Engineering News : Page 5 of 10

shovel digs and deposits 82.5-ton payloads in three passes to fully load a 240-ton truck.

"We used MSC/NASTRAN to predict stress levels and the behavior of components, then we evaluated the data against established historical profiles," says Bill Powers, staff engineer. Specific parts of the shovel analyzed: dipper body, twin-leg dipper handle, and deep mid-section boom.

Powers used the software's cyclic symmetry option. It allows engineers to save time by modeling only half of a symmetrical model and then get results for both sides.

Lab fashions fluid-control components

Yellow Springs, OH -In applications ranging from automobile engines to hospital catheters, Vernay Labs' flow-control devices must withstand a variety of demanding tasks while surviving high pressures, vacuums, and caustic or hot fluids-and still remain elastic and durable.

Using ANVIL-5000 software from Manufacturing and Consulting Services, Inc., Scottsdale, AZ, has made most design jobs 25 to 50% faster at Vernay Labs, estimates Tom Rex, design supervisor and tool engineer. One example: a production mold for making a needle valve with 144 cavities. Vernay's family of parts are similar enough, Rex says, that designers can take different upper and lower cavities and use them to generate a new mold structure.

The company uses its CAD models to download crucial design information for finite element anaylsis in popular formats such as IGES or DXF.

CAD helps design custom-fit workouts

Falmouth, KY -When Shaquille O'Neal wants customized exercise equipment, you don't want to keep him waiting. Hammer/Strength, Inc. understands this need, and uses a 3-D CAD system from Hewlett-Packard to save design time-and keep "The Shaq" and other customers happy.

Hammer/Strength, Inc., a Falmouth, KY-based customized exercise equipment supplier, uses the ME Series 30 to design, test, and analyze new exercise machines using "Reggie," a fully functional digital model.

"Reggie" is modeled on Reggie Williams, a former all-pro linebacker for the Cincinnati Bengals. Using two HP 9000 workstations, this 3-D solid model provides enough information on weight, balance, and movement so no physical model is needed.

The system's macro language also allows Hammer/Strength to change Reggie's size to accommodate women or smaller men, for example, since commonly used design features, such as geometric calculations or standard library parts, are completely automated. In addition, the company uses VDS Environment, customization macros provided by Visionary Design Systems, to boost productivity.

Gary Jones, founder, vice president, and director of manufacturing and engineering for Hammer/Strength, says HP ME CAD is easy to use. "What used to take days on paper or an hour on a traditional CAD system we can do in seconds," he says. "And we get a perfect fit and alignment."

To customize the machines, the process begins with Jones, seated in a dentist's chair with angle gauges, discussing exercise needs with the customer and a staff physiologist. Jones then returns to the workstation, places Reggie in his own chair on the screen, and moves him through natural human motions, digitizing the motion's axis of rotation. Those measurements build the arm of the proposed machine, the part of the machine that moves. Finally, a seat for Reggie is built

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