Wind Energy Equipment Testing

Some friends were discussing the recent visit of Department of Energy Secretary Steven Chiu to Clemson University to deliver a check for $45 million to start a test facility for horizontal wind turbine gearboxes.  It seems that there have been a number of gearbox failures in recent years that suggest a wider problem that will need to be solved in order for wind energy to become as reliable and cost effective as promised.  Gear boxes are failing in the range of 10 years of operation, and occasionally, sooner than that.

This is not difficult to understand.  The forces acting on the gearbox are huge.  On the input side you have 3 blade propeller with blades that are now approaching 200 feet in length.  I don’t care how light weight they are, carbon fiber epoxy or Kevlar or whatever, the forces are tremendous.  In addition the blades have to rotate to take them out of the wind when the wind is too fast for the system to operate.  So there are actuators at the base of the blades adding to the weight and mechanical complexity.

Then there is the intermittency of the wind itself.  This can manifest itself as bursts of wind or winds of different speeds hitting the same rotor.  Which can lead to all kinds of impulse loads on the gearbox.  Gear teeth becoming momentarily unloaded and loaded in response to the wind.  This is actually one of my favorite “Stump the Band” questions for mechanical engineers; what is the formula for the shock load of gear tooth reversal?  It’s big, whatever it is.  And the shock load of the propellers is driving the gearbox against a high inertia load, the generator.  So there is a lot of resistance to overcome.

But the really scary part is that the gear systems are often in the range of 30,000 pounds in weight.  And they are mounted on metal masts at heights of 1.5 times the blade length.  So that would be 300 feet up in the air in the case of a system with a 200 foot blade.  Making the replacement of a failed gearbox a bit more complex than dropping the transmission out of a car, for example.  Especially since most wind farms are in very remote locations where the land is cheap and the wind blows some of the time.

This lead the Department of Energy to put out requests for proposals to address the technical question of providing the industry with a resource to help in the design of gearbox systems with much higher reliability than the current designs.  Total cost of this effort, approximately $100 million dollars.  The proposed test facility is targeting 20 megawatt power handling capability, or approximatley 27,000 horsepower depending on the exact rpm of the system.  This is an incredibly big piece of machinery.

Clearly, gearbox technology has to get better for the wind industry to continue to prosper.   I wonder if we are putting a band aid on a technology that is fundamentally flawed.  Maybe we need to be concentrating on the next generation of the technology and improving the cost performance by an order of magnitude.  Surely we can do better.

Scientists Create First-Ever Circuit Powered By Light

For the first time, scientists have created a circuit that can power itself, as long as it’s left in a beam of sunshine. Created by scientists from the University of Pennsylvania, the world’s first photovoltaic circuit could eventually power a new line of consumer devices or even model the human brain.

Right now the creators can only coax minuscule amounts of electricity from their photovoltaic circuits, far too little to power consumer electrical devices, although those amounts could quickly skyrocket.  There are plenty of other ways they say that they can squeeze more electricity from light. Right now only about 10 percent of the photovoltaic circuits on a glass side work. Increasing that number will boost the power output.  Another way to get more power is by turning their 2D structures into 3D structures. Stacking multiple layers of light-collecting and electricity-using circuits would also boost power.

The photovoltaic circuit is a scientific breakthrough, not a technological one. These new circuits will most likely never replace their silicon counterparts.

Photovoltaic circuits could be ideal for other applications, however, such as powering tiny robotic devices or running computer calculations at the speed of light.  Far into the future, these circuits could even be used to set up as artificial neural networks that could model the brain.

At their most basic, computers represent data as on or off, a “0″ or a “1.” Using light instead of electrons, these photovoltaic circuits could store data from, say, one, two, three or four. Each number would correspond to a certain wavelength or color of light — red, green, blue and yellow, for example. To model the human nervous system, each color of light could correspond to a different neurotransmitter, say red for dopamine and blue for serotonin.

