Miniature IP68 Rated Data Recorder

The new SLICE IP68 data acquisition system from DTS (Seal Beach, CA) is designed to capture physical signals in challenging environments. Targeted at applications with size or mass constraints, SLICE IP68's 60 × 60 mm footprint makes it easy to embed in most test articles. The rugged housing is impervious to shock, water and dust, making SLICE suitable for testing in non-pressurized environments with inclement weather or with quick altitude changes that result in condensation on the instrumentation.

SLICE features onboard signal conditioning, supporting a variety of external sensors including bridge and IEPE transducers for gathering critical measurements like acceleration, displacement, strain, pressure, temperature, voltage and more. Data direct-writes to 16 GB internal flash memory. The 3-channel sensor input layers are stacked and configurable up to 24-channels. Higher channel count systems are created by daisy-chaining SLICE stacks together.

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2000°F Inert Atmosphere Bench Furnace

No. 1044 is a 2000°F (1093°C), inert atmosphere bench furnace from Grieve (Palatine, IL) used for heat treating. Workspace dimensions of this furnace measure 12“W × 18“D × 8“H. 6 KW are installed in nickel chrome wire coils supported by ceramic plates.

This Grieve bench furnace features 5” thick insulated walls comprised of 1” of 2600°F ceramic fiber and 1” of 2300°F ceramic fiber and 3” of 1900°F block insulation. Features include a vertical lift door with gas spring counter balance and inert atmosphere construction, including a continuously welded outer shell, high-temperature door gasket, sealed heater terminal boxes, inert atmosphere inlet and inert atmosphere outlet. Additional features include an inert atmosphere flow meter and normally closed solenoid valve on atmosphere inlet.

Controls on the No. 1044 include a digital programming temperature controller and manual reset excess temperature controller with separate contactors.

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SELF-LOCK™ Threading Tools

Emuge Corp. (West Boylston, MA) a manufacturer of high-performance taps, drills, end mills and other rotary tools, recently announced its SELF-LOCK integrated locking system. The Emuge thread locking feature is integrated in the internal thread and has a modified profile with a 30-degree ramp surface in the direction of stress, which provides the self-locking effect. In an ideal screw connection for high-stress situations, where there is a standard external thread in an Emuge SELF-LOCK internal thread, the internal thread yields a self-locking screw connection that can be used repeatedly.

Emuge SELF-LOCK Threading Tools work with standard external threads (screws) with tolerance class “medium”. Internal threads can be produced with Emuge taps, cold forming taps or thread mills.

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Thermal Interface Material

Fujipoly® (Carteret, NJ) has introduced a new thermal interface material that also absorbs a wide range of unwanted electromagnetic energy. The tacky, gel-like consistency of Sarcon ® EGR-11F makes it easy to handle and apply without requiring additional adhesive. When placed on top of a heat source such as an IC chip, the compliant material fills any unwanted air gaps allowing for more efficient transfer of heat.

Sarcon® EGR-11F also provides excellent shielding effectiveness across a broad frequency spectrum while exhibiting a thermal conductivity of 1.0 W/m°K (ASTM D 2326) and a thermal resistance of 1.05°Cin2/W at 14.5 PSI. This material is available in three sheet thicknesses (0.5, 1.0, 1.5 mm) up to a maximum dimension of 300 mm x 200 mm. Sarcon® EGR-11F can also be ordered in die-cut form to fit almost any application shape. Fujipoly's new material is suitable for environments with operating temperatures that range from -30 to +120°C and exhibits a UL94 flame retardant rating of V-0.

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Metal-Spinning Machines

MJC Engineering (Huntington Beach, CA) is a custom machine tool builder specializing in metal-spinning machines for such applications as sheet spinning, flow forming, wheel spinning and rotary forging. The company recently built a series of metal-spinning machines for GKN to produce lip skins for the engine housings on Boeing 777X and 737MAX aircraft. Using advanced CNC from Siemens and robotic handling technology, plus its proprietary servopump-controlled Green Power™ hydraulic power unit, the team at MJC devised a unique solution to an engineering challenge.

