-prick blood accuracy of the measurements taken printing, which could support a dispos- tests are unnecessary. such that calibration via a blood sample able, widely affordable device. The patch could eventually become a is not required. The next steps include further refine- low-cost, wearable sensor that sends reg- The architecture of the array permits ment of the design of the patch to opti- ular, clinically relevant glucose measure- calibration-free operation, and has the fur- mize the number of sensors in the array, ments to the wearer’s phone or smart- ther benefit of allowing realization with a to demonstrate full functionality over a watch wirelessly, alerting them when they variety of materials in combination. 24-hour wear period, and to undertake a may need to take action. An important Graphene was used as one of the compo- number of key clinical trials. advantage of this device over others is nents, as it brings important advantages; For more information, contact Chris that each miniature sensor of the array specifically, it is strong, conductive, flexi- Melvin at [email protected]; +44(0) can operate on a small area over an indi- ble, and potentially low-cost and environ- 1225 383941.

Ingestible Sensors Powered by Stomach Acid These ingestible electronic devices could monitor physiological conditions or deliver drugs. Massachusetts Institute of Technology, Cambridge, Massachusetts

small voltaic cell was developed could lead to a new generation of elec- cell known as a lemon battery that con- Athat is sustained by the acidic fluids tronic ingestible pills that could some- sists of two electrodes — often a galva- in the stomach. The system can generate day enable novel ways of monitoring nized nail and a copper penny — stuck enough power to run small sensors or patient health and/or treating disease. in a lemon. The citric acid in the lemon drug delivery devices that can reside in These devices are usually powered by carries a small electric current between the gastrointestinal tract for extended small batteries, but conventional batter- the two electrodes. periods of time. This type of power ies self-discharge over time and pose a To replicate that strategy, researchers could offer a safer and lower-cost alter- possible safety risk. To overcome those attached zinc and copper electrodes to native to the traditional batteries now disadvantages, researchers took inspira- the surface of the ingestible sensor. The used to power such devices. This work tion from a very simple type of voltaic zinc emits ions into the acid in the stom-

Tech Briefs, August 2018 www.techbriefs.com 45 Health & Biotech

building a customized integrated circuit that would carry the energy harvester, transmitter, and a small microprocessor. A challenge in implantable medical devices involves managing energy generation, conversion, storage, and utilization. This work will enable re searchers to envision new medical devices where the body itself contributes to energy generation, en - abling a fully self-sustaining system. Once the researchers miniaturize the device, other types of sensors can be added, and it could be developed for applications such as long-term monitoring of vital signs. For example, a self- powered pill could monitor vital signs from inside the body for a couple of A small, ingestible voltaic cell is sustained by the acidic fluids in the stomach. (Photo: Diemut Strebe) weeks, making measurements and transmitting them to a mobile phone. Such ach to power the voltaic circuit, generat- device moved into the small intestine, devices could also be used for drug deliv- ing enough energy to power a commer- which is less acidic than the stomach, the ery. The power generated by the voltaic cial temperature sensor and a 900-mega- cell generated only about 1/100 of what cell could release drugs encapsulated by hertz transmitter. While in the stomach, it produced in the stomach. a gold film. This could be useful for situ- the voltaic cell produced enough energy The current prototype of the device is a ations in which doctors need to try dif- to power a temperature sensor, and to cylinder about 40 millimeters long and 12 ferent dosages of a drug, such as medica- wirelessly transmit the data to a base sta- millimeters in diameter, but the re- tion for controlling blood pressure. tion located two meters away, with a sig- searchers anticipate that they could make For more information, contact Sarah nal sent every 12 seconds. Once the the capsule about one-third that size by McDonnell at [email protected]; 617-253-8923.

Self-Powered Paper Patch Measures Glucose This one-time-use paper-based device allows diabetics to measure glucose levels during exercise. Binghamton University, Binghamton, New York

he most common methods for glu- Tcose self-testing involve monitoring glucose levels in blood. These conventional measurements are not suitable for preventing hypoglycemia during exercise. The underlying process relies on invasive and inconvenient blood sampling, which can cause skin irritation with perspiration containing electrolytes and proteins. In addition, blood testing requires that diabetics keep testing equipment such as lancets, alcohol, and a glucometer with them during exercise. A new paper-based sensor patch allows diabetics to effectively measure glucose levels during exercise. The wearable and disposable patch allows for non-invasive The paper-based sensor patch attaches directly to the skin. monitoring of glucose in human sweat. The single-use biosensor integrates a ver- external power and sophisticated read- ates shortcomings of conventional non- tically stacked, paper-based, glucose/ out instruments. invasive sweat sensors that can be ham- oxygen enzymatic fuel cell into a stan- Sweat-based glucose sensing is attrac- pered by not being able to collect enough dard BAND-AID® adhesive patch. tive for managing exercise-induced hypo- sweat for analysis, sample evaporation, The device attaches directly to the skin glycemia because the measurement is and the relatively long time required for and wicks sweat to a reservoir where performed during or immediately after sample collection. chemical energy is converted to electri- exercise when there is enough sweat to For more information, contact Ryan Yarosh cal energy. It monitors glucose without obtain an adequate sample. This allevi- at [email protected]; 607-777-2174.

46 www.techbriefs.com Tech Briefs, August 2018 Portable Brain Imaging System This technology can be used in concussion treatment, and to monitor injury and recovery times. University of Calgary, Alberta, Canada

urrently, concussion is measured by Cthe symptoms someone experi- ences, but it is difficult to know what is happening in the brain in any one person. To address this problem, a portable brain imaging system was developed that uses light to detect and monitor damage in the brain from concussion. The device, a Near-Infrared Spectroscope, measures communication in the brain by measuring oxygen levels. When the brain is working well, major regions on each side of the brain are communicating and have similar patterns of blood flow and oxygen levels in blood. Researchers measure the changes in blood oxygen levels as a marker of brain function. Results show that these patterns change after concussion. There can be physiological changes The brain imaging cap contains LED lights that illuminate the skull and allow researchers to monitor in the brain that last for months to years and measure brain activity. after a brain injury due to concussion. The new technology can be used to see person. The images obtained using the top of the head. The cap contains small how important these changes are, and new system could show a connection be - lights that have sensors connected to a how concussion evolves over time. tween symptoms and abnormalities in computer. When researchers turn on Symptoms can vary greatly between the brain that could help doctors identi- the lights, they can monitor and meas- individuals, and can include headaches, fy treatment protocols and recovery ure brain activity. The device is non- nausea, loss of memory, and lack of timelines. invasive and portable. coordination, making it even more diffi- To image the brain, a cap, similar to a For more information, contact Kelly Johnston cult to find treatment options for each swim or bathing cap, is placed on the at [email protected]; 403-220-5012.

Mobile Phone Detection of Atrial Fibrillation This app enables detection of atrial fibrillation — an indication of stroke — without any additional equipment. University of Turku, Finland

ecause atrial fibrillation (AF) often becoming ubiquitous, providing signifi- which patients had atrial fibrillation with Bdoes not present symptoms, stroke is cant possibilities for screening applica- 96 percent accuracy. The group includ- too often its first manifestation. For tions. In mechanocardiography, mechan - ed different kinds of patients, some of effective stroke prevention, timely diag- ical cardiac activity is recorded with whom had heart failure, coronary dis- nosis of AF is crucial. Mobile devices are accelerometers and gyroscopes, which ease, and ventricular extrasystole at the are standard components of modern same time. smartphones. This technology indicates how ordi- A smartphone application was devel- nary consumer electronics can be bene- oped that reliably detects atrial fibrilla- ficial for a patient’s medical care. Having tion from the micro-movements in the the ability to detect — with an ordinary chest using small accelerometers. In a smartphone — whether someone has study of the technology, a three-minute atrial fibrillation could direct patients to mechanocardiography recording was the doctor and further testing without acquired from each subject using a Sony any delay. The smartphone app uses small accelerometers to reliably detect atrial fibrillation from the Xperia smartphone placed on the ster- For more information, contact Anne Paasi micro-movements in the chest. num. The mobile application detected at [email protected]; +358 29 450 2587.

Tech Briefs, August 2018 www.techbriefs.com 47 Software

Information Sharing Protocol VCR (ISPVCR) Lyndon B. Johnson Space Center, Houston, Texas

he Information Sharing Protocol playback of the SITF data file. The cap ability provided only a command T(ISP) VCR (ISPVCR) is a software Orion Program chose to use the ISP to line interface and was limited to 20,000 program written in Tcl/Tk that provides distribute data within the mission con- symbols, while this software has no the capability to record and play back trol center and other facilities. The restrictions on number of symbols ISP data (telemetry, computations, ISPVCR package provides the capability recorded. ground system status, etc.) via Source to leverage legacy ISP software to pro- This work was done by Brian O’Hagan of Independent Telemetry Format (SITF) vide record and playback of vehicle Johnson Space Center. NASA has decided not files. The ISPVCR provides a graphical telemetry data via the ISP. to apply for a patent on this technology. For user interface (GUI) that allows start/stop The software provides a GUI on top further information, please contact JSC at of the recording capability, specifying of existing ISP applications for the play- 281-483-3809 or e-mail jsc-techtran@mail. output file names, and start/stop of the back of recorded data. The previous nasa.gov. Refer to MSC-25608-1

Modification of SURFICE Code Marshall Space Flight Center, Alabama

s part of the continued thermal sup- during the space shuttle program as a or thermal protection system (TPS), and Aport for the Space Launch System tool for engineers to analytically predict how the software analyzes weather (several (SLS) program, MSFC is constantly devel- potential ice and frost growth during weeks/months/years or 10-hour pre- oping or modifying software tools to aid shuttle launches. The existing SURFICE launch timeline). The code has been mod- in analytical efforts to solve thermal issues code does not allow for changes to mate- ified to handle the SLS geometries, and is and problems posed by the project. In rials or analytical runtime, or for use on Windows 7/8 and Mac OS compatible. some cases, existing software used by pre- geometries different from the STS exter- This work was done by Mark Wall of vious heritage programs provides an nal tank (ET). Jacobs Technology for Marshall Space Flight excellent template for the engineer to The proposed software takes the engi- Center. For more information, contact develop a tool perfectly suited for the cur- neering algorithms of SURFICE and adds Ronald C. Darty, Licensing Executive in rent task without starting from scratch. a graphical user interface for easy changes the MSFC Technology Transfer Office, at SURFICE, a Windows-based program to be made. These include inputs to the [email protected]. Refer to MFS- developed by Lockheed Martin, was used ambient weather, thickness of insulation 33296-1

Comprehensive Software Simulation on Ground Special Power at Kennedy Space Center A complete virtual environment can be created to emulate controllers and power supply hardware. John F. Kennedy Space Center, Florida

s the number of channels, or op- trol applications during code reviews, cus- ware components or adding more chan- Aerative sites, increases in present and tomer demonstrations, unit testing, and nels to the system in a lab environment future ground special power (GSP) devel- possibly for future personnel training. can be difficult and costly. In a virtual opment efforts, the amount of hardware The critical problem that motivated environment, the control system can be required to test development codes this innovation was the fact that the replicated to accommodate for the addi- becomes substantially expensive. By simu- available simulator can only be used to tional hardware with less difficulty. lating/emulating the hardware, code build an application that simulates and A multi-threaded software application development in a control system can be emulates I/O signals in the I/O mod- has been developed using Java program- tested and verified using software simula- ules, but not data transfers or message ming language in Windows 7 Operating tion. Having simulation and emulation of instructions to the power supplies. To System (OS). The application concur- the complete system is also crucial for support future development of the GSP rently simulates and emulates a set of facilitating the development of the con- system, performing upgrades to hard- four DC-power supply units and one bat-

48 www.techbriefs.com Tech Briefs, August 2018 tery backup unit that provide regulated late and emulate each one of the five DC- Outputs (I/O) in the I/O module cards. DC power to launch support control sys- power units in concurrent communica- MiMIC simulator runs simultaneously tems at multiple operative sites called tion with the redundant systems A and B. with Java-based DC-power simulation channels. The software application emu- One software application launches four instances to not only emulate the com- lates not only the concurrent operation independent instances to simulate and plete hardware system, but also provide and functionality of each DC-power unit, emulate four power units. The second power balancing of simulated A/C loads but also establishes concurrent client- software application launches a single between multiple power buses. server communication via open-socket instance to simulate and emulate battery This work was done by Jesus Dominguez, protocol just as the actual DC-power units backup unit or Battery Man agement Angel Vazquez, Alfredo Urbina, and Elias do with the redundant control system. System (BMS). MiMiC, a commercially Victor of John F. Kennedy Space Center. For Two different Java multi-threaded soft- available Windows-based simulation en - additional information on this software, ware applications were designed, devel- abler tool, was used to simulate and emu- please contact KSC-DL-TechnologyTransfer@ oped, and deployed to individually simulate digital and analog Inputs and mail.nasa.gov. KSC-14016