The potential applications of the technology are huge, but will take years to develop into any kind of practical equipment.

www.news.discovery.com

New Motion Feedback

The field of motion control is heavily dependent on the feedback device.  There are a world of issues encompassed in this statement.  But I will skip the majority of them and jump to the conclusion that magnetic encoder technology has long been a favorite of mine as a potentially ideal solution for a number of reasons.  Magnetic position technology tends to be more resistant to environmental problems such as temperature, dust, dirt and humidity.  Since all motors are heat producing systems, temperature restrictions for feedback technology can be a problem.  And since electric motors are frequently found in environments where there is dust, dirt and humidity, magnetic feedback would be ideal.

On the other hand, magnetic feedback has been complex and expensive in the past.  Resolvers require high precision windings in the sensor and precision power supplies to excite them.  Can you spell “expensive”?

Enter the Hall sensor.  In spite of the fact that the Hall Effect has been understood since 1879, the use of the technology has only recently become widespread with the fabrication of semiconductor level Hall devices.  The Hall sensor as a transistor found very popular application in sensing the three phases of brushless dc motors’ permanent magnet rotor.  The bldc motor technology was essentially impossible without this crucial piece of technology because in the early versions of the control, it was impossible to start the motor without knowing which phase to energize.  This has been less of a problem with the advent of low cost, high performance microprocessor controls that are able to run brushless dc motors with or without Hall sensors.

New arrangements of the Hall devices into arrays with greater capabilities is where the Hall effect technology intersects the position feedback technology.  The Hall arrays are capable of sensing small permanent magnet domains on rings that permit rotorary position to be sensed in either analog or digital form.

While there are a number of suppliers of Hall sensing arrays for motion control, a couple of new twists have been added.  The Timken company has added some new features to the Hall array that have additional benefits.  Among them are the ability to program the numerical value of the digital output, which can be a very helpful feature that eliminates fractional remainders and rollover error in control systems.

In addition, Timken is introducing a new linear version of the technology which is a real first for the motion community.  Most linear motion is the result of converting the rotary motion through a linear mechanical device, either a belt or leadscrew.  But the control system is measuring the position from the feedback  on the motor that’s driving the system and not on the load.  So the mechanical error of the leadscrew or belt is the limiting factor in high performance linear.

And to make the new magnetic feedback really interesting, it is comparable in cost to conventional optical encoders.  Which is really going to create some new opportunities for everyone in the motion control field.

DASH, The Robotic Cockroach, To Save Lives In Haiti

UC Berkeley’s Department of Electrical Engineering is developing mini-robots to help locate earthquake survivors easily, cheaply, and quickly, and without jeopardizing the lives of rescuers.

First Robotic Radical Cystectomy Deemed a Success

The first first robotic radical cystectomy, a surgical procedure to treat invasive cancer of the bladder, was recently performed at Saint Joseph’s Hospital of Atlanta. Dr. Rajesh Laungani, Director of Robotic Urology at Saint Joseph’s, performed the minimally-invasive surgery.

Invasive bladder cancer has a very high mortality rate and generally results in death if not treated. During a radical cystectomy, the entire bladder (and prostate, if the patient is male) is removed. According to Laungani, performing this robotically allows for a minimally invasive approach. The advantages include less blood loss, less pain, and quicker recovery. Just as importantly, it provides comparable rates of cancer cure as compared to more traditional surgery.

In 2004, Saint Joseph’s Hospital in Atlanta was designated as the exclusive training center in the Southeastern United States (Georgia, Alabama, Florida, South Carolina and Mississippi) for robotic surgical systems. Since that time, Saint Joseph’s has become the world-wide site for surgeons to train on robotics.

www.stjosephsatlanta.org

Innovation and Growth in Robotics

The robot industry has gone through some interesting changes over the years.  Most of the companies that were involved in the start of the real robot revolution are gone, unable to meet the extraordinary cost reductions that were sure tocome in order to make robots cost effective in most industries.  The biggest lesson, in my opinion, was the idea that robots had to be narrowly defined in terms of their application.   There was a time where there were only a few companies with the control technology to be able to make the multi-axis coordination work correctly.  So every application had to be programmed from scratch and the learning curve was huge.