The key aspects of the solution consisted of finding a way to spin-form production run components out-of-round by 8” to 9” in various aluminum alloy blanks measuring up to 270” diameters and 5/8” thickness, while holding tight tolerances to be verified by thermo-imaging cameras and fed back by the CNC for accuracy tracking, plus integrating the heating torch for in-process adjustments.

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High-Energy CT Inspection Service

Jesse Garant Metrology Center (Dearborn, MI) announced the launch of its new high-energy industrial CT scanning service. The system is the first of its kind that pairs a 3 MeV cone-beam x-ray source with a large format 2k × 2k flat panel digital detector. It will be able to accommodate rapid inspection of mid-size parts, up to 44.5 inches in diameter by 63 inches in height. The new capabilities will directly support the aerospace industry, allowing for a feasible internal inspection in 3D and 100% validation of production parts.

The unique system offers advantages for non-destructive testing, including a drastic reduction in inspection time for scanning mid-size parts and assemblies. While existing high energy CT inspection services may take 416 hours to complete scans, the new system is able to scan parts in less than an hour. The service will also be beneficial for inspection of multi-material parts and assemblies, allowing for cleaner separation of internal components, and inspection of higher density materials not possible with lower energy micro CT systems.

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Non-Contact Measurement Systems

Vision Engineering (New Milford, CT) announced the launch of the Swift PRO series, non-contact measurement systems designed to deliver fast and accurate 2 and 3-axis measurements. The Swift PRO series includes Swift PRO Duo, Swift PRO Cam and Swift PRO Elite.

Based on Vision Engineering's Swift Family metrology products, the Swift PRO is available with optical, video or both optical and video measurement capabilities. All optical systems are built using Vision Engineering's patented, Dynascope® technology, which gives operators an eyepiece-less and ergonomic viewing experience. The video systems are equipped with a high definition video camera and easy to use software. The Swift PRO is available with either an 8” × 4” (200mm × 100mm) or 6” × 4” (150mm × 100mm) measuring stage.

New features built into the Swift PRO series include illumination enhancements, an integrated Z-axis tape encoder, and a reduced number of system components and cabling.

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24-Bit Data Acquisition System

Saelig Company, Inc. (Fairport, NY) announced the availability of the Teledyne LeCroy SAM40 Data Acquisition Unit which provides up to 24 analog or digital input channels for low frequency (e.g. sensor signal) acquisition and analysis when connected to a 4 or 8 channel Teledyne LeCroy 12-bit resolution high-definition oscilloscope. The SAM40 offers high precision and accuracy 24-bit resolution measurements for signals up to 40 kHz bandwidth with a sample rate of 100kS/s. Operation is easy with plug-and-play support from a 4 or 8 channel 12-bit resolution Teledyne LeCroy oscilloscope. The SAM40 simply connects to the oscilloscope with a USB2.0 cable for data transfer and control/trigger commands, and with BNC cables for clock and timebase synchronization.

IEPE/ICP sensors are also supported with the built-in internal 4mA bias supply. The SAM40's features include bandwidth limiting, with settings as low as 100 Hz to reduce visible noise, and adjustable gain in 1/2/5 steps, to accurately acquire and display a wide range of signal levels. All channels have 24-bit resolution, stored in 32-bit floating point format, with 0.05% total accuracy.

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Boring Insert Selector

Allied Machine & Engineering (Dover, OH) recently announced their newest online tool: the Boring Insert Selector. This resource saves time by simplifying the boring insert selection process and ensures machinists are given the correct boring insert for each job's unique details. Rather than hunting through multiple catalog pages in order to narrow the field of possibilities, this online tool guides the user to the correct boring insert for the job in just six easy steps.

Allied's Boring Insert Selector allows end users to select job-specific criteria from drop-down menus. Criteria include roughing/finishing, shape, substrate, form, nose radius, and material to be machined. If users are unsure which nose radius to select for their finish boring application, this tool provides tips on formulating that as well. Once all criteria are selected, users simply click “find insert” to reveal the best choice for their unique boring application. The online tool also provides an image and link for more detailed information and pricing.