Location Awareness Algorithm for Internet of Things Devices Devices connected on 5G networks can help locate themselves, rather than relying on centralized “anchors.” Tufts University, Medford, Massachusetts

ositioning of wireless devices is cen- The devices locate themselves with- sacrificing accuracy. This was accom- Ptralized, depending on “anchors” with out all of them needing direct access to plished by substituting the non-linear known locations such as cell towers or GPS anchors. Sensing and calculations are position calculations — which are com- satellites to communicate directly with done locally on the device, so there is putationally demanding and can miss each device. As the number of devices no need for a central coordinator to their mark if the initial guess at position increases, anchors must be installed at collect and process the data. The self- is in the wrong place — with a linear higher density. Centralized positioning localization algorithm makes use of model that quickly and reliably con- can become unwieldy as the number of device-to-device communication, and verges on the accurate position of the items to track grows significantly. can take place indoors (e.g., in offices device. The move to a computationally Anticipating a critical strain on the and manufacturing facilities), under- simpler linear calculation emerges as a ability of fifth generation (5G) networks ground, under water, or under thick result of the devices measuring their to keep track of a rapidly growing num- cloud cover. This is an advantage over location relative to each other or a ber of mobile devices, an improved algo- GPS systems, which not only can go point representing the “center of mass” rithm enables the localizing and tracking dark under those conditions, but also of neighboring devices, rather than of these products by distributing the task add to the cost and power requirements having all of them reference a set of sta- among the devices themselves. The scala- of the device. tionary anchors. Convergence to accu- ble solution could meet the demands of The mobility of the devices makes rate positions is extremely fast, making a projected 50 billion connected prod- self-localization challenging. The key is real-time tracking of a large number of ucts in the Internet-of-Things by 2020, to obtain positions rapidly to track devices feasible. and would enable a widening range of them in real time, which means the cal- For more information, contact Mike location-based services. culations must be simplified without Silver at [email protected]; 617-627-0545.

Simulation Technique Models Material-Aging Process Henry Samueli School of Engineering, University of California, Irvine

he nation’s aging infrastructure re - not only better understand how materi- ture is subjected to cyclic stress fluctua- Tquires massive investment. Imagine if als weaken with age, but also develop tions, and then the material’s response engineers could build structures with materials that maintain their strength to such perturbations is followed. materials that do not degrade over time. indefinitely. This new technique will be applied to A simulation technique was developed Aging originates at the atomic and explore the relationship between the that could help engineers do just that. molecular levels. Because of this minis- composition and texture of structural The numerical method simulates the cule scale, it is nearly impossible to track materials and their time-dependent molecular aging process in amorphous microscopic changes over long periods. behavior. materials such as concrete and glass. In the incremental stress-marching tech- For more information, contact Lori This technique could help researchers nique, the material’s molecular struc- Brandt at [email protected]; 949-824-8306.

Tech Briefs, August 2018 www.techbriefs.com 49 APPLICATION BRIEFS

Reducing Weight and Design Time for Dream Chaser Spacecraft Collier Research Corporation Newport News, VA www.hypersizer.com

ith the go-ahead from NASA for a first mission to the WInternational Space Station (ISS), the Sierra Nevada Corporation’s (SNC) Dream Chaser® spacecraft team is now reviewing flight performance data and refining the vehicle’s design adaptations to meet mission requirements and changing payloads using Collier Research’s HyperSizer software. and non-pressurized items, and withstand significant deflection HyperSizer provides insights into the strength, weight, and forces. To meet these challenges, HyperSizer was used on nearly manufacturability of designs for both composite and metal all primary composite structures for the launch-approved CRS-2. structures. Typically able to reduce the weight of existing “HyperSizer’s suite of industry-standard failure criteria was designs by 20% to 40%, the software plays an important role in extremely valuable for our team, enabling us to quickly size the margin-of-safety certification for aerospace projects, and is also Dream Chaser structure and perform architectural trade studies,” valuable for wind, marine, and other fields that demand per- said Andy Kim, Senior Structural Engineer for SNC. “The soft- formance with durability. ware’s rapid analysis capability gave us more time to interrogate The current model of the autonomous, reusable Dream our results and gain insights into the sensitivity of the structural Chaser — Commercial Resupply Service 2 (CRS-2) — will weight to various design features and stiffener cross sections.” transport pressurized and unpressurized cargo to and from the “HyperSizer helped us improve and automate the design- ISS, with a launch window of late 2020. The vehicle also has the analysis process for the CRS-2,” added Eric Schleicher, SNC potential for satellite servicing, orbital debris removal, and Principal Structural Engineer. “We found some of the most exploration technology testing. In every case, the demands of useful aspects of the software to be load processing, sizing, mar- low-orbit flight, Earth re-entry, runway landing, and vehicle re- gin reporting, and the finite-element model update feature.” use require precision design optimization for reliability, dura- SNC incorporated HyperSizer into their design and analysis bility, and safety. Each type of mission requires additional process in order to meet the weight and schedule targets. The analysis due to new flight trajectories and corresponding software’s scripting API customized the workflow and automat- changes to the vehicle loads. ed data exchange with their suite of CAE software tools. This The unique challenges faced by the structural engineers at SNC enabled the team to move rapidly from whole-scale optimiza- were to design the Dream Chaser to accommodate changing tion to detailed analysis and stress reporting. cargo weights and different re-entry trajectories, carry pressurized For Free Info Visit http://info.hotims.com/69509-115

System Tests Dream Chaser’s Contracted by SNC to design and build the atmospheric Atmospheric Flight Control System flight control system, SwRI selected SAKOR to build a sophisticated system to exercise Dream Chaser’s new control system SAKOR Technologies and simulate flight, from atmospheric interface to landing. Owosso, MI The system characterizes overall design performance as well as www.sakor.com dynamic response to physical forces typically experienced in standard and extreme flight conditions. AKOR Technolo - Dream Chaser features seven control surfaces, and the Sgies supplied a test SAKOR-designed test system features seven dynamometers, system to South west Re - each simulating dynamic loads on a specific control surface. search Insti tute® (SwRI) SAKOR’s DynoLAB™ data acquisition and control system con- to be used to test the atmospheric flight control system for trols the entire test stand, acting as a spacecraft emulator. the Dream Chaser spacecraft. Dream Chaser is a lifting- Sending test profiles to the atmospheric flight controller as body, reusable, crewed or uncrewed, horizontal-landing well as simulating force feedback from each control surface, vehicle owned and operated by Sierra Nevada Corporation DynoLAB communicates directly with the atmospheric flight (SNC), and is designed as a space utility vehicle for low- control system via MIL-STD-1553B bus, which is a built-in capa- Earth orbit. SwRI is one of the oldest independent applied bility of the DynoLAB system. R&D organizations in the U.S. For Free Info Visit http://info.hotims.com/69509-116

50 www.techbriefs.com Tech Briefs, August 2018 Upcoming... Webinars Spacecraft Thermal Management: Board, Box and System Level Solutions Wednesday, August 15, 2018 at 2:00 pm U.S. EDT Whether it’s a small CubeSat or large GEO satellite, Aerospace Engineers are always trying to package more capability in a smaller and more mass-efficient design. These objectives lead to increased thermal densities and put more importance on reducing temperature rise through the entire thermal resistance network. This Webinar will cover enhanced heat transfer options such as heat pipes with various space-flown working fluids, thermal storage with phase change material (PCM) modules, and system level design considerations. Speakers: Bryan Muzyka Ryan Spangler This 30-minute Webinar includes: Sales Manager, Sales Manager, • Live Q&A session Advanced Cooling Advanced Cooling • Application Demo Technologies, Inc. Technologies, Inc. • Access to archived event on demand

Please visit www.techbriefs.com/webinar553

Simulating the Real World – Using Programmable Resistors for Sensor Simulation in Test Wednesday, August 22, 2018 at 2:00 pm U.S. EDT Virtually all electronic control units (ECUs) used in transportation employ various types of sensors to assess the environment they are working in. This Webinar will review the types of programmable resistor modules that are commercially available. The presentation will also review the basic construction, how to select the correct modules, and look at applications where sensor simulation is an integral part of the adopted test strategies. Speaker: Paul Bovingdon This 60-minute Webinar includes: Simulation Product Manager, • Live Q&A session Pickering Interfaces • Application Demo • Access to archived event on demand

Please visit www.techbriefs.com/webinar555

Understanding Machine Vision for Industrial Inspection Thursday, August 23, 2018 at Noon U.S. EDT Machine vision is a vital tool for optimizing and monitoring industrial processes. This 60-minute Technical Webinar from the editors of Tech Briefs Media looks at machine vision systems and how to choose the appropriate components for a particular application. It also examines what to expect the system to do — or not do — and how the proper choice of cameras and optics can ensure the highest level of performance. Speaker: Steven King This 60-minute Webinar includes: Product Manager, • Live Q&A session Machine Vision, • Application Demo Omron Microscan • Access to archived event on demand

Please visit www.techbriefs.com/webinar556 New on the MARKET

Product of the Month Pepperl+Fuchs, Twinsburg, OH, introduced the R200 and R201 photoelectric sensors in a design that is suitable for specific mounting situations. Standardized IO-Link connection via smart sensor profiles enables integration of the sensors. The sensors include DuraBeam laser technology and Multi Pixel Technology (MPT) for distance measurement. Standardized usability facilitates parameterization of the sensors during commissioning and when there is a change to the functional principle or to another series. The series offers thru-beam sensors, retroreflective sensors with a polarization filter or for clear object recognition, energetic diffuse mode sensors, sensors with background suppression and foreground suppression, measuring light barriers with two switch points, and distance sensors. Sensor adjustment is enabled by a multiturn potentiometer and a pushbutton that function as a combined operating element with three LEDs for visualizing the configuration, status, and diagnostics. For Free Info Visit http://info.hotims.com/69509-120

IMTS Product Preview — See these and other products on display at IMTS, Sept. 10-15, Chicago, IL

Cable Carrier Vision System igus, East Providence, RI, offers the E4.1L L.S. Starrett, Athol, MA, offers the general-purpose energy chain (e-chain) HVR100 “FLIP” digital video system that cable carrier with high dynamics that works upright vertically, or on its side hori- includes a honeycomb strain relief block. zontally. The system provides rapid measure- It also includes separators for quick instal- ment results, and features a large field of lation and for multi-level cable outlets. view, automatic part recognition, and easy- The e-chain features snap-open crossbars on both sides, optimized to-use measuring tools. The AVR300 Automatic Vision System for interior-exterior dimension ratio due to narrower outer links and repetitive measurements and automatic comparison to CAD files fea- optimized crossbar shape, an inner diameter completely accessible tures both zoom optics and interchangeable telecentric lenses for for easy filling, and a side plate with a tongue-and-groove system. micron-level resolution and accurate field-of-view measurements. (Booth 134521) (Booth 135532) For Free Info Visit http://info.hotims.com/69509-100 For Free Info Visit http://info.hotims.com/69509-103

CAM Programming Power Supplies 3D Systems, Rock Hill, SC, announced Phoenix Contact, Middletown, PA, GibbsCAM® 13 CAM programming software offers QUINT POWER compact AC/DC for programming CNC machining centers. power supplies ranging from 30 to 100 W New functionality includes broaching and a for low-power applications. They feature new G-code editor. In this release, users can power boost of up to 200 percent the nominal current, allowing program parts that require elliptical and eccentric turning such as inductive loads to start without disrupting the output voltage. The camshafts. Improvements to turning include advanced control over power boost provides additional power to an application, eliminating non-cutting-tool movement, automatic chip breaking, and bar cham- the need to install an oversized power supply. (Booth 134238) fering. (Booth 133310) For Free Info Visit http://info.hotims.com/69509-104 For Free Info Visit http://info.hotims.com/69509-101 Swiss-Style Lathe Mechanical Sensors The Citizen D25 Swiss-style lathe from The MP600 Series mechanical sensors Marubeni Citizen-Cincom, Allendale, NJ, is from Wilbrecht LEDCO, a Microprecision equipped with double gang tool posts and B company, St. Paul, MN, is designed to axis, enabling short cycle times. The large num- detect two positions within one product. ber of tools, for both the main and sub-spindle, The distance between the two positions provides production of complex workpieces. The lathe features inde- can be customized between 0.3 and 1.5 mm. Repeatability is greater pendent, adjustable-angle rotary tools to sub-spindle; B axis for front- than 5 μm and depending on cable selection, the operational tem- back machining; up to 59 tools; switchable operation for use with or perature ranges from -40 to 130 °C. The cable termination can be without guide bushing; next-generation CNC system with touchscreen; supplied with a M12 connector. The switching mechanism is and a variety of interface choices (USB memory, SD card, RS232, designed for low-voltage applications up to 30 VDC. (Booth 134038) Ethernet). (Booth 339419) For Free Info Visit http://info.hotims.com/69509-102 For Free Info Visit http://info.hotims.com/69509-105