The fact is that a welding robot is nothing like a Cartesian robot for electronic assembly.  And part of the learning curve of the industry was understanding what applications to focus on.  This first big reality set in when many companies began to compete for welding applications because the automotive market  opportunity was huge.  And just figuring out one application was a big enough task that it consumed most of the development resources available in  companies like GE and ABB robotics.

Consider the huge learning curve that has taken place in 35 years.  Medical robots have matured to the point where orthopedic surgery by a robot is faster and more precise than the best surgeons.  Researching the human genome would have been impossible without the high speed sample management systems of bio-assay robots.  And autonomous robots have searched the inside of volcanoes, taken samples on the moon and roamed and photographed Mars.  Pretty impressive.

Consider the forecast for the future of robotics. Motors and controls have become incredibly sophisticated and costs have dropped dramatically.   Computing power has increased to the point where memory and processing costs are almost trivial.  The First Robotics Competition is bringing 150,000 school children into the field of robotics through its programs with schools all over the US.  And the knowledge base and experience is so pervasive that we have Lego making teaching systems for grade school children to begin to get exposure to robotics.

Among the amazing developments, Barrett Technology has an anthropomorphic arm and “hand” gripper that is designed to low force, low power consumption and safe enough to be in proximity to humans.  The Robots and Mechanisms Lab at Virginia Polytechnic has demonstrated many new solutions to common problems of robot locomotion culminating in the Darwin soccer playing robot that operates autonomously.  Their goal?  Team Darwin wants to be able to compete with human soccer players by the year 2050.

With this kind of innovation, the future of robotics is going to be great.

Magnetics 2010 and Motion, Drive & Automation

There is a small industry conference that takes place every year with a lineup of industry experts that is top notch by any standard.  It’s called the Motion, Drive and Automation Conference put on by E-Drive magazine.  This year it is located at the Disney Hilton Resort in Orlando and is taking place on January 28 & 29.   The conference includes a wide range of industry experts from many fields of advanced electric motor design, advanced motor control concepts, power semiconductors and state of the art motor testing system.  There will be a lot of technical and product presentations that showcase leading edge technology in electric motors, precision gear reducers, new technology for motion sensing, and a number of improved power semiconductor devices for the motor control industry.  This is a great place to get up to date on the latest technology that will impact of motor and control technology across many industries over the next few years.

In addition, the Magnetics 2010 Conference will be running concurrently at the same venue.  Magnets are a strategic material without which many motors would simply not operate.  In the ever-changing motor industry, there is always a new design that seeks to make an enhancement over previous solutions, or introduce a new solution to old problems.  Declining prices for Neodymium Iron Boron magnets over the last few years have created a number of novel design shifts which have been instrumental in bringing more varieties of permanent magnet machines into the forefront of motion control and mechatronic technology.  To the point where over the last two years a resurgance of permanent magnet rotor designs have been created to improve the energy denisty and lower the cost of specialty motors in washing machines and air conditioning compressors.

This last development, combined with the forecast increase of hybrid electric car sales coming this year, are expected to increase the sale of permanent magnets by 10-15 percent by 2011.  That’s a staggering jump in a market that is almost exclusively supplied by China.  And there is no assurance that China can meet the forecast production.

The US Department of Commerce usually has a say in the sale of products or businesses to foreign countries that are deemed to be strategic or sensitive technology.  In fact, I got stuck in a situation where my employer was told specifically that we could not sell a CNC controller to a Korean customer.  That’s pretty small potatoes compared to controlling the supply of permanent magnets which influences billions of dollars worth of electric motors manufactured and sold all over the world.  So it strikes me as a little odd that the sale of Magnequench to its current owners, Neo Materials, was completed without a much discussion. leaving the US without a domestic magnet supplier.

