Archive of articles written by Larry Boulden.

Larry Boulden Larry Boulden :: Staff Editor Larry has worked as a design engineer, engineering manager, and engineering communicator. He holds M.E. degrees from New Mexico State University and has practiced engineering with firms like Lockheed, the Atomic Energy Commission, and the U.S. Army. In his 38 years as a communicator, Larry has been a writer, editor, and publisher of engineering magazines, and is a four-time winner of Neal Awards for Outstanding Journalism. He has also ghostwritten eight books on engineering subjects.

Experts speak out for Model-Centric CAD

Larry Boulden
November 15th, 2008.

Consultant Jennifer Herron has written a great article on Model-Centric CAD.  The article, slated for our December 2008 issue, stresses the benefits of using CAD to develop 3D models of your design, rather than settling for 2D CAD drawings.

Here is some of the expert reaction to what she’s saying:

“We are used to seeing things in our life in three dimensions. Using model-based design to create, view, study, assemble and analyze our designs eliminates time, money and mistakes spent on two dimension translation.”

- Bob Saunders, Synergy Technology, Inc. (www.synergytec.com)

And more…

 ”To produce more complex designs without increasing labor, hardware companies must have self-organized parts, data, analysis and trade studies so individuals can focus on the design challenges.”

                        Walter Holemans, Planetary Systems Corporation(www.planetarysystemscorp.com)

Holemans also had this to say…

 “Innovation is possible when a team can visualize the whole system. This insight allows them to discover mistakes. With passion, then, innovation happens.”

Check this article out when it appears in about five weeks. It will be in our print magazine and also posted on designworldonline.com   If your company is one of the 85% still working in 2D, author Herron shows you how to start the transition.  And why you might want to.

Larry B

 

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How Yaskawa Puts CAD to Work

Larry Boulden
September 09th, 2008.

We all know how the huge engineering teams in automotive and aerospace companies depend on modern CAD systems. But here’s a story about an eight-engineer team designing custom drive packages in Wisconsin, getting the same benefits from modern 3D CAD as the Big Guys.

In New Berlin, Wis, Yaskawa builds packages for sophisticated electric-motor drives. And Jason Schultz and his fellow engineers are moving from a dated 2D drawing system to modern 3D CAD software from SolidWorks to customize those drive packages. Benefits include quicker customization, faster response, and use of more powerful analysis tools. (more…)

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Reader Feedback on Gas Bottles

Larry Boulden
June 03rd, 2008.

We’re always happy when a reader takes the time to write about one of our feature articles.  So we were pleased to hear from Wayne Baldridge when he saw one way to improve a recent article on using gas bottles to supplement hydraulic accumulators.

Wayne wrote, “ Nowhere in the article was there a ‘reason’ given.  

“The gas volume has an initial pressure which the incoming fluid must exceed in pressure to displace or assume the space. As the volume decreases, the pressure increases. The initial pressure and the pressure at fluid volume determine the useful volume of the accumulator as defined by working pressure. 

“At half fluid volume the pressure must be 2X of the initial pressure. What the backup gas does is reduce the compression change of the gas so that the accumulator empty pressure and the full pressure are closer together. Working pressure then need not change as much to exchange fluid in the accumulator. 

“A stand alone accumulator requires a working pressure change of 2X to access ½ of its volume. With a back-up gas bottle, that pressure change can be substantially less to access the accumulator’s full volume.  

“For what it’s worth.  Wayne.”

You can read the article, “Reduce hydraulic accumulator cost with backup gas bottles” in the current (May 08) issue of Design World, or on this website.  Take a look, then let us know what you think.

–Larry B

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A Kink in the Digital Pipeline

Larry Boulden
May 10th, 2008.

The flow of digital information through a plant is often referred to as the Digital Pipeline. When something interrupts that flow, it can create a major kink.

Autodesk’s Jay Tedeschi remembers one kink, the type of event that still produces problems in organizations. “I was part of a small R & D team that was investigating viability of pure 3D design. We spent weeks not only securing workflows within our organization that could support working in this fashion, but we also carefully picked vendors that could work with our digital data instead of traditional paper drawings.

“One morning, after sending several parts and drawings to our own manufacturing group, I walked back to see how they were progressing. I found one of the manufacturing engineers working with what looked like one of our parts. However, while we had sent them 3D models, this gentleman was working with 2D orthographic views—views that he had created by taking projections of the 3D model. He was laying out fixturing and creating toolpaths on the 2D views, and when I asked him why, he said that it was how he always did it. I pointed out that he could simply import the native 3D model and work on that,  ,but the look on his face told me that I was barking up the wrong tree

Jay concluded, “He didn’t realize that once he began re-creating work that was already done, he had severed the link to the current design, and that he was essentially working with ’stale’ data. Indeed, many design/manufacturing mismatches can be traced to this type of loss of continuity.

Advice from the knowledgeable: don’t let your Digital Prototyping plan be foiled by an employee trying to do something “the way I’ve always done it.” For more advice, check out Jay’s upcoming article in our June issue, or read it then on www.designworldonline.com

Larry B

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Of Mechatronics and Missiles

Larry Boulden
May 10th, 2008.

My first brush with Mechatronics came courtesy of White Sands Missile Range.

“Imagine a missile launch,” my boss explained. “It comes out of the silo without warning, goes like a streak, and sometimes explodes on launch. We want an unmanned tracking mount that will sit close to the launch area, pick up the missile, and track it — no matter what.”

The engineering assignment was pure Mechatronics. Make the mechanical pieces strong but light enough for the accelerations and slew rates to come. Give the drives enough power, speed, and responsiveness. Make sure the sensors could pick up the bird, lock on it and follow it to the death. Fashion controls that would tie it all together and make it all work.It was, in short, classic Mechatronics, though we never used that word. It would be two years later, in 1969, before Tetsuro Mori, a senior engineer at Yaskawa, coined it. But how the practice of Mechatronics, and the engineering disciplines it uses, have grown in the years since then.

According to Wikipedia, Mechatronics is the synergistic combination of mechanical, electronic, and software engineering. The purpose of this interdisciplinary engineering field is the study of automated machines from an engineering perspective.

The “automated machines” so created range from planetary rovers to production machines, from automotive subsystems like antilock braking to synergy drives. And yes, the roster of Mechatronics successes includes a bevy of common consumer products such as autofocus cameras, CD-players, washing machines, and hard drives for computers.

Here at Design World, we regard Mechatronics as one of the most challenging and exciting subjects we cover. We hope you’ll visit our Project Mechatronics Website,

www.projectmechatronics.com, and check out our blog, our Wiki, and the rest of the coverage we offer. While you’re there, we suggest you log on and add your comments to the Wiki. We welcome your contributions to Project Mechatronics.

Larry B

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