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Fluid Cell Sheet Hydroforming Press

Beckwood Press Company (St. Louis, MO) was recently awarded a contract by H&R Parts Company to manufacture a Triform model 24-5BD fluid cell sheet hydroforming press. With a 24”-diameter forming area and 5,000 PSI, the new Triform will support H&R's aluminum aerospace part production.

During the fluid cell process, a pressurized rubber diaphragm filled with hydraulic oil shapes sheet material against a single tool. This evenly-distributed pressure results in net shape part production, virtually eliminating the need for hand-finishing. Due to the universal nature of the Triform diaphragm, which conforms to any shape within the forming chamber, the need for expensive mated male/female dies is eliminated. Additionally, multiple parts can be formed in a single cycle, as long as the tools and blanks fit within the forming area.

Utilizing a stationary blank holder in conjunction with a single tool, H&R will be able to form parts with closed corners and severe curves in 20 seconds or less without the need for secondary hand finishing. The advanced engineering and unique pressure containment system on the 24-5BD significantly reduces the press size and weight without sacrificing structural integrity or durability, and the flush-floor design uses minimal floor space.

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Frame Grabber

BitFlow (Woburn, MA) has responded to the demands of the robotics industry by introducing frame grabbers based on the CoaXPress (CXP) machine vision standard, currently the fastest and most powerful interface on the market. In robotics applications, the five to seven meters restriction of a USB cable connection is insufficient. BitFlow CXP frame grabbers allow up to 100 meters between the frame grabber and the camera, without any loss in quality.

BitFlow's latest model, the Aon-CXP frame grabber, is engineered for simplified integration into a robotics system. Although small, the Aon-CXP receives 6.25 Gb/S worth of data over its single link, almost twice the real-world data rate of the USB3 Vision standard and significantly quicker than the latest GigE Vision data rates. The Aon-CXP is designed for use with a new series of single-link CXP cameras that are smaller, less expensive and cooler running than previous models, making them ideal for robotics.

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Compact DIN-Rail Filter

SCHURTER's (Santa Rosa, CA) new FPBB RAIL is a slim double-stage, single-phase filter, measuring only 25 mm in width. The space-saving design integrates an optional fuseholder or circuit breaker. Additionally, an overvoltage varistor is available in all three variations.

The FPBB RAIL is designed for currents from 1A to 16A with a maximum of 125 / 250 VAC and 250 VDC according to IEC and UL / CSA standards.The series is ENEC and cURus approved. The filter version can be used over a wide temperature range from -40°C to 100°C. Versions with fuseholder and overvoltage protection operate over a temperature range of -40°C to 85°C, while those with a circuit breaker are rated for a range of -5°C to 60°C.

Typical areas of application for the FPBB RAIL are industrial or machine controls, where downsizing and possible relocation of the control cabinet to a more accessible area can be realized. A backplane screw mount version is also available for further flexibility in design. Further features include cage clamp terminals for particularly efficient, fast wiring.

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Portable Emissions Analyzer

The new E9000 emissions analyzer with Heated Sample Line from E Instruments International LLC (Langhorne, PA) is a complete portable system for EPA compliance level emissions monitoring and testing. The E9000 is ideal for regulatory & maintenance use in burner, engine, turbine, and other combustion applications.

Features of the new E9000 emissions analyzer include: Up to (9) total gas sensors; electrochemical sensors for O2, CO, NO, NO2, SO2, H2S; NDIR sensors for CO2, CxHy (HC), high CO; internal thermoelectric chiller with automatic condensate removal; internal data storage memory (16,000 tests); low NOx and true NOx capable; heated probe head and sample line; android app to monitor and save data; and software with automatic data logging.

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Composite Applications Software

CGTech (Irvine, CA) is now shipping the next major release of VER-ICUT Composite Applications: VERICUT Composite Programming (VCP) and VERICUT Composite Simulation (VCS). VERICUT Composite Applications are currently being used to program and simulate automated fiber placement and tape-laying machinery from machine tool builders. Many features have been added in version 8.1, including a new “Laminate Manager” which automates file management and processing for the entire laminate. This release also includes a completely redesigned graphical interface, enhanced reports, laminate analysis tools, advanced collision avoidance, and more.