52 www.techbriefs.com Tech Briefs, August 2018 IMTS Product Preview

Ultrasonic Cleaning Units Strain Gauge Probe The 1900BT and 1900BTX ultrasonic Renishaw, West Dundee, IL, intro- cleaning units from Omegasonics, Simi duced the RMP400 machine tool probe Valley, CA, generate cavitation energy designed for small 5-axis machine tools. inside the bath, creating internal pressure The strain gauge probe provides a that dissolves the support structure of 3D- touch-trigger solution for part setting, printed parts. The 1900BT is specifically feature measurement, and machine designed for cleaning 3D prototype parts, performance checking. The probe combines silicon strain gauge and serves as a hybrid between traditional technology with ultra-compact electronics. Suitable for installations benchtop cleaners and portable floor models. The 1900BTX fea- where there is no line-of-sight between the spindle probe and the tures two cleaning technologies — a water agitation cleaning process communication interface, the probe uses radio transmission with and ultrasonic cavitation. Each operates independently to facilitate a frequency hopping spread spectrum technology (FHSS) that enables more thorough cleaning process. (Booth 121150) devices to avoid interference and transmission dead spots, and allows For Free Info Visit http://info.hotims.com/69509-106 the probe to operate reliably in high-density radio frequency environments. (Booth 135509) Robot Vision System For Free Info Visit http://info.hotims.com/69509-110 ABB, Auburn Hills, MI, offers the FlexLoader robot guiding vision system for machine tool CAM Software tending applications. The system features high Milltronics USA, Waconia, MN, re - speed, short teach-in times, and software that leased ChipBoss™ CAM software that identifies the workpiece location and orientation uses proprietary algorithms to calculate from the picking area, and guides the robot in the toolpaths and control maximum allow- robot cell. It can handle an unlimited number of workable cutter engagement, allowing use of pieces in various sizes and with complex geometries without the the entire length of a tool rather than just need for mechanical fixtures. Control and communications with the the tip. The software automatically controls the tool’s chip load, robot are integrated into the software. The system is open to commu- keeping it constant, and allows the load, heat, and wear to be spread nicate with a variety of camera sensors and can be used for both 2D out evenly over a larger area of the tool. It also reduces the number and semi-oriented 3D applications. (Booth 236520) of times a machine needs to accelerate and decelerate. (Booth For Free Info Visit http://info.hotims.com/69509-107 338329) For Free Info Visit http://info.hotims.com/69509-117 Robot Machine Tools Suhner Industrial Products, Linear Actuators Rome, GA, offers robot solutions Rollon Corp., Hackettstown, NJ, offers SMART SYS- for fully automated manufacturing. TEM linear actuators with a self-sustaining The quick-change tool system anodized aluminum frame and steel offers a number of machine tools reinforced driving belt. The E-SMART that can be mounted directly on series features an extruded and the robot arm. The power-pack anodized aluminum self-sustaining tools are compatible with all robot manufacturers and feature pro- structure with a profile available in four grammable touch forces of the active flange and interactive surface sizes from 30 to 100 mm. The R-SMART series is suitable for heavy tracking. Other features include programmable process forces, bal- loads, possible cantilever or gantry mounting, and operation in indus- anced tolerances (shapes), and reduced programming for complex trial automated lines. The S-SMART series linear units meet the verti- parts. Tools are available for brushing, polishing, filing, belt sanding, cal motion requirements in gantry applications, or for applications or tool spindles, and are easily integrated. (Booth 431474) where the aluminum profile must be moving and the carriage must For Free Info Visit http://info.hotims.com/69509-108 be fixed. (Booth 134841) For Free Info Visit http://info.hotims.com/69509-118 CNC Software SPRING Technologies, Boston, Touch Probe MA, announced 2018 NCSIMUL HEIDENHAIN, Schaumburg, IL, offers CNC machine software. Enhanced the TS 460 touch probe for workpiece meas- modules are NCSIMUL MACHINE, urement that provides both radio and 4CAM for CNC part transfer, OPTI- infrared optical trigger signal transmissions. TOOL for operation cycle reduction, Designed for workpiece measurement and compen- AUTOMATION for automatic verification, DNC for program transfer, sation for workpiece misalignment, it offers an optional MONITOR for machine status monitoring, PUBLISHER for technical collision adapter that also provides thermal isolation. Radio trans- sheets, and PLAYER for immersive, collaborative, and mobile 3D. The mission offers 16 channels and has a transmission times of 10 ms. new release improves forecasts, reduces operating cycles, and auto- The optical sensor is free of wear and provides the specified probing mates production. A numerical chain links automatically from the reproducibility even after a large number of probing processes. engineering department to the shop floor. (Booth 133267) (Booth 135226) For Free Info Visit http://info.hotims.com/69509-109 For Free Info Visit http://info.hotims.com/69509-119

Tech Briefs, August 2018 www.techbriefs.com 53 New on the Market

DC Current Transducers Signal Routing Software NK Technologies, San Jose, CA, introduced Pickering Interfaces, Grants Pass, OR, DT-FD Series DC current transducers that pro- introduced Switch Path Manager™ version vide a large sensing window and the ability to 6 signal routing software that simplifies sig- safely monitor circuits with voltages up to 1500 nal routing through complex switching sys- VDC, and up to 400 amps. The sensor can be tems and speeds development of switching mounted on a DIN rail or attached to a back system software. An enhanced System panel with screws. The accessible power supply, Configurator Editor gives the user the abili- output-signal, and finger-safe terminals are located on the top of the ty to apply standard functionality like copy, paste, delete, find, replace, sensor to allow for easy installation. A one-piece design combines the and cell manipulation. An API function has been added that lets users current sensing elements and the signal conditioning to provide an out- find out whether given endpoints have been connected by the soft- put compatible with most control systems. ware. This functionality is used when a route uses multiple relays, and For Free Info Visit http://info.hotims.com/69509-113 on that route, there are more endpoints connected to each other. For Free Info Visit http://info.hotims.com/69509-111 Optical Design Software Version 18.4 of OpticStudio optical Control Components design software is available from RAFI USA, Lynnwood, WA, Zemax, Kirkland, WA. It can be used offers the RAFIX22 FS+ low- to solve sequential and non-sequential profile, modular control com- optical design challenges before phys- ponent family that lets design- ical prototypes are built. Enhance - ers individually adapt control compo- ments include full-field aberration analysis for freeform surface design nents to customize a control panel. The 9.2-mm behind-the-panel depth and visualization of how aberrations change across the full field of view. for the activation elements enables very thin product casing solutions. A non-sequential converter automatically converts sequential systems The series includes ring illumination options in a range of colors, as well with off-axis mirrors or custom lenses to the equivalent non-sequential as a tactile version that offers haptic responses. The actuator series covers system. A compound lens object simulates complex lenses for stray light illuminated and non-illuminated pushbuttons, rotary selector, keylock, analysis or optomechanical design. A Boolean native object runs ray and various emergency stop (E-stop) pushbuttons. Signal indicators, traces with Boolean combinations of non-sequential objects. potentiometer actuators, and USB feed-throughs also are available. For Free Info Visit http://info.hotims.com/69509-114 For Free Info Visit http://info.hotims.com/69509-112

LASER DIODE MULTIPHYSICS DIVERSE OPTICS: DRIVERS WITH MODELING, POLYMER BUTTERFLY SIMULATION, APP OPTICS SOCKETS DESIGN AND PERFECTED Each of the 19 models in the DEPLOYMENT We specialize in injection Avtech AVO-9 series of SOFTWARE molding and diamond pulsed laser diode drivers includes a replaceable out- turning custom polymer optics for defense, medical, ® put module with an ultra-high-speed socket suitable COMSOL Multiphysics is an integrated software envi- and commercial applications. Our dedicated team for use with sub-nanosecond rise time pulses. Models ronment for creating physics-based models and simula- uses advanced technology to guide you from proto- with maximum currents of 0.1A to 10A are available tion apps. Add-on products allow the simulation of elec- typing to series production of: spheres, aspheres, with pulse widths from 400 ps to 1 us. GPIB, RS-232, tromagnetics, structural, acoustics, fluid flow, heat trans- free-forms, Frensels, lens arrays, micro-optics, and and Ethernet control available. Since 1975. fer, and chemical applications. Interfacing tools enable its everything in between. Let our experience transform www.avtechpulse.com integration with all major technical computing and CAD your optics. Come visit us at SPIE Optics and tools. Simulation experts rely on COMSOL Server™ Photonics #529. www.diverseoptics.com product to deploy apps to their colleagues and customers worldwide. https://www.comsol.com/products Avtech Electrosystems Ltd. Diverse Optics COMSOL, Inc. Free Info at http://info.hotims.com/69509-723 Free Info at http://info.hotims.com/69509-724 Free Info at http://info.hotims.com/69509-725

BI-DIRECTIONAL NANOSILICA LASER MICRO- FIBER OPTIC FILLED, DUAL MACHINING SWITCHES CURE ADHESIVE Laser systems and con- Liteway, Inc. offers a Master Bond UV22DC80- tract manufacturing, line of full bi-directional fiber optic switches in the 10F is a single component, PhotoMachining has following styles: 1¥N, 2¥N, 1¥3, 1¥4, Latching or nanosilica filled compound featuring a UV and heat the latest technology – Non-Latching, Signal Sensing, Manual or Remote curing mechanism. This thixotropic system features a femtosecond, picosec- controlled. Since there is no light to/from electrical moderately low viscosity of 8,000-12,000 cps at 75°F. It ond and nanosecond lasers for heat free microman- data conversion, there is no data to intercept. provides outstanding dimensional stability and superior ufacturing. From prototype to mass production, Switches can be used Stand-alone, DIN rail or Rack physical strength properties. UV22DC80-10F is optically start-ups to Fortune 500 companies, our expertise is mounted, are available with all standard optical con- clear and offers the ability to be cured in shadowed out available for you. For a free analysis of your applica- nectors and are ready for immediate use. All switches areas. https://www.masterbond.com/tds/uv22dc80-10f tion, contact us today: [email protected], are manufactured in the USA. Visit www. 603-882-9944, www.photomachining.com. foswitch.com or call Liteway, Inc. at 1-516-931-2800.

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54 www.techbriefs.com Tech Briefs, August 2018 FACILITY FOCUS Air Force Research Laboratory

Directed Energy – Located at Kirt - land Air Force Base in New Mexico, this directorate develops and transitions technologies in four technical competencies: laser systems, high- power electromagnetics, weapons modeling and simulation, and directed energy and electro-optics for space superiority. The AFRL pio- neered the first and only megawatt- class airborne laser and is the world leader in ground-based space imaging using adaptive optics. Improving Human Performance – This directorate is the first human- centric warfare wing to consolidate human performance research, education, and consultation in a single organization. The 711th Human Performance Wing encompasses 75 occupational specialties including science and engineering, occupational health and safety, medical pro- Dr. Richard A. McKinley, who leads the Non-Invasive Brain Stimulation (NIBS) team in the 711th Human fessions, technicians, educators, and Performance Wing at AFRL, explores how electrical stimulation to the human brain affects cognition, fatigue, mood, and other areas, with the end goal of improving warfighter awareness, memory, and business operations and support. focus. (U.S. Air Force photo by J.M. Eddins Jr.) Information – This directorate is the premier research organization he Air Force Research Laboratory (AFRL), headquartered at for Command, Control, Communications, Computers, and TWright-Patterson Air Force Base in Ohio, was formed in Intelligence (C4I), and cyber technologies. It explores, proto- October 1997 through the consolidation of four former Air Force types, and demonstrates high-impact, affordable, and game- laboratories and the Air Force Office of Scientific Research. changing technologies that transform data into information, AFRL’s mission is leading the discovery, development, and and subsequently knowledge, for decision-makers and com- integration of warfighting technologies for U.S. air, space, and mand and control forces. cyberspace forces. The lab consists of scientists, researchers, Materials & Manufacturing – Air Force product centers, logis- and entrepreneurs who perform basic and applied research, tics centers, and operating commands rely on this directorate’s and advanced technology development in these areas. experience in materials, nondestructive inspection, systems sup- AFRL accomplishes its mission through eight Technology port, and advanced manufacturing methods. The directorate Directorates (Aerospace Systems, Directed Energy, Improving develops materials, processes, and manufacturing technologies Human Performance, Information, Materials and Manufacturing, for aircraft, spacecraft, missiles, rockets, and ground-based sys- Munitions, Sensors, and Space Vehicles), the Air Force Office tems and their structural, electronic, and optical components. of Scientific Research (AFOSR), and the 711th Human Munitions – Located at Eglin Air Force Base in Florida, this Performance Wing. It also operates the Major Shared Resource directorate develops conventional munitions technologies to Center at Wright-Patterson, one of four high-performance com- provide a strong technology base upon which future air-deliv- puting centers in the Department of Defense (DOD). The center ered munitions can be developed. tackles large-scale problems previously beyond the reach of pro- Sensors – This directorate’s mission is to lead the discovery cessing platforms, and provides an array of services. and development of future capabilities, providing integrated Intelligence, Surveillance, and Reconnaissance (ISR); combat Directorates identification; and spectrum warfare effects. Aerospace Systems – Among the technologies in development Space Vehicles – Headquartered at Kirtland Air Force Base, within this directorate are scramjet engines, alternative fuels, the Space Vehicles Directorate is the Air Force Center of unmanned vehicles, hypersonic vehicles, collision avoidance Excellence for space technology research and development. systems, and aircraft energy optimization. The directorate develops and transitions space technologies