There will surely be a lot of discussion about this situation at the conference, and I will be in attendance to get the latest information on the subject.  So look forward to a review of the conference in an upcoming post.

Multi-Touch ‘Resistive’ Touchscreen Controller Chip

As the latest high-tech devices such as smartphones, mobile internet devices and netbooks adopt multi-touch touchscreens to support increasingly sophisticated ‘apps’ and games,STMicroelectronics has introduced a multi-touch ‘resistive’ touchscreen controller chip to optimize the Bill of Materials of the electronics supporting this advanced capability. The STM32TS60 is the first member of ST’s new STMTouch family, which offers a broad portfolio of solutions including multi-touch devices and proximity and touch-key sensors.

The new multi-touch controller detects up to ten simultaneous touches with fingers, nails or stylus, enabling application designers to replace complex menu sequences with more direct and natural user controls. Actions made easier with multi-touch capabilities include browsing and selecting options, handwriting and data entry, arranging and sizing windows, picking up and dragging images, and fast and intuitive game play. Other abilities include drawing pictures, using touch pressure to adjust line thickness.

Employing resistive touch-panel technology, the STM32TS60 controller offers customers a real alternative and complements the recent industry trend for using capacitive touch technology. Resistive technology is a cost effective and mature high-volume solution that has seen dramatically improved performance over the past few years in terms of durability and display transparency. In addition, it easily overcomes EMI (electromagnetic interference) noise issues, which can be an inherent limitation with alternative touch technologies. Resistive technology is already widely used in PDAs and similar touch-enabled devices and the screens are readily available in standard LCD sizes and at competitive prices.

The new chip combines the company’s STM32 microcontroller architecture with PMatrix^TM Multi-Touch technology from ST‘s partner Stantum to achieve fast response times while minimizing system complexity and component count.

The STM32TS60 single-core microcontroller is an added-value solution compared to other expensive multi-core processor or digital signal processors (DSPs) requiring specialized programming expertise.

The STM32TS60’s high EMI immunity makes it suitable for use in multi-function wireless products such as cellphones, notebook PCs, netbooks and mobile Internet devices. Moreover, its low power consumption helps to maximize operating times and recharge intervals, and is a direct benefit of the STM32’s energy-saving design features and ARM® Cortex™-M3 processor conceived for power-sensitive embedded applications. In addition, very-low-power idle mode with ‘wake-up on touch only’ helps further extend mobile battery life.

The STM32TS60 is housed in a 7 x 7mm 144-pin UFBGA package, and is now sampling to lead customers. Volume production is expected for Q2 2010.

www.st.com

Inventing Industry in the (near) Future

The future of the US economy, and our future as an industrial power will be the result of our cumulative creativity.  New industries will be the result of new ideas, new technologies, new thinking.  It’s gratifying to see programs like the First Robotic Competition getting 215,000 junior high school and high school students exposed to and involved in robotics.  Problem solving, finding solutions, getting their creativity flowing to make a box of parts into a working machine with real world performance.  It will be even more interesting to see what those same kids will be into 5 to 10 years from now as they begin their careers in the many technology pursuits they are likely to follow.

Technology is a major driving force in the economy.  The ability to create whole new industries that have never existed before.

And there is a second driving force, sometimes made less obvious by the flash of the latest technical breakthrough.  Cost.  What is the relationship of cost to the development of industry?  As costs decline volume goes up.  Steel manufacturing per man year of labor increased 500% during a period of intense competition between the US and Japan.  And interestingly, one of the breakthroughs was the creation of the “mini-mill” which could produce specialty steels more cost effectively by making them in smaller batches.  Sometimes the solution is counter intuitive.  The steel industry was all about increasing batch size.  But serving the market with more complex products turned out to be easier with smaller batches, ultimately increasing overall sales and defending the US market to some extent from foreign competition.