VCP starts by reading in CATIA, NX, Solidworks, STEP, or ACIS surface models. This data can be combined with information from composite design packages such as Fibersim and CATIA Composite Workbench. VCP adds material to fill ply boundaries according to user-specified manufacturing standards and machine limitations. VCS reads CAD models and NC programs, either from VCP or other composite layup path-generation applications and simulates the sequence of NC programs on a virtual machine. Material is applied to the layup form via NC program instructions in a virtual CNC simulation environment.

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Flexible Ducting

AVS-SYS (Cheshire, UK) announced that its ultra-lightweight aerospace flexible ducting, insulated flexible ducting and flexible muffler (silencer) ducting have all passed milestone flammability tests. Three samples of eight different configurations of ducting were tested, each subjected to 12-second vertical Bunsen burner tests at a UKAS accredited test facility and each passed the FAR/CS-25 25.853(a) Amdt.17 App.F Part. I(a) (1) (ii) & (b)(4) flammability testing.

The primary use of the aerospace flexible ducting is in the low-pressure air distribution system, which is part of the Environmental Control System on-board aircraft. The flexible ducting comes in a range of lengths and diameters with various cuff ends to provide all the possible options needed across the full spectrum of aircraft types. Both single ply for positive pressure and twin ply for negative pressure applications are available.

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Gaging Software and Modules

Mahr Inc. (Providence, RI) announced the launch of MarWin Millimar Cockpit Software and Millimar N 1700 Modules, an interactive new MarWin-based gaging software and modular-based gaging system that allow users to configure and implement simple to complex gaging solutions. The software is already set up and configured by on-screen measurement icons, so users are not required to have specialized programming knowledge. The various input modules are stackable plug-and-play devices which are immediately recognized and implemented.

Millimar gaging modules allow multi-gage measuring devices to be designed and assembled for the widest possible range of applications. Modules are available for high-performance LVDT and/or air applications along with I/O modules for basic controlling functions set through the Cockpit Software. A USB module ties all the modules back to the computer's USB port with a simple one-wire connection.

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Cloth Insulators

BriskHeat (Columbus, OH) has announced a new line of Silver-Series Cloth Insulators. Silver-Series Insulators are a configurable system of cloth insulators that feature durable high-temperature cloth, 1 “-thick needle-punched fiberglass insulation, and hook and loop closures for easy installation and removal.

Designed for use in a wide variety of industries including petrochemical, aerospace, construction, oil and gas, plastics and many others, versions of the insulators are available for straight pipes, valves, elbows, “T”-connections, and flanges. Custom shapes and sizes are also available. Examples of how the insulators might be used include wrapping pipes, tanks, vessels or steam lines to maximize thermal efficiency. The insulators save energy and improve safety by protecting users from burns.

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Server Blade

Artesyn Embedded Technologies (Tempe, AZ) has launched a new packet processing and high-performance server blade, the ATCA-7540, based on dual Intel® Xeon® Scalable processors (codename Skylake). The ATCA-7540 provides a migration path and future-proof platform for defense applications in air/shipborne data centers, ground control stations, network data analytics, ad-hoc mobile networks and other C4ISR tasks.

The blade design features two new Intel Xeon Gold or Intel Xeon Silver processors, allowing for scalable performance. Data paths to main memory and I/O are highly optimized by the use of six memory channels per processor that support DDR4 memory. Memory capacity can scale up to 384 GB using 12 VLP DIMM sockets.

The CentOS operating system will be available for the Artesyn ATCA-7540 and the blade is designed to support other open source and commercial operating systems thanks to pre-installed BIOS, IPMC firmware and Artesyn's Basic Blade Services (BBS) software. The blade will also support RedHawk Linux RTOS. The ATCA-7540 can be configured for virtualization using Linux KVM or VMware ESXi, and is designed to operate with the Intel® Data Plane Development Kit (DPDK).

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Aerospace Manufacturing and Machining Magazine

This article first appeared in the June, 2018 issue of Aerospace Manufacturing and Machining Magazine.

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