Tech Briefs, August 2018 www.techbriefs.com 55 Facility Focus

less susceptible to radar. Soon afterwards, his work helped lead to radar reflectivity solutions for stealth applications. In the early 1960s, AFOSR awarded a contract to Dr. Douglas Engelbart and the Stanford Research Institute for research on augmenting human intellect and the potential for computers to assist people in complex decision-making. His 1962 report to AFOSR served as a roadmap for developing computer technologies — particularly in the area of human interfaces. This was followed in 1964 with his design of the first computer mouse, a wooden casing with two metal wheels that provided a way to “point and click” on a display screen. His team also was involved in the development of ARPANET, the precursor of the Internet. Superconductivity has been a key field Using a quadcopter drone and a first-person-view video headset, Fast Lightweight Autonomy (FLA) of endeavor for AFOSR research for more would reduce operator workload and stress, and allow humans to focus on higher-level supervision of multiple formations of manned and unmanned platforms as part of a single system. (U.S. Air than 50 years. In 1964, an AFOSR-funded Force photo by Tech. Sgt. Brandon Shapiro) team at the University of California, San Diego (UCSD) discovered a new category to provide space-based capabilities. Primary mission areas of superconducting materials. High-transition-temperature include space-based ISR, space situational awareness, space superconductors are used in Air Force telecommunication sys- communications, position navigation and timing, and defen- tems, resulting in more secure communications and superior sive space control (protecting space assets from manmade and radar systems. natural effects). AFOSR was a pioneer in what is now termed biomimetics — The Air Force Office of Scientific Research (AFOSR) contin- the study of the structure and function of biological systems as ues to expand the horizon of scientific knowledge through models for the design and engineering of materials and management of the Air Force’s basic research program. machines. One of the first biomimetic breakthroughs occurred AFOSR’s mission is to support Air Force goals of control and through the efforts of AFOSR’s European Office of Aerospace maximum utilization of air, space, and cyberspace. AFOSR Research and Development, which funded research that result- accomplishes its mission by investing in basic research efforts ed in the biological equivalent of lens coatings. This program for the Air Force in relevant scientific areas. found that the surface of the compound eye of certain insects and crustaceans is covered with geometrically spaced, dome- Early Technology Breakthroughs shaped protuberances. These protuberances, because of their In 1951 and 1952, AFOSR awarded research grants to Dr. shape and spacing, efficiently reduce reflections from the sur- Joseph Keller to explore ways in which airborne vehicles would be face of the eye, thus allowing the eye to capture more available light and see better in dim light. Several large-scale models of these projections, made of semiconducting material, were built to study the mechanism of this system with the use of microwaves. It was found that by varying the size and spacing of the projections, nearly all the microwaves can be reflected, thereby reducing the band of frequencies to a very narrow band. This early research precipitated further endeavors towards the application of this discovery to optical and radio sensing devices and to the design of more sensitive and selective antennas. The first suggestion that energetic protons could be an effective method for medical treatment was made in 1946 by a researcher at the Harvard Cyclotron Laboratory (HCL). The first treatments were performed with particle accelerators built for physics research. This was followed by AFOSR-supported investigations in Sweden regarding the effect of irradiation by Air National Guardsmen set up a remote operational video-enhanced high-energy proton beams on brain tissue, which helped lead receiver for video from overhead aircraft to provide situational aware- to the refinement of proton beam therapy, whereby techniques ness. AFRL is investigating the use of artificial intelligence (AI) to scan a were developed to target certain areas of the brain for irradia- live video feed faster and more accurately than any human, and then warn commanders of imminent danger. (Photo by Master Sgt. John tion. The most important application of the proton beam is its Nimmo Sr./Louisiana National Guard) use as a microsurgical tool.

56 www.techbriefs.com Tech Briefs, August 2018 An early 1960s AFOSR research program resulted in the Code Division Multiple Access (CDMA) System that provided precise ranging and timing data, and allowed all satellites within a constellation to broadcast on the same frequency without interfering with each other. While operating under an AFOSR grant in 1967, Dr. Byron Knowles of Texas A&M University conceptualized a design for a low-cost Global Positioning System. In 1973, the results of this GPS design were integrated with other system initiatives and eventually resulted in the NAVSTAR GPS program. Today, the Air Force operates the largest GPS constellation in history with more than 30 satellites. Swept wing design in supersonic aircraft reduces performance loss resulting from the shock wave interaction with the wing. This same concept was studied by AFOSR to make rotor blades in axial flow compressors more efficient, which led to increased performance. This new development improved compressor efficiency by almost 90 percent. Use of these blades resulted in aircraft engines with fewer stages and higher thrust- to-weight ratios. Better thrust-to-weight ratios meant more A base-layer shirt with an embedded sensor is used to monitor human powerful engine performance with an accompanying 20 per- performance at the AFRL’s 711th Human Performance Wing as part of the cent increase in range due to reduced fuel consumption for STRONG program in which researchers in physiology, bio-signatures, physical training, nutrition, and sensors assess cognitive and physical perform- longer loiter times. This technological breakthrough in engine ance in order to develop training, supplementation, and technology for component design solved a problem that aerodynamicists had performance enhancement. (U.S. Air Force photo by J.M. Eddins Jr.) struggled with for years. Swept blade technology is now commonplace in current engine design. This technological advance has saved millions in fuel costs.

Today’s Technologies In 1993, Professor Frank Karasz of the University of Massachusetts at Amherst successfully synthesized a new polymer that allowed “high-definition” information to be seen on flat- panel displays. This technology lead to today’s HD televisions. AFOSR has provided research funding for fast, bendable electronics on two fronts: organic/polymeric materials and inorganic/semiconductor applications. Because organic materials are flexible and can be printed onto large areas, they have potential uses in conformal electronics over large structural areas or antennas. The organic/polymeric electronic materials research effort is now investigating materials that can be applicable to “stretchable” electronics. With advances in inorganic membrane research, flexible — or bendable — electronics can be fabricated from more traditional inorganic materials. The ability to synthesize and manipulate extremely thin films of solid-state materials enables wholly new approaches for improving performance and reducing size, weight, and power in defense and commercial systems. Studying laser and optical technologies for medical applications, AFOSR focuses on diagnosing and treating wounded military personnel, with significant spinoff civilian applications often further funded by the National Institutes of Health or commercial companies. One significant area funded by AFOSR is Optical Coherence Tomography (OCT). Today, OCT is the standard of care in diagnosing eye diseases. It is also becoming indispensable in diagnosing and understanding cardiac disease, understanding diseases of the airway — including early diagnosis due to smoke inhalation — as well as burn and eye trauma injuries. Geospatial Information Interoperability Exploitation Portable (GIIEP) “go Since 2005, AFOSR-funded work has resulted in the develop- kits” feature self-contained communications equipment and other hard- ment of many new artificial muscle types, including electro- ware that allows for real-time and near-real-time full-motion video, digital imagery, and in-flight chat capability with federal, state, and local chemical carbon nanotube and conducting polymer muscles, as emergency operations centers supporting emergency situations. (Civil Air well as fuel-powered muscles. The latter, powered chemically by Patrol photo by Steve Cox)

Tech Briefs, August 2018 www.techbriefs.com 57 Facility Focus www.techbriefs.com

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TECH BRIEFS MEDIA GROUP, AN SAE INTERNATIONAL COMPANY 261 Fifth Avenue, Suite 1901, New York, NY 10016 (212) 490-3999 FAX (646) 829-0800 Chief Executive Officer...... Domenic A. Mucchetti Executive Vice-President...... Luke Schnirring Technology Director ...... Oliver Rockwell An AFRL-developed transparent coating causes water to bead up into drops and roll or bounce off Systems Administrator...... Vlad Gladoun a surface. This technology will help protect and sustain Air Force systems by preventing corrosion Digital Production Manager...... Howard Ng and reducing ice formation on optical elements and aircraft. (U.S. Air Force photo) Digital Production Associates ...... Jerry Aultz, Andrew Greenberg Digital Media Assistants...... Peter Weiland, Md Jaliluzzaman alcohol or hydrogen, operate similarly to is continually looking at auditory, visual, Credit/Collection ...... Felecia Lahey Accounting/Human Resources Manager...... 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Tech Briefs, August 2018 www.techbriefs.com 59 Spinoff is NASA’s annual publication featuring successfully commercialized NASA technology. This commercialization has contributed to the development of products and services in the fields of health and medicine, consumer goods, transportation, public safety, SPINOFF computer technology, and environmental resources. Plant Food for Space Grows Crops on Earth NASA and commercial company team up to develop fertilizer for space station plants.

he goal of NASA’s Veggie team is a mostly space-tested. It used the same poly - T fresh and tasty salad on Mars. While mer coating, the same release character- other NASA programs are working on istics, and the same nutrients, with the getting to the Red Planet, the Veggie nitrogen reduced and the potassium team is figuring out how to grow salad increased. The result was a 14-4-14 NPK ingredients in space, with an interim formulation — 14 parts nitrogen, 4 parts goal of a salad on the International phosphate, and 14 parts potassium. Space Station (ISS). The Veggie pro- With the guidance of Kennedy Space gram is named for modular growing Center researchers, Florikan began units designed by Orbital Technologies, developing fertilizer with the “NASA- and is a type of astronaut garden. To grade” polymer coating the company grow red romaine lettuce on the ISS, still uses today. An early version of this NASA scientists teamed up with fertilizer didn’t hold up in heavy rain, Sarasota, FL-based Florikan, a company which wasn’t a consideration for space. that had already been working with For earthbound farmers, the company NASA to develop polymer-coated, con- came up with a polyurethane wax under- trolled-release fertilizer systems. The ISS crew has grown mixed greens and is now coat that successfully resolved the issue. For NASA’s hydroponic growing sys- running two Veggie facilities simultaneously. The 14-4-14 formula that was already (NASA) tem in space, the injectable liquid fertil- being used in NASA experiments and izer that’s typically used in hydroponic commercial hydroponics on Earth is the systems could not be used because water first controlled-release fertilizer to work floats in microgravity, and those systems successfully in vertical hydroponic farm- typically require multiple applications, ing, replacing liquid feed and the need which isn’t practical for astronauts. for multiple applications. Single-application nutrients had to be Among the earliest commercial adap- provided without mixing them in water. tors of the 14-4-14 formula was Sarasota, The team developed a way to incorpo- FL-based Sweetgrass Farm, a fully hydro- rate Florikan controlled-release fertilizer ponic operation that in 2016 began the into the baked ceramic that holds the process of converting to exclusive use of roots of NASA’s Veggie plants instead of Florikan’s fertilizer system. The plants normal soil. The fertilizer released itself grown with the fertilizer were healthy, over the life of the plants so the astro- vibrant, productive, and of exceptional nauts didn’t have to tinker with it. By quality. August 2015, astronauts were eating red Florikan worked with Sweetgrass Farm romaine lettuce grown in the ISS, but a to test seed-to-seedling yields using a nano- real salad needs more than just lettuce. sized version of the 14-4-14 formula, which Flowering vegetables like tomatoes and involves much smaller granules. NASA peppers are the true keys to excellent also started testing the nano-formula, salads. Although NASA has been testing which makes it possible to achieve nearly Red Robin tomatoes, growing in vertical hydro- a Chinese cabbage in the interim, the ponics at Sweetgrass Farms, use the fertilizer for- perfectly even fertilizer distribution. next plan is to grow dwarf tomatoes. mula developed by Florikan for use in space. Such applications have environmental The fertilizer adapted for NASA’s let- benefits as well. Farmers don’t have to tuce crop was Nutricote 18-6-8 formula, peppers with the 18-6-8 formula and buy as much fertilizer because less of it named for its ratio of nitrogen, phos- manually add extra potassium, but gets lost in runoff that contaminates phate, and potassium. Florikan has been NASA aimed to make the process as rivers, streams, and entire watersheds. selling Nutricote for decades, but when hands-off as possible. Florikan has been recognized by the contacted about growing tomatoes and Florikan came up with a new formula U.S. Environmental Protection Agency peppers, Florikan determined that the specifically designed for hydroponically (EPA) for its success in reducing excess 18-6-8 ratio was not the right formula- grown flowering plants. The product was fertilizing nutrients. tion for flowering plants. On Earth, similar to the fertilizer that successfully Visit https://spinoff.nasa.gov/Spinoff2018/ farmers might just grow tomatoes and grew red romaine on the ISS, so it was ee_3.html.