Are there other cases where innovation was economically driven?  In the machine tool world the majority of manufacturers develop bigger and more complex machines so that a single machine can handle any operation.  This complexity tends to drive costs up quickly.  So the tendency is to find high performance machine tools costing hundreds of thousands of dollars.  In contrast, the HAAS company re-invented the machine tool business by focusing on making a low cost, high quality machine tool that many shops could afford to buy.  They were one of the first companies to have several models of machine tool in the $50K range.

They did it by concentrating on the economics of a machine tool that was profitable in operation.  That means a machine with a low cost to purchase, low operating and maintenance costs, and sufficient precision to meet the requirements of most operations.   In order to reduce their machine cost they had to develop their own controls platform.  They restructured everything in the design and manufacture of the CNC system to meet the cost objective.

In act, they are so successful, that HAAS is the largest CNC company in the western world.

Many similar situations exist in other industries.  In small plastic parts manufacturing there are a number of breakthroughs that have created lower cost parts in smaller batches based on innovative new tooling systems.  In metal fabrication there are new process like thixotropic molding and metal injection molding that have been developed to lower the cost of metal goods by making parts at lower costs.  These solutions are focused on reducing costs and other barriers to the entre of new products like tooling costs and minimum batch sizes.  And they represent major new markets that were not possible in the past, because they are focused on the economics of the industry they serve.  Decreasing the cost of entry and the cost of part manufacturing opens up new markets

So inventing the future can be technology.  Or as it can be economics.   It’s all innovation.  And it’s all about delivering value.

The Road to Recovery

Economic recovery, job creation, whatever you want to call it, everyone is trying to figure out how to get employment numbers back up and get the economy back on track.  Seems that the situation is pretty severe, and we’ve managed to export it to all of our trading partners.  But there is controversy over the information being reported.  The news is in the position of impacting the tone, so they can make things sound bad, or not, depending on who’s data they use and how they phrase their comments.

Many analysts have commented that the reporting of employment data in the US has been manipulated over the last few years and, for example, there is a whole category of people who are unemployed and are not being counted because they are assumed to have quit looking for work.  (How’s that for cynicism)   And China has been accused of artificially holding it’s currency value low in order to minimize the impact of decreased exports.   Interestingly, US exports are up significantly due to the weak dollar, so there’s at least some silver lining to the clouds of an economic downturn.

But the real road to recovery is based on real value.  Technology is great, it enables a lot of new product concepts that make our lives more convenient.  But the root is in the value that is delivered.  That value can be something compelling, like the iPod, which offers the convenience of incredible portability and simplicity in delivering entertainment media, or a major improvement in the energy storage capacity of batteries which makes hybrid cars possible.  The value that a product delivers is what makes it attractive and drives a customer to own it.

This means that technology cannot be dissociated from it’s economics.  The electric car is still a challenge because a cup (about 20 cents worth) of gasoline contains enough energy to move a 2 ton car down the road to the gas station when you’ve run out.   Which is a very cost effective exchange instead of you and several of your friends pushing your SUV to the next station to fill up.  So an electric car should cost about the same to operate as a gasoline car unless there are many people who are willing and able to pay a premium to drive electric.  And it’s getting there, and there are quite people who will pay the premium.  About 300,000 a year now.

But there is no product on the market that is immune to improvement.  So the thing that will really get the economy moving, and get people working, is product development.  Any improvement that enhances the value of a product is important to the success of the US as a nation.  That means everything.

That’s why the current dialog in the alternative energy sector is so important.  Significant improvements such as direct drive generators in the wind market and lower cost tracking technology in solar offer big advantages in the overall economic performance of these technologies.  This will reduce the amount of tax dollars that have to be used to subsidize the emerging industries.  And I’m betting there are a lot more improvements to come.

So the road to recovery is improving value.  In any product, in any market.  And that’s change we can really count on.

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