Manufacturing & Prototyping

Gear Shift Modeling and Analysis for Automatic Transmissions in MapleSim

In this paper, a simple dynamic physical model of an automatic transmission was created to evaluate all required forces and motion characteristics of the system during the shift process. Gear shift quality was assessed by setting different timing sequences for the engage/disengage process of the frictional components (pressure on the clutches), during the upshift process. The output torque of the transmission was analyzed under two conditions, with the timing to apply/remove pressure from the clutches being different in both cases.

Posted in: White Papers

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Development of Real-Time Battery Models for HIL testing of Battery Management Systems

The explosion in the use of electronic devices, electrified vehicles and decentralized power utilities has driven demand for rechargeable batteries. This has led to a significant increase in research investment into battery technologies to address challenges including thermal stability and battery life extension. This whitepaper outlines how such challenges can be overcome in the development of a Hardware-in-the-Loop (HIL) testing system for the Battery Management Systems (BMS) used in electrical energy storage products.

Posted in: White Papers, Electronics

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Parallel Prototyping and the Engineer’s Dilemma

R&D Engineers face rapidly shrinking development cycles and rising competitive pressures. In the high-stakes practice of regulatory compliance, balancing development costs with speed, safety and performance are critical to a product’s success. This paper demonstrates how the parallel prototyping of two materials in a heating component contributes to the return on investment of a new product launch in the medical device industry. The study addresses the verification, validation, form and fit testing relative to the FDA approval process, as well as its execution within component design, product design and pilot production.

Posted in: White Papers, White Papers

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Design and Engineering of Process Plants Based on the “Lego Principle”

Users can add automation modules or switch them off in line with requirements. Festo Corporation, Hauppauge, New York Manufacturers in the process industries need to adjust to smaller batches and different types of product in the same plant. Plants based on the “Lego principle” are designed and engineered precisely to the respective task, whether for the production of a specific product in units per time unit, or for the throughput of a specific substance in a quantity per time unit. The mechanical design of the plant as a whole is geared towards meeting specifications and guaranteeing the required performance data over the projected lifecycle of the plant. The corresponding automation is carried out using management systems comprising process-specific (control) components, operating and monitoring stations, as well as engineering stations. The entire process is centrally controlled by a single management system.

Posted in: Briefs, Industrial Controls & Automation

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Electrochemically Enhanced Mechanical Polishing of Optics

A combined method results in a significant reduction of manufacturing time for optical components. Marshall Space Flight Center, Alabama Optical component fabrication using metals or ceramic materials involves many grinding and/or machining and polishing steps to achieve the proper form to the tolerances of imaging or photonic focusing instruments. These instruments range from infrared sensors, through visible and ultraviolet, to X-ray and even thermal neutron focusing. Conventional manufacturing methods require many days or even months of precise polishing to improve selected areas of the component.

Posted in: Briefs

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Expendable Cooling System for Venus Lander Concept

The concept could be applicable to the trucking industry to provide temporary cooling where power is not readily available. NASA’s Jet Propulsion Laboratory, Pasadena, California This innovation is a concept for a novel thermal architecture that would enable a day-long surface mission on Venus. A Venus lander mission could last much longer than a few hours on the surface of the planet by absorbing heat from the Venus environment, and from the electronics within the lander, by using an expendable fluid cooling system. The fluid would evaporate in the structural shell, absorbing heat coming from the ambient environment, keeping the shell relatively cool compared to the ambient temperature. The evaporating fluid would create a liquid flow from a reservoir used to cool electronic components within the lander. The liquid reservoir must be contained within the lander structure to serve as a heat sink to maximize the lander lifetime on the surface. A pressure tank would be used to bring the fluid to a point where it could boil and vent into the Venus atmosphere.

Posted in: Briefs, TSP

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Rapid Quench Furnace for Processing Powder in an Inert Environment

The system is able to process particles and/or powder, preserving inert environmental conditions throughout. Langley Research Center, Hampton, Virginia Ongoing work in the development and characterization of sensory materials requires the development of shape memory alloy (SMA) powder or particles. These are embedded in structural material so that the progression of localized damage that occurs during fatigue crack growth will produce an audible acoustic emission (AE) as the SMA transforms from an austenite phase to a martensite phase. In order to set the shape memory effect in these particles, the SMA must be solution-treated (ST) to produce the austenite phase, and rapidly quenched to or below room temperature to preserve the austenite phase at room temperature.

Posted in: Briefs, TSP

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