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APPLICATIONS Don’t Get Caught In a 17 Drive Technology: The Recipe for Precise Actuator Control Labyrinth of Bad Seals 18 High-Speed Reluctance Machine Design TECH BRIEFS 20 Using Direct Current with Inverter Technology in Resistance Our patented centrifugal pressure Welding seals are proven to: 21 Hydraulic-Based Spherical Robot 21 Ultra-Thin Capacitive Sensor Has the Least Possible Keep lubricants in and contaminants out Resistance to Motion 22 Variable-Camber Compliant Wing Reduce downtime 23 Autonomous Crop-Counting Robot Support horizontal and vertical applications 24 Fast, Low-Voltage Actuator for Soft and Wearable Robotics Prevent friction and overheating with DEPARTMENTS a non-contact design 26 New Products Create a dynamic pressurized barrier Support extremely low-viscosity ﬂuids ON THE COVER Using ultrasound, dolphins and whales are able to find their way even in dark and murky waters. The BionicFinWave from Festo (Islandia, NY) swims collision-free through a pipe system made of acrylic glass thanks to ultrasound sensors on its head that measure the distance to the walls and its current direction in the water. The fin drive unit is particularly suitable for slow, precise motion. While it moves through the tubes, it communicates with the outside world via radio and transmits data, such as temperature and pressure sensor readings, to a mobile device. Technologies used in the BionicFinWave are being applied to other Festo products. Learn more about the com- A Carlyle Johnson Company pany’s latest product on page 26. centritecseals.com (Image courtesy of Festo) 860-643-1531

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Figure 1. The HAWK MV-4000 smart camera inspects a line of printed circuit boards.

he ability to automatically extract In addition to awe-inspir- ing the gradient of neighboring information from digital images ing processing speed, proper pixel intensities) to the edges of a Topens many doors for manufacturers illumination is essential on the template. There are many ways that pat- striving to cut costs, improve quality, and production line to ensure that the tern matching is performed and opti- streamline their processes overall. The camera “sees” the key features it is trying mized, but the focus here is the resulting primary uses of machine vision are to process and ignores irrelevant details functionality that industrial profession- inspection, gauging, and robot guidance. (such as bumps on a surface carrying a als can use. These tasks require repetitive activities to date stamp). Illumination requirements be performed as quickly as possible and depend heavily on the nature of the in- Basic Function: Location with a high degree of accuracy, which is spection task. Trying to inspect a date In many cases, complex machine precisely where machine vision systems stamp on a rough surface requires light- vision processing tasks begin with excel. They have also become increasing- ing that minimizes the appearance of object location. The system is trained to ly cost-effective and simpler to implement surface irregularities, whereas trying to recognize a specific pattern that it will over the last couple of decades. find dents on what should be a smooth then locate in various images featuring Automated inspection is usually per- surface requires lighting that specifically a variety of backgrounds. A common formed in-line, i.e. in tandem with items highlights these irregularities. example of something a machine vision moving along the production line. With advanced optics, superior illumi- system would be expected to locate Although the technology is complex, the nation technology, and state-of-the-art repeatedly is a two-dimensional bar- basic sequence of using machine vision algorithms, machine vision systems can code such as a data matrix. The system to perform automation tasks is simple: perform a wide array of industrial must find a barcode before it can the vision system is triggered to capture automation tasks, including product decode it, and it must often do this an image when the part is in front of it, inspection, print inspection, surface extremely quickly as products bearing and then the system processes the image defect detection, gauging, and robot the codes fly by at high speeds. In fact, and extracts key features and data. guidance. high-performance smart cameras can Finally, it communicates the resulting inspect up to 4,000 parts per minute, or data, which can be as simple as Pass/Fail, A Foundational Toolkit the equivalent of a conveyor belt mov- so that actions and decisions can be Even with near-perfect lighting on the ing at 300 inches per second. Specific made. Such actions include triggering a production line, there is still bound to aspects of the codes indicate to the reject mechanism or giving the locations be plenty of variation. How can machine vision system that a barcode is present, of all parts for a robot to pick up. vision deal with so much irregularity and as do other graphics that typically m o .c

Production lines move quickly — and still perform its tasks in a reliable man- reside near barcodes, such as logos. k c the faster they can move, the better, as ner? As it turns out, the extensive capa- Matching specified patterns within long as quality is maintained. For this bilities of machine vision boil down to the field of view also makes it possible to reason, machine vision systems need to just a few fundamental functions: loca- detect defects based upon how closely be able to almost instantaneously extract tion, measurement, counting, and the located object corresponds to the relevant information about the parts fly- decoding. These four tasks depend on pat tern supplied for training. If the ing past them. In general, the highest the common capabilities of recognizing image of an item has a significant k Bestsellers/Shuttersto ic processing speeds are reached by hook- pixel intensity values, finding edge con- amount of deviation from the expected l C ing up multiple cameras to a PC, but tours, and matching shapes and pat- pattern — for instance, the presence of : ge recent advances in smart camera tech- terns. These are complex tasks that pixels not matching the expected color, ima nology have made single, self-contained involve comparing an image to a tem- or edges in places that shouldn’t have devices almost as powerful as multi-cam- plate pixel-by-pixel or comparing a set of edges — it will be flagged for rework or era systems (Figure 1). perceived edges (generated by calculat- rejected from the production line. kground ac B

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Free Info at http://info.hotims.com/69509-735 Basic Function: Counting Once a machine vision system can locate an object of interest, it can count the number of similar objects present in an image. It can also tell whether the object is not present in an image, so a presence/absence test also falls under the category of counting. In the automotive industry, for example, the counting function is used to determine whether a component has the proper number of machined holes (Figure 2). Components with the wrong number or size of holes will be removed from the production line instead of becoming part of a new car.

Basic Function: Measurement Machine vision can also calculate the distances between objects that it has located — a task known as gauging. It makes exceptionally precise measurements to verify that the distance between two components of a product — such as the bottom of a medication vial and the point to which the bottle is filled — meet expectations. Before the vision system can perform measurements, it must first be calibrated. Simple calibration involves telling the system that a unit of measure equals a certain number of pixels. More complex calibration involves showing the system a grid pattern wherein the grid spacing equals a known value. This ensures that measurements will be good even if the camera is tilted or rotated, or if there is distortion in the lens. No physical manipulation of the objects on a production line is necessary to take measurements using vision, so there’s no associated risk of damaging parts as there is with contact gauging. For this reason, machine vision gauging has virtually replaced contact gauging now that machine vision systems cost less to set up and require less programming knowledge. They can perform thousands of measurements per second, including tricky calculations like circularity that contact gauging has a hard time with. (This is because contact gauging is limited to a few points of contact, whereas vision can quickly and easily utilize up to 360 points on a circle to get a much better answer.)

Basic Function: 1D and 2D Decoding In many industries, especially consumer electronics and Booth automotive, all parts are marked with machine-readable codes. It is an essential function of the machine vision system that it #E-134357 can decode these symbologies so that the parts can be tracked throughout the production process, and documented as to which finished product they become part of. This is a concept :RUOGnVąUVWLQGLJLWDOL]HGSQHXPDWLFV known as Track and Trace. This information can be recorded Festo Motion Terminal VTEM as historical data in case questions arise at a later date, such as when trying to determine what limited set of products may The VTEM is opening up radical new dimensions need to be recalled because of a faulty component. LQWKHZRUOGRIDXWRPDWLRQ,WnVWKHZRUOGnVąUVW By combining these basic functions — location, counting, valve to be controlled by apps and combines the measurement, and decoding — in various ways, industrial advantages of electric and pneumatic technology automation systems can take care of nearly any inspection task for numerous functions. put in front of them. The one thing they can’t do, however, is read the minds of humans. For this reason, industrial automa- Visit our booth to experience the tion solution providers need to tell machine vision software what to look for by pre-programming it with specific patterns digitalization of pneumatics through and logical proceedings. augmented reality! An Applied Science with Concrete Benefits Compared with human inspectors, machine vision offers vast improvements in speed and consistency. It also works tirelessly www.festo.us

6 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -7 3 6 Motion Design, August 2018 fly. Data gathered over time on the suit- Machine vision can also recognize and ability of inspected items can also be verify human-readable symbols — tasks analyzed to discover trends such as the known as Optical Character Recognition wear and tear of cutting tools. (OCR) and Optical Character Verification One good example of the process (OCV). These are important functions control benefits of machine vision is because many items bear human-read- code verification. Essential for the trace- able codes alongside the machine-readability of products and product parts, able ones, and both types of marks need machine-readable codes are printed, to be read to verify that the data match- dot-peened, or engraved onto compo- es. OCR is used to do the actual reading, nents about to embark on the produc- and its strength is in reading characters tion journey. The quality of codes can be even when they are deformed. OCV, on inconsistent and can degrade over time the other hand, is used to look at the based on the performance of the mark- quality of the printing. It ensures that ing system, so machine vision technolo- characters such as a 3, 8, 6, or B are suffi- gy is used to verify the readability of ciently clear that they will not be con- Figure 2: A part is inspected for the correct number these codes. Advanced code verification fused when read by a human. Preforming and placement of holes. systems grade a variety of symbologies OCV on printed expiration dates is the according to standards set by the perfect example of the usefulness of this around the clock to consistently deliver International Organization for Standard- technology. You would not want anyone quality products and reliably catch ization (ISO). They also keep track of misreading an expiration date and ingest- botched items. Downtime is minimized grading trends and record information ing expired food or medicine. Figure 3 as machine vision systems take care of about barcode quality in order to keep shows how OCV looks at the shape of inspection-related tasks quickly, accu- an eye on printer functionality and pro- characters on a pixel-by-pixel basis. rately, and consistently, allowing correc- vide a reference in case disputes arise Today’s automobiles are more com- tive measures to be performed on the over symbols that don’t scan. plex and have more selectable options

Motion Design, August 2018 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -7 3 7 7 Position Sensors for Commercial, Space & Military Applications

Symbol9 Total Residue Area: Trained Inspected Residue 65 pixels 22.34% of Symbol Size Symbol Size: 291

Figure 3: Screenshot showing OCV data.

Sensor Solutions for: and features than ever before, making the desired objects in the image. The Laser Communication production errors increasingly likely. system calculates the position and orien- Fast Steering Mirrors Machine vision helps manufacturers and tation data for each part, adding what it suppliers prevent defects throughout knows about how far the objects would Directed Energy the production process. It can guide have traveled from the time it was trig- Airborne Night Vision Systems robots to pick parts out of racks, verify gered, and then sends the “pick” loca- that they are the correct parts, inspect tion of these parts to a robot. Basically, the parts for quality, and then position the computer version of skeet-shooting the parts for assembly. — where you need to aim and fire the The introduction of smart cameras gripper towards a point where the has greatly improved the options for object will be — is what allows a vision- using machine vision in the automotive controlled robot to pick up objects on industry because it allows for a distrib- the fly. Given that robot guidance deci- uted system of independent inspection sions need to be made in a fraction of a at multiple points along the production second, it’s important that the machine line. Smart cameras combine optics, vision system, or smart camera, can lighting, vision software, and communi- achieve a near-real-time response. cations in a single device, making it unnecessary to have a single processing A Rapidly Evolving center for all inspection points. Technology Capitalizing upon its ability to locate Machine vision is getting more ad - patterns, machine vision technology vanced all the time. Once an expensive excels at guiding robotic equipment to investment that required a significant pick up necessary objects. Without amount of programming know-how to machine vision, these objects would implement, this technology is now sim- For more information about need to be placed in the exact same ple to set up, simple to use, and much, our full line of products, spot every time, and the slightest devia- much cheaper than before. The dramat- contact us today! tion from the expected location would ic improvements in accuracy, speed, and discontinue processing for at least one reliability have made machine vision — product and possibly stop the produc- and particularly smart cameras — an 800-552-6267 tion line altogether. It would also be extremely hot engineering topic. Given [email protected] extremely tricky to direct robots to the wide variety of tasks that machine grasp objects on a moving conveyor vision systems can already accomplish, it kamansensors.com belt. will be exciting to see what innovations With machine vision, however, find- the near future brings. ing the location of objects — including This article was contributed by Omron moving targets — is relatively easy. The Microscan, Renton, WA. For more informa- system triggers vision at a specific tion, visit http://info.hotims.com/69509- instant in time, and the software locates 323.

