In this issue of the Mechanical Monthly Newsletter there are articles on an unmanned helicopter that set an endurance record, monitoring jet engine bearings wirelessly, and platic chains.

The highlighted products are roller-pinion gear systems, precision couplings, flexible couplings, and spring-applied brakes.

Be sure to check out the industry update to find out about a dynamic gear tester.

Thanks for reading and have a great day!

Hummingbird sets helo record
The A160T Hummingbird, an unmanned helicopter from Boeing, recently set a flight endurance record when it stayed aloft for 12.1 hr. It was carrying a 500-lb payload at 5,000 ft over California, and landed with 40% of its full fuel load still onboard. The 35-ft-long Hummingbird has a 36-ft-diameter rotor and can climb to 30,000 ft, 10,000 ft higher than conventional helicopters can fly. It has a range of 2,500 miles and top speed of 140 knots. The helo is designed to carry a 300-lb payload, but has been flight tested with a 1,000-lb load.
Full Article

Cable Carriers Shipped the Same Day; No Order Too Small Igus® Inc. is the leading developer of Energy Chain® cable carriers that guide, protect and extend the service life of cables and hoses attached to automated machinery and Chainflex® continuous-flex cables. The company offers customers same-day shipping and no minimum order requirements. Most products are available from stock. Live design technicians are available for free consultation from 8 to 8 EST. Igus believes every customer is important from a single-unit maintenance repair order to the largest OEM. 2D and 3D CAD files are available online with no registration required. Contact igus for a free design consultation and free samples. www.igus.com

Monitoring jet engine bearings, wirelessly
Researchers at Purdue University working with the U.S. Air Force have developed wireless sensors strong enough to survive inside operating jet engines where temperatures can climb to 572°F. The sensors detect when critical bearings are close to failing, as well as how long before they fail, letting maintenance personnel prevent costly breakdowns. The MEMS sensors are also small enough that they don’t interfere with the bearings. The sensors actually measure temperature, a good indicator of how well bearings are performing and when they can be expected to fail. Conventional bearing monitors track engine-oil temperature, an indirect method which yields less specific data. The sensors do not need batteries, which is a plus because batteries don’t perform well in hot environments.
Full Article

Components for Drivelines: Plastic Chain
The variety of plastic chain available includes traditional designs with discrete links that connect to form almost any length, and newer designs that include one, two, and three parallel strength members. The traditional chain form of separable links is available from 0.125 to 6-in. pitches, and newer styles from 0.098 to 0.5 in. The advantages of chain over belts is that it can be assembled around obstacles, is readily connected to form almost any length, and has favorable load and life ratings. Typically, a 0.125-in. pitch chain of acetal resin has a break strength of 7 lb, a working load of 5 lb or less, and need not be replaced until elongation exceeds about 3%.
Full Article

Roller-pinion gear system
The Roller Pinion Gear system (RPG) provides zero backlash in both directions, very-high positional accuracy, 99% efficiency, high rigidity, low maintenance, and corrosion resistance. An innovative ring gear and roller pinion combine for accurate positioning. Bearing-supported rollers move smoothly along each tooth face, reducing noise by eliminating tooth slap. Accurate positioning at speeds to 11 m/sec is maintained. For designs under a meter, a solid ring gear is available; larger ring-gear segments can be combined for ring gears of any size.
More Information:
Nexen Group Inc.

Precision couplings
The CD couplings, with zero-backlash precision and high-torsional stiffness, are designed with clampstyle hubs for increased torque capacity on shafts without using keyways. The couplings handle speeds to 17,000 rpm with torque ratings to 10,666 Nm (94,400 lb-in.). A large size range is available. Users can choose combinations of inch and metric hub bore sizes to meet specific needs. The CD couplings are for use in packaging machines, pick-and-place systems, printing machinery, machine tools, and systems that use servomotors.
More Information:
Zero-Max

Flexible couplings
Flexible couplings serve as the weak link in drive systems. The couplings are precision machined from steel or stainless steel with a thermally and chemically stable, wear-resistant, polyurethane insert press fit between the two hubs for zero backlash. This helps compensate for lateral, angular, and axial shaft misalignment. To eliminate arcing from one hub to another, the insert is graphite impregnated, giving it electrically conductive properties. Nine sizes are available in torques from 2 to 2,150 Nm (17 to 19,000 lb-in.) and in metric and English bore diameters ranging from 3 to 80 mm, with or without keyways.
More Information:
R+W America L.P

Spring-applied brake
The BFK458-L long-life, spring-applied brake is released by applying dc voltage to an electromagnetic coil. Service life of the brakes is said to be 10,000,000 cycles or two years. The cast-iron cased brakes come in four sizes with shaft sizes from 10 to 25 mm and feature 4 to 46-Nm rated torque. Brake coils can be supplied for 24-V low-voltage connection or rectified mains at 103, 180, and 250 V.
More Information:
Lenze-AC Tech

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Dynamic gear tester
A new gear tester from Promess Inc., Brighton, Mich. (promessinc.com), measures tooth-to-tooth contact variations in both directions at each degree of rotation, and can take 10,000 samples/sec. This lets it monitor and control torque-to-turn requirements of the assembly being tested. The device can also be used to monitor and apply axial loads. The test station uses high-resolution angular encoders on the input and output shafts to measure angular position. Both shafts are also driven by a torque functional tester with built-in torque sensors.
Full Article

Zero-Max
ServoClass Couplings meet the precision positioning requirements of AC and DC servomotor applications. Featuring zero backlash, flexible metal disks in both single and double disk designs. Ideal for up to 10,000 RPM applications and torque capability up to 885 lb-in. They also provide high torsional stiffness, low inertia, clamp-type hubs, bore sizes from 4mm to 35mm.
More info at: www.zero-max.com
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