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THK America, Inc. )%% #$$!!%(% $ % %& Free Info at http://info.hotims.com/69509-739 Conical, Floating-Piston Isolation Valve

new valve concept consists of a still cannot be opened with a pressure The Concept Design solid piston floating in a medium drop across them; equalization is required In trying to eliminate or control the Ato control a flowstream. Although before opening. forces acting on the ball and stem, the the conical shape of the seat is a promi- Instead of improving the current seat retainer that pressed the seat to the nent feature of the valve, especially when valve, it was decided to determine what ball using springs, plus the additional the concept was first developed, the key was causing the failure and design that force of the pressure drop across the feature of the valve is the balanced float- out of the valve. It was determined that valve, was first approached. This design ing piston that acts as both the valve plug the forces acting on the ball by the seat — a version found in most ball valves — and the actuator. The origin of this design retainers were extremely high, and the causes the seating force to vary greatly, was based upon the need for large, internal pressure acting on the valve depending on the pressure across the extremely high-pressure valves to replace stem to eject it was also extremely high. valve. This is also common in other valve the ball valves currently used as supply Failures were occurring in the trunnion designs such as globe valves. It was deter- valve tank pressurants in rocket testing. and in the seat itself due to the excessive mined that the force generated by the The ball valves currently in use are force being applied by the seat retainer, valve’s internal pressure could be re- 12,000-psi, 8" ball valves that flow 890 which used both springs and the inter- moved by adding an additional set of lbm/sec of gas through them during nal pressure of the valve to generate a seals, and the pressure could be used to testing. They have been problematic very high load on the seat retainer to actually work against the springs, if during operation, with very short lives, hold it onto the ball. Because of this desired, to lift the seat completely off the and expensive rebuilds and redesigns force, a large-diameter stem is required ball, allowing for free rotation. Upon that are often required. As supplied, the to transmit the force of a very large actu- noticing that when both seats were lift- valves only operate two or three cycles ator to the ball to get it to turn. As a ed, flow would move around the ball before failure and cannot be opened result, the large-diameter stem is also try- before the ball was moved, it seemed with a pressure drop across them. A ing to be ejected by the internal pressure that by increasing the retraction of the recent redesign has extended their life of the valve, which requires a thrust take- seat, or now the valve stroke, the ball span to more than 20 cycles, but they out feature that allows turning. could be eliminated. The ball was Rolling bearings were not desired due replaced with a fixed seat, moving the to damaging effects upon failure they wear item over to the non-moving part, would have on expensive equipment, and designing channels to route the and lubrication use was limited because flow around the seat and out the other the work is being conducted in a very side of the valve. high-pressure oxygen environment. An additional chamber was added to These issues lead to a design that initial- eliminate the spring and power the valve ly featured bronze sliding thrust bear- in both the open and closed directions. ings, which led to subsequent revisions The motive force for the piston could be that ended up with Torlon thrust bear- either an external source or the working ings. This process can be equated to try- fluid inside the valve itself. Finally, a final ing to turn the wheels of a car while the chamber was added to balance the force disc brake is applied. The Torlon disc of the downstream pressure. This last Figure 1. The entire body and pressure boundary is formed by three parts: the main body, the bushing, actually wears much like the pads on innovation allowed all forces to be bal- and the head. disc brakes, but with a much shorter life. anced on the floating piston no matter

10 Motion Design, August 2018 what position the valve was in or what the and through the connecting passages are pressure drop was across the valve. This designed to at least 150% of the cross-sec- means the valve always opens or closes tional flow area of the inlet and outlet with the same force as per the design. pipes. The inlet, outlet, and piston passages The design is essentially a globe valve should match the pipe, exactly as with ball in which all of the flow passes through valves. The 150% area is estimated to re - the center of the plug instead of just duce the velocity in the turbulent regions being diverted off to the side of the plug. and minimize flow losses. Modeling indi- In this case, the plug and the seat are cates that this design will have an approx- reversed; the seat is a solid disc, whereas imate 15% improvement in flow over a on typical globe valves, the seat is a ring similarly sized standard globe valve. and all of the flow passes through the The greatest advantage is the elimina- Figure 2. The first chamber is connected to the down- seat. The piston is designed so that it is tion of the valve stem and any conventional stream face of the piston through a series of holes not influenced by the pressure drop or actuator. No matter how large or how high drilled through the piston. flow inside the valve. the pressure, the valve is designed for one or two small solenoid valves that will oper- bonnet is eliminated as well. Instead, the Advantages and Features ate the valve completely. For very high-pres- body of this valve is formed by two cylin- This concept has many unique features sure valves, stem seals and bending of the drical parts that are squeezed together and design advantages over conventional valve stem are two major issues that cause with a bushing between them. The elim- valve concepts. First, the flow path is always valve failure. Because of the design concept ination of the bonnet reduces the envel- axially and radially symmetric, eliminating of this valve, there are essentially no bend- op and mass of the valve by an estimated almost all of the flow-induced thrust loads, ing forces that have to be addressed. Since 30%. even during transition from closed to open. there is no valve stem, there are no stem Additionally, the features of the parts This minimizes the need for mounting seals to leak, or to protect from dirt and are all simple circular features, so every- restraints and a thrust take-out structure. scarring or binding the stem. thing can be either turned on a lathe or Next, the flow areas where the flow is With the elimination of the valve drilled on a simple mill. This reduces required to change direction over the seat stem, the need for a conventional valve fabrication time and cost.

Motion Design, August 2018 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -74 0 11 ing may not be required. If slowing is required, it will be achieved through baf- fling the venting process of the opening chamber and therefore, no hard pulling or stretching is required. Additionally, contact will always be with the same amount of force no matter what the pressure drop is across the valve. Another benefit to eliminating the connection to a valve stem is the elimination of the need for valve adjustments. Con - ventional valves require the stroke to be

adjusted as the seat wears or is coined in. Figure 3. The valve in the open position (left) allows fluids and gases to flow. In the closed position (right), the Because the piston floats in this valve, it will valve is hermetically sealed. move forward until it is stopped on the seat. Seat wear or temperature changes will Because of the large-diameter seat, the amount of piston not affect either the force of the closure or the contact area with movement needed to achieve full flow is greatly reduced. Typical the seat. globe valves may have a plug assembly that has to travel over 3" Because the piston is balanced within the flow stream and the in order to get sufficient flow area. With this concept, travel of force required to close the valve is always the same, the amount only about 3/4" will meet the design requirement of 150% cross- of gas required to operate the valve is reduced by more than sectional flow area through the seat opening. This short stroke 90% of that required for a conventional, pneumatically actuat- allows for reduced valve actuation times while keeping the pis- ed valve. Large pneumatic actuators can cost more than ton velocity much lower. An issue seen with large, rapid-actua- $50,000 and be several feet in diameter and length, adding to tion valves is that the valve stem actually stretches when the actu- the envelope of the valve. Although the large reduction of gas ator tries to slow the valve, right before it slams into the seat. required to operate the valve may be a small portion of the total With the reduced velocity and increased seat contact area, slow- cost, it may allow the valves to be operated with a gas source such as a K-Bottle or a compressor, and thus eliminate the need to run high-pressure gas tubing to every valve in a system. Overall, with fewer parts, smaller size, robust component shapes and designs, shorter stroke, and consistent seating force, the valve is expected to demonstrate increased reliability and life over comparable conventional valve designs. The cost of fabrication should also be significantly less and should require less raw material. Because of the balanced design, the valve is also inherently bidirectional. The closing force is exactly the same, even if the higher-pressure fluid is on the “downstream” side of the valve.

Operation The functional operation of the valve is very simple. The entire body and pressure boundary is formed by three parts: the main body, the bushing, and the head (Figure 1). In the first concept, these are all held together by bolts or studs squeezing the three parts together, with the bushing in the middle and everything sealed with O-rings. The floating piston is positioned inside the body assembly and seals to the body assembly in four places with circular seals such as O-rings, or pressure-energized seals such as omni-seals. The piston and body shape, combined with the four seals, forms three annular chambers on the outside of the piston. The first chamber is connected to the downstream face of the piston through a series of holes drilled through the piston. This connection between the chamber and the downstream face can be done externally through the body if desired, but as shown in Figure 2, it is through the piston. The annular area of the downstream face of the piston is exactly equal to the connected face area of the piston in the cavity. Because the two faces have the same area and see the same pressure, no force is generated to try to move the piston by either of these areas, no matter what the pressure is inside the valve.

12 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -74 1 Motion Design, August 2018 In similar engineering, the upstream with exactly the same force as long as the nance. In addition, the reduction in com- face of the piston is equal in area to the driving medium is at the same pressure modities needed to operate the valve will expanding area of the flowpath inside the as designed. The fact that no adjustment reduce overall lifecycle cost and enable piston. So again, the pressure acting on is required in the design will ensure designs that operate longer on smaller both of these faces will be equal, and thus valve performance throughout its life. accumulators in case of loss of the operat- the forces generated by these pressures will The one moving part with incorporating medium or in power failures. cancel each other out and not generate a ed simple seals in a well-protected config- This article was written by Bruce Farner of motive force trying to move the piston. uration — along with the short travel of NASA’s Stennis Space Center, Mississippi. The remaining two chambers are equal the piston — should add to the life of the For more information, visit https://technology. in size and connected to the outside of the valve and reduce associated mainte- nasa.gov/patent/SSC-TOPS-2. valve body through a drill passage for each. These chambers are the operating chambers and provide the force to open and close the valve. The working fluid to operate the valve is up to the valve designer and user. The force required can be generated by gas of any pressure by varying the outer diameter of the chamber. The working fluid can come from an external source or from the inside of the WHEN SAFETY IS A valve. The operation of the valve is simple — one chamber is pressurized and the REQUIREMENT 0.1-2,800 NM. other chamber is vented. The piston moves in the direction of the vented chamber until it is physically stopped by either the seat on closing or the main body surface on opening. The speed of the piston is easily controlled by controlling the rate at which the venting chamber bleeds off.

Challenges The most significant challenge associated with this valve concept is that there is no obvious way to see the position of the piston in the valve. Another challenge is that the valve has to be removed from the line in order to be serviced. Many ball, globe, and gate valves permit the bonnet to be removed and the valve serviced while the body remains installed in the field. Designers generally design the wear parts in a way that they are accessible and replaceable in the field. That may not be possible with this valve concept; however, the lower part count and predicted increased reliability may make that a minimal factor.

Summary The balanced, floating piston valve design has a wide range of potential applications of all sizes and pressure ranges. The extremely simple design and few parts makes the concept inherently reliable, simple to manufacture, and easy to service. The valve concept works with soft or hard metal seats, and the closing force is easily adjustable so WWW.RW-AMERICA.COM that any closing force desired can be created. The valve will consistently close

Motion Design, August 2018 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -742 13 Preview

resented by the Association for Man - co-located shows presented by Han- process automation, pneumatic systems, ufacturing Technology (AMT), the nover Messe, USA. and exhaust-air cleaning systems. PInternational Manufacturing Tech- Integrated Automation, Motion & Industrial Supply USA: This show also nology Show (IMTS) has been the pre- Drives USA: Two trade fairs — Industrial made its debut at IMTS 2016, and covers mier manufacturing technology show in Automation and Motion & Drives USA — the spectrum of industrial subcontract- the Northern Hemisphere. IMTS is held have been combined to present a spec- ing, supply solutions, and lightweight every even year and attracts attendees trum of industrial automation, IT, power construction. from more than 117 countries. The 2018 transmission, and fluid power technology. edition will be the 32nd show. Surface Technology USA: This event Emerging Technology Center Here are some of the things you can for surface treatment and finishing At IMTS 2004, the ETC made its debut expect to see at IMTS 2018, which will debuted at IMTS in 2016. It features as a place to educate and inform the take place September 10-15 at McCormick everything from cleaning and pre-treat- manufacturing community about some Place in Chicago. ment, to coatings, paint finishes, and ground-breaking innovations specific to electroplating technologies. the advanced technology industry; par- Co-Located Shows ComVac USA: This international trade ticularly, state-of-the-art and disruptive A range of manufacturing technolo- fair for compressed air and vacuum tech- technologies that will impact manufac- gy solutions will be presented at four nology will cover technologies vital to turing in years to come. For the first

14 Motion Design, August 2018 Abrasive Machining/Sawing/Finishing – These technologies are particularly important to the auto, aerospace, and medical industries, all of which require a high degree of accuracy and precision. All varieties of grinding technology, as well as sawing and cutoff machines and a variety of finishing technologies such as lapping, balancing, honing, and polishing machines will be displayed. Additive Manufacturing – Additive manufacturing enables layer-by-layer processes to fabricate three-dimensional products. See the continued improvements in materials and processes that are producing more industrial additive solutions than ever. Controls & CAD/CAM – The world of custom automation and the latest software is on display in this pavilion, optimiz- time, IMTS will feature two ETCs — one ject matter experts from within the ing plant operations and cost efficiency. focusing on Digital Transformation and IMTS exhibitor community. CAD/CAM and other digitally enabled the other focusing on Additive Manu- Conference main topic areas are tools help define Smart Manufacturing, facturing. Manufacturing Process Innovations, the Industrial Internet of Things, Industry Digital Transformation – Just as digital Alternative/Additive Manufacturing, Qual - 4.0, and other advancements in the digital technology has revolutionized every ity/Inspection/Metrology, and Systems enterprise. Visitors will learn how to con- aspect of our lives, it is just beginning to Integra tion/Industry 4.0/IIoT. For nect islands of digital data into a fully inte- transform the advanced manufacturing information on the full conference pro- grated solution from design to perform- industry. This ETC shows how businesses gram, visit www.imts.com/education/ ance to recycle and reuse. in aerospace, automotive, medical, and conference.html. EDM – This is a proven, reliable, energy sectors are implementing lead- high-accuracy technology for those in ing-edge innovations. Visitors will see a Exhibition the tool and die industry, and especial- physically and digitally connected More than 2,000 exhibiting compa- ly those who specialize in one-off or machine tool, robot arm, and coordi- nies will present their new technologies specialty components. Everything from nate measuring machine (CMM). in ten Pavilions geared toward specific CNC wire EDM equipment to die sink- Additive Manufacturing – Additive industries, technologies, and solutions. ing machines can be found here. manufacturing has expanded into all markets and has become a valuable component to every manufacturing facility. This ETC will feature video, live manufacturing, and state-of-the-art design to showcase innovations in materials and methods, and offer insights into where additive manufacturing is going. Visitors will encounter demonstrations of breakthroughs in materials and technologies as recently developed by Oak Ridge National Laboratory (ORNL), public- private collaborations, and exhibiting additive manufacturers.

Conference An array of conference sessions is designed to provide insights into all manufacturing operations. The IMTS conference features more than 70 sessions, attended by more than 1,500 visitors. All sessions are presented by sub-

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16 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -74 3 Motion Design, August 2018 Drive Technology: The Recipe for Precise Actuator Control

orldwide, there are only a handful able on startup,” said Vasiljevic. Pre- Wof manufacturers of electrical viously, this requirement usually meant actuators for the process industry, and using an oversized converter. With the Vienna, Austria-based company Danfoss’ VLT® Midi Drive FC 280, this is Schiebel Antriebstechnik GmbH is the now no longer necessary, which has a smallest of these. The company’s tech- positive impact, not least of which is on nology is tucked away in the interior of the costs. Control and parameterization the actuators, ensuring that flows can be of the AC drive is performed using regulated in an accurately controlled Schiebel’s Smartcon control. Danfoss manner, even in difficult applications. has launched an AC drive that repre- The VLT® Midi Drive FC 280 AC drive sents the state of the art across all its from Danfoss Drives is used to ensure characteristics. “The support of a wide actuator quality at Schiebel. range of fieldbus systems, the control of Schiebel is the only Austrian producer permanent magnet motors, an integrat- of electric actuators. These actuators are ed STO (Safe Torque Off) function, the Schiebel actuators provide precision control for a used anywhere that the supply and wide range of industries, even in extreme climates USB interface, and last, but not least, removal of solid, liquid, or gaseous sub- and harsh environments. the new memory module are just some stances needs to be controlled. Ac - of the features that make the FC 280 a cording to company director Klaus nology,” said Schiebel. But Schiebel also consistent package for OEMs,” accord- Schiebel, “At our factory in Vienna, we has taken into account the trend ing to Gunter Schwarz, Global Product produce around 7,000 actuators each towards decentralization in process Marketing Manager at Danfoss in Gun- year with 56 employees, and we have the automation with the development of its tramsdorf. entire production chain in our own own control system for actuators. hands, from development to construc- “With Smartcon controls, the intelli- A Complete Solution tion, mechanical finishing, and assembly gence is moving out into the field,” Another important factor is having and packaging.” explained Vasiljevic. “The integration to excellent support, both very close by and This is due to the fact that the Schiebel the control system uses widespread field- globally. Klaus Schiebel is satisfied with actuators are considerably more compact bus technologies.” In addition, the control the FC 280 drive on all counts. “It is tech- than competitive products with the same system enables comprehensive diagnostics. nologically state-of-the-art, offers high per - performance. When it comes to markets, formance with cor- the Viennese company delivers world- Precision Control re spondingly short wide, but with a leaning towards Eastern While most actuators only have a rela- response times, and Southeast Europe, partly due to his- tively simple “open-closed” functionality, eas ily fits into our tory and partly due to market conditions. a number of applications are significantly en closures thanks Schiebel places value on proximity to the more demanding. These require a high to its compactness, customer, and is represented interna- degree of accuracy, and the flow control and offers very tionally not only by dealers, but also by its must be able to be carried out in precise, good value for the own subsidiaries. small steps. “Applications for this type of money.” actuator can be found, for example, in It is no surprise, A Technological Specialty gas pipelines or steam conditioning,” said then, that Danfoss Schiebel builds on a technological spe- Vasiljevic. This fine process control is AC drives are also cialty: their “failsafe” actuators. “Electric realized by means of an AC drive, and this part of the largest actuators have a weak point — if the power is where Danfoss comes in. individual order The Danfoss VLT Midi supply fails, then the actuator fails, which The AC drives have to meet a range of in Schiebel’s histo- Drive FC 280 fits into the Schiebel actuators, and can lead to problems in certain areas of requirements. One point is the frame, ry. Schiebel sales eliminates the need for the oil and gas industry,” explained since the AC drive is not placed in a and service manag- an oversized converter. Stephan Vasiljevic, who is responsible for switch cabinet, but is integrated directly er Michael Piller electrical engineering at Schiebel. into the actuator control. This in turn said, “We are delivering around 1,000 About 20 years ago, technicians from means that the heat dissipation must actuators for the construction of a 660 Schiebel had to deal with this weakness occur without additional cooling. Very MW lignite power plant in Greece using a spring reset mechanism. Today, few other AC drives on the market have (Ptolemais V), about 300 of which are the technology that evolved from this is the required compact and robust controlled by AC drives.” highly in demand on the market. “Our design. This article was contributed by Danfoss failsafe function is a major factor in our “One of our most important require- Drives, Baltimore, MD. For more information, strategy of winning customers with tech- ments is that the highest torque is avail- visit http://info.hotims.com/69509-322.

Motion Design, August 2018 17 High-Speed Reluctance Machine Design

ilphenix GmbH is an engineering and was successfully modeled using MAG - Sconsulting firm in Switzerland special- NETO and AMPERES interactively. The izing in high-speed electrical machines, torque was calculated with MAGNETO, magnetic bearings, and electromagnetic yielding torque values for a rotor length field analysis. One project focus is com- of 1,000 mm. For a rotor length of 15 pact high-speed flywheel systems for day mm, the torque values are normalized storage of solar photovoltaic energy on by a factor of 15/1,000. The torque can the order of 0.5 to 5 KWh usable energy. also be computed with AMPERES, which An important constraint for energy day requires more computing time; howev- storage is extremely low loss per day (e.g. er, the results obtained with either pro- 1% per hour). This means that the idling gram are within comparable limits. losses have to be less than 5 W and 50 W The rotor and stator have salient poles for 0.5-kWh and 5-kWh units, respective- of unequal numbers, as shown in Figure ly. Minimizing the idling losses requires 2. The torque is generated through the not only operation in a vacuum environ- physical phenomenon of reducing mag- ment, but also low bearing losses (magnetic reluctance. When one stator coil netic bearings), low eddy current losses pair is energized, a rotor torque is gener- (reluctance machine), and low drag loss- Figure 2. The reluctance motor geometry designed ated, as shown in Figure 3. The nearest with MAGNETO has salient poles for both rotor and es (cylindrical rotor surface). stator. A preferred choice is four rotor poles and six rotor pole is pulled from the nonaligned Design tools used were the field analysis stator poles with three stator coil pairs. position (e.g. -30 deg) towards the programs MAGNETO 2D and AMPERES aligned position (0 deg). When the three 3D from Integrated Engineering Software ment dz between -5.0 mm and +5.0 mm. stator coil pairs are connected to a 3- (IES) that enabled modeling of both In the axial center position, the radial phase variable frequency current source, magnetic bearings and the reluctance force F(y) is positive, providing a restor- the rotor follows the rotating field. The machine. Particular features of these pro- ing force compensating for the rotor phenomenon of magnetic reluctance can grams are the exceptional ease of geomet- weight. The axial force F(z) near the be visualized by pictorially replacing the ric modeling and the interactive use of center position is zero, while at the dz = field lines (Figure 3) with rubber bands, the two programs to create the geometric -0.5 mm point, F(z) = -39.4 (N), indicat- which exert a maximum restoring torque model and the currents in the stator coils. ing axial instability that has to be con- (i.e. maximum reluctance) on the rotor Using a parametric solver mode, the force fined mechanically in both directions in the non-aligned position (e.g. -30 deg), value’s axial rotor position with respect to (e.g. with a flat precision-ground steel and a zero torque in the center position the magnetic bearings, and the torque val- disk inserted at the end of the rotating (i.e. minimum reluctance). ues versus the rotor angle are obtained. axis against a small stationary steel sphere on both ends). Therefore, the Cylindrical Rotor Surface Magnetic Bearings actual mechanical bearing losses Special attention had to be given to The passive magnetic bearing (dual depend on a low axial destabilization minimize the drag losses of the rotor ring pair), as shown in Figure 1, consists force Fz obtained by manually adjusting with its four salient magnetic poles, as of two ring pairs with repulsive magneti- the axial air gap and the optimum mate- zation in both radial and axial direc- rial choice (e.g. high-grade ceramics) tions. For a horizontal orientation of the for both the disk and the sphere. motor axis, the forces have been com- Alternatively, an axial active magnetic puted with the parametric solver mode bearing can be used that requires low of AMPERES for an axial rotor displace- power for stabilization. The radial restoring force Fy for a radial displacement of -0.5 mm is 19.4 Newton. For a rotor mass of 1 kg (9.81 N), the radial restoring force is reduced to 9.7 Newton. If a higher radial restoring force was needed, the geometry of rings or the number of ring pairs could be altered. Reluctance Motor The choice of a reluctance motor was made due to the inherent low eddy current losses and the absence of both per- Figure 3. The field lines of the reluctance motor Figure 1. The passive magnetic bearing consists of shown with the rotor in the -30-degree position. two ring pairs with repulsive magnetization in both manent magnets and rotor coils. The Maximum reluctance was obtained with MAGNETO radial and axial directions. geometry of stator, rotor, and the coils with current flow in one coil pair only.

18 Motion Design, August 2018 All the supporting structures for the stator and the magnetic bearings were designed using MAGNETO and AMPERES interactively. The assembly of system components was greatly facilitated using the object-mode of AMPERES. This mode allows a number of useful options (e.g. display of all the motor and magnetic bearing components, or an exploded view of the motor components). In particular, individual system components can be singled out and modified, if necessary. Figure 4. (Left) The 2D geometry of the salient rotor with its four sectorial sections and the rotor mounting disk An opto-electronic sensor above the were designed with MAGNETO 2D. (Right) The 3D geometry was generated with AMPERES 3D. magnetic bearing was added to measure the rpm during run down, since no elec- shown in Figure 4. In order to obtain a generated using the “sweep mode” of tric stator signals were available. The radial smooth cylindrical rotor surface, four AMPERES, as shown in Figure 4. Fur- air gap of only 0.7 mm requires an excel- sectorial elements were integrated into thermore, the “object mode” allows a lent dynamic rotor balancing and a fine the salient rotor. The five rotor ele- total or partial exploded view of the adjustment of the axial rotor position. ments can be fastened with the two sup- reluctance motor. The model of the This article was written by Dr. Hans K. porting discs and 12 screws into a com- reluctance motor is shown in Figure 5. Asper of Silphenix GmbH, Meilen, Switz - pact cylindrical rotor with a cylindrical When all the components of the reluc- erland using software from Integrated surface; however, in order keep the radi- tance motor were completed with Engineering Software, Winnipeg, Manitoba, al stress of the rotor within its design AMPERES, all the data were transferred Canada. For more information on the prod- limits, several layers of carbon filaments as drawings and step-mode files to the ucts used in this application, visit http:// (0.3 mm radially) were added to the machine shop. info.hotims.com/69509-321. cylindrical surface, reducing the actual air gap to 0.7 mm, which is still within the radial operation range of the magnetic bearing. The rotor geometry was modeled with MAGNETO in 2D, as shown in Figure 4. The holes for the axis and the rotor mounting screws were added. Next, the 2D rotor elements are loaded with AMPERES 3D. The volumes of all rotor parts with the four sectorial sections, two mounting disks, the hub for the rotor axis, and the mounting holes were then

Figure 5. The reluctance motor MAGNETO model with two passive magnetic bearings, three coil pairs, two stator supporting structures, and the rotor.

Motion Design, August 2018 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -744 19 Using Direct Current with Inverter Technology in Resistance Welding Resistance welding with inverter technology reduces costs by improving quality, reducing maintenance, and increasing productivity. Amada Miyachi America, Monrovia, California

esistance welding with direct current nology has led to very precise control rectification process. This cleans up the R(DC) using inverter technology re - over the DC output. In addition to this waveform and results in more consistent duces costs by improving quality, reduc- controllability, resistance welding bene- current. The capacitors do not act as a ing maintenance, and increasing pro- fits from the use of stable and durable storage medium, as in capacitive discharge ductivity. Switching from traditional electronic components. As a result, the (CD) style machines, even though they do alternative current (AC) to DC with inverter technology used today to gener- store energy during this rectification. inverters also reduces a range of facili- ate DC power now challenges AC welding BLOCK D is the switching process, ties costs and improves the process. in almost every welding application. during which IGBTs use the rectified and Finally, it provides the ability to weld new Figure 1 illustrates how the 3-phase AC filtered waveform, and switch the output materials, so it can add to a company’s power is converted to DC power, showing power on and off. The waveform shows capability or product scope. what happens inside the weld control sys- that the IGBTs produce positive and neg- The resistance welding industry has tem. BLOCK A is the incoming 3-phase AC ative pulses. The resulting waveform is traditionally used rectified 3-phase AC to power, typically ranging from 220V to 480V called a bipolar square wave. The IGBTs create DC power. This method of creat- in the United States. BLOCK B is the first switch on and off at a specified rate or ing power requires large machines and rectification stage, in which the incoming frequency measured in hertz. large transformers, and also lacks the 3-phase AC power goes through a bridge BLOCK E is the welding transformer. precise process control that many users rectifier. The bridge rectifier changes, or The bipolar square wave is fed into the are seeking. rectifies, the 3-phase AC power to provide transformer, which steps down the volt- Over the past few decades, power a DC reference voltage. As shown in the age and steps up the current. BLOCK F switching technology has gained greater waveform, this produces only positive puls- is the second rectifier, which is located acceptance as a solution. There is now a es. The rectification process has inverted within the transformer. In this stage, the long history of using insulated gate bipo- the negative half of the wave to create this bipolar square wave is rectified, produc- lar transistors (IGBTs) as power switching DC reference voltage. ing only positive pulses. BLOCK G shows devices in resistance welding, as well as in BLOCK C is the filtering stage, in which the weld head. servo drives and personal computers. capacitors filter out the noise and mini- Current feedback is configured in two The move to electronic switching tech- mize the ripple effect left over from the ways: Primary current feedback or secondary current feedback. With primary

A B C D E F G feedback, the current is sensed at the input to the transformer. When secondary feedback is used, the current is sensed

TW WELD HEAD after the transformer in what is called the S2 S1 “secondary loop.” In both cases, the control uses the sensed current to dynamical-

S2 S1

SECONDARY FEEDBACK Piston Rod Water Heater Spud A B C D E F G

SWITCH 30 AC RECTIFIER FILTER TRANSFORMER RECTIFIER WELD HEAD POWER IN (IGBTs)

Nut Welding to Bracket Stranded Copper Wire to Buss PRIMARY FEEDBACK Figure 2. Examples of welding using inverter Figure 1. Generating DC power using inverter technology. technology.

20 Motion Design, August 2018 ly adjust the output. Inverter technology responds in milliseconds rather than in welding and inverters can provide the also allows for other feedback modes, AC cycles, which is 16.67 milliseconds at answer for most welding needs. Figure 2 including automatic voltage compensa- 60 Hz. In addition, inverters can be pro- shows a variety of examples of welding tion (AVC), constant current, constant gramed in millisecond increments. applications that successfully use the voltage, and constant power. One of the The specific advantages of resistance inverter technology. key advantages of the inverter welding welding with inverter technology vary For more information, visit http://info. technology is that the feedback control from user to user; however, using DC hotims.com/69509-324.

Hydraulic-Based Spherical Robot This robot is capable of locomotion without the use of mechanical weights. Space and Naval Warfare Systems Command – Systems Center Pacific, San Diego, California

urrent spherical robots rely upon ture. Microcontrollers open and close The robot is designed to be controlled Crotating mechanical weights inside valves, filling chambers that will change through wireless technology or possibly the sphere to change the center of gravity the center of gravity and allow the robot functioned in a preprogrammed mode. of the sphere, causing the robot to roll. to move in any direction on the XY plane. The device can be equipped with various The use of rotating mechanical weights is The function of the system is based on sensors (e.g., chemical/biological sen- not optimal due to the reliance upon fluid dynamics and pressure systems, sor, ambient sensor, motion sensor, and moving parts, which can present burden- removing the need for mechanical actu- camera), depending on its intended some maintenance issues. It would be ators, and thus reducing potential points purpose. The robot’s size can vary from desirable, for certain applications, to of failure. This design provides for excel- the size of a softball to that of a large have a spherical robot that does not rely lent control over the movements of the tire, giving it a wide range of potential on mechanical weights for propulsion. robot. It is also possible for the robot to applications. This innovation allows a spherical have a lower electromagnetic signature For more information, contact Joan Wu- robot to move by use of a series of fluid as there is only one pump in the core of Singel at [email protected]; 406-994- tanks, evenly spaced on its inner struc- the device. 7705.

Ultra-Thin Capacitive Sensor Has the Least Possible Resistance to Motion This workable sensor moves with the airflow made by even the softest noises. Binghamton University, Binghamton, New York

thin and flexible sensor was devel- with some challenges. The new sensor This is a critical part of the design Aoped for sensing sounds, since it can platform provides a way to detect the because the sensors need to have a high move with the airflow made by even the motion of extremely thin fibers or films bias voltage — the voltage required for a softest noises. With the least possible resis - by sensing changes in an electric field device to operate — to be effective since tance to motion, the sensor addresses issues without the use of a magnet. It hasn’t the sensitivity of the sensor increases with with accelerometers, microphones, and previously been feasible to use capacitive a high bias voltage. many other similar sensors. The goal was to sensing on extremely flexible, thin mate- This design means that capacitive sen- create a sensor that only resists gravity. It rials because they’ve needed to resist sors, like the ones used in smartphones, needs to stay connected to the device, but electrostatic forces that can either dam- can be both smaller and more efficient. otherwise needed to move with even the age them or impede their movement. The design also provides other benefits slightest sounds or air movement. Being The new design allows the thin, flexi- important in various applications; for able to move with the air is how sensors ble sensor — which could be spider silk example, it has a nearly constant poten- are able to tell when a sound is present or any other material just as thin — to tial energy, but can also return to its and from which direction it is coming. swing above two fixed electrodes. equilibrium after large motions. Two billion capacitive microphones Because the sensor is at a 90-degree For more information, contact Ryan are produced every year, but making angle from the electrodes, the electro- Yarosh at [email protected]; 607- them both small and effective comes static forces don’t affect its movement. 777-2180.

Motion Design, August 2018 21 Make your machinema move Variable-Camber Compliant Wing The airfoil camber morphs in flight without using discrete control surfaces such as flaps. Air Force Research Laboratory, Wright-Patterson Air Force Base, Ohio

n the early years of manned flight, wing warping was used for Ilateral control of an aircraft. This technique consisted of a system of pulleys and cables used to twist the trailing edges of the wings in opposite directions. Because most wing warping designs involved flexing of structural members, they were difficult to control, and the risk of structural failure was high. As MICRO LINEAR ACTUATORSACTU aircraft further developed, wing warping was replaced by multiple, independent, rigid flight control surfaces — such as ·1 0mm-300mm stroke · 25kg+ available force ailerons, leading edge slats, and flaps — and while this · 6v-12v power supply · 15g-100g net weight approach is still in use, it is not without problems. The control surfaces create drag during use, which can result in unnecessary fuel consumption. There are also inher- ACTUONIX.COM ent gaps formed between the control surfaces and the wing structure that generate noise. Finally, fixed, independent con-

Free Info at http://info.hotims.com/69509-745 trol surfaces limit the variation in wing shape and thus the overall utility of an aircraft. To advance aircraft capabilities, a novel adaptive variable camber compliant wing (VCCW) was developed that can re-contour the airfoil camber in flight. These are flexible, often single-piece structures that change shape through elastic deformation. This distributed camber control enables a continuous wing reconfiguration that optimizes wing geometry for current altitude, air- speed, and lift-to-drag ratio requirements. The VCCW also limits separated flow and parasitic drag with seamless construction (no holes or gaps), which increases overall range and endurance of an aircraft in addition to controlling surface effectiveness and power use reductions. The wing reconfiguration also decreases aircraft noise, e.g., the flap side-edge noise, and with a seamless skin, reduces control surface gap and edge noise. Notably, the wing skin is not required to be stretchable or to slide over the ribs to change camber because bending of the ribs is the main deformation mode of the mechanism. This trait

(a) (b)

Technology Quality Service

The Variable Camber Compliant Wing Prototype: (a) Undeformed wing geometry, (b) Deformed (6% camber change), (c) Twist, and (d) Deformed (rear view).

22 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -746 Motion Design, August 2018 is desirable for manufacturing and ener- sheet, glass fiber, composite material, or to change the shape of a wing in flight gy perspectives since the attachment of other thin bendable material. allows for the combination of flight the skin is simplified, and the bending of The deformation designs make the characteristics including enhanced lift, the skin with the ribs requires less actua- compliant mechanism lightweight, low- speed, range, and maneuverability. tion energy than a surface that stretches. power, with minimal maintenance, no For more information, contact Austin The skin may also be constructed from a backlash, and longer life span com- Leach, PhD, at [email protected]; single piece of material such as a metal pared to multi-body designs. The ability 406-994-7707.

Autonomous Crop-Counting Robot This robot uses sensors, cameras, and deep learning to measure plant traits. University of Illinois at Urbana-Champaign, Champaign, Illinois

oday’s crop breeders are trying to dreds of acres and measure key traits, benchmark datasets), and the robot has to Tboost yields while preparing plants to like plant emergence or height, by hand. stay within the tight rows in the challenging withstand severe weather and changing The task is expensive, time-consuming, under-canopy environment. climates. To succeed, they must locate inaccurate, and ultimately impossible — A 13"-wide, 24-pound, four-wheeled the genes for high-yielding, hardy traits a team can only manually measure a robot was developed that is transportable, in crop plants’ DNA, a task that is need- fraction of plants in a field. compact, and autonomous. The robot, ed to accelerate breeding to meet global The lack of automation for measuring called TerraSentia, captures each plant food demand. plant traits is a bottleneck to progress, but from top to bottom using a suite of sensors Crop breeders run massive experi- it remains difficult to make robotic systems (cameras), algorithms, and deep learning. ments comparing thousands of different that can count plants auton omously: the The robot transmits the data in real time cultivars, or varieties, of crops over hun- fields are vast, the data can be noisy (unlike to the operator’s phone or laptop. POWER & SPEED IN EVERY SHAPE AND SIZE

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Motion Design, August 2018 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/6 9509 -747 23 MOTION CONTR OL CHANNEL