eNewsletter

March 2010

'Ferropaper' is New Technology for Small Motors, Robots
Researchers at Purdue University have created a magnetic "ferropaper" that might be used to make low-cost "micromotors" for surgical instruments, tiny tweezers to study cells and miniature speakers.

The material is made by impregnating ordinary paper, even newsprint, with a mixture of mineral oil and "magnetic nanoparticles" of iron oxide. The nanoparticle-laden paper can then be moved using a magnetic field.

"Paper is a porous matrix, so you can load a lot of this material into it," said Babak Ziaie, a professor of electrical and computer engineering and biomedical engineering.

The new technique represents a low-cost way to make small stereo speakers, miniature robots or motors for a variety of potential applications, including tweezers to manipulate cells and flexible fingers for minimally invasive surgery.

"Because paper is very soft it won't damage cells or tissue," Ziaie said. "It is very inexpensive to make. You put a droplet on a piece of paper, and that is your actuator, or motor."

Once saturated with this "ferrofluid" mixture, the paper is coated with a biocompatible plastic film, which makes it water resistant, prevents the fluid from evaporating and improves mechanical properties such as strength, stiffness and elasticity.

Because the technique is inexpensive and doesn't require specialized laboratory facilities, it could be used in community colleges and high schools to teach about micro robots and other engineering and scientific principles, Ziaie said.

The magnetic particles, which are commercially available, have a diameter of about 10 nanometers, or billionths of a meter, which is roughly 1/10,000th the width of a human hair. Ferro is short for ferrous, or related to iron.

"You wouldn't have to use nanoparticles, but they are easier and cheaper to manufacture than larger-size particles," Ziaie said. "They are commercially available at very low cost."
The researchers used an instrument called a field-emission scanning electron microscope to study how well the nanoparticle mixture impregnates certain types of paper.

"All types of paper can be used, but newspaper and soft tissue paper are especially suitable because they have good porosity," Ziaie said.

The researchers fashioned the material into a small cantilever, a structure resembling a diving board that can be moved or caused to vibrate by applying a magnetic field.

"Cantilever actuators are very common, but usually they are made from silicon, which is expensive and requires special cleanroom facilities to manufacture," Ziaie said. "So using the ferropaper could be a very inexpensive, simple alternative. This is like 100 times cheaper than the silicon devices now available."

The researchers also have experimented with other shapes and structures resembling Origami to study more complicated movements.

MEDER electronic, Inc. today announced the release of their new LS05 Liquid Level Sensors , made of tough stainless steel tubing, these sensors can be customized up to 6.5 feet in length, detect multiple liquid levels and withstand exposure to many chemical solutions, high pressure and high temperatures.

The LS05 Series Liquid Level Sensors is the most diverse level sensor yet, combining hundreds of standard options ranging from switching power and  connectivity to fluid types and  number of liquid levels.  The LS05 housing stem, constructed of V2A stainless steel can vary in length up to 6.5 feet long and hold any number of magnetic floats with a minimum spacing of 1.5” between them.  Its stainless steel housing will withstand high pressure up to 12bar and temperatures up to 200°C when coupled with stainless steel floats.  Choose from 10 different magnetic floats, available in four different materials: Polyamide, Polypropylene, Nitrile Butadiene Rubber and Stainless Steel.

Mix and match more than one float material to detect multiple fluid types in the same tank, such as in a diesel tank that may build up water condensation over time.  The LS05 can be mounted to the top or bottom of a tank using a number of different mounting options.  Using our OKI and KSK Reed Switches, the LS05 can switch low and  high voltages up to 1000 Volts and produce single, multiple or continuous output signals.

A link for more information: http://www.meder.com/sensor_ls05_us.html

Bunting Releases New Magnetic Lifting Tool
Moving steel and iron around within a manufacturing operation or metal fabrication business has been simplified with the introduction of the MagFORKLift by Bunting Magnetics. This new device works in conjunction with any type of fork truck to move up to 1,100 pounds of material.

“The MagFORKLift is suitable for any business that either lacks an overhead crane or their crane doesn’t cover certain areas of their operation,” said Don Lindstrom, general manager for Bunting’s Magnet Materials Division. “Either way, the MagFORKLift can handle the situation and get the metal or iron where it needs to go.”

The MagFORKLift attaches to the two forks on any fork truck and works in conjunction with four different sizes of Bunting MagLift hand-controlled lifters. MagLift lifters are designed to save time and labor by holding, carrying, and releasing loads more efficiently than a manual or mechanical method. These lifters attach to the MagFORKLift and get their holding power from powerful permanent magnets and do not require special cables or costly electrical hookups.

The MagFORKLift and MagLift Permanent Magnetic Lifters can safely handle many different shapes and sizes of loads. They concentrate their magnetic energy and hold securely through air gaps and surface coatings. Once the powerful magnet has been turned on by rotating the control handle on the MagLifter, the fail-safe mechanical locking mechanism ensures that it cannot be turned off accidentally.

New Surface Mount Inductors for Power Applications
Gowanda Electronics, a manufacturer of high performance inductors and other precision electronic components for RF and power applications, has introduced a new surface mount inductor series. The SMP1210S series combines high current, shielding and small size with inductance values from 1.0 to 100 uH and current ratings from 205 to 1,384 mA DC.

The SMP1210S is designed for use in power applications including filters for DC/DC converters, switching regulated power supplies, and other power supply applications where high current handling capability, shielding and footprint size are important.

Specific applications for the SMP1210S include microprocessor and distributed power applications especially in test & measurement equipment, automotive electronics, medical diagnostic equipment, and industrial process control equipment.  Other applications include use in security systems, instrumentation, bar code and laboratory analysis equipment.

Technical specifications for products in Gowanda’s SMP1210S inductor series include: inductance from 1.0 to 100 uH (at 1 kHz), current rating from 205 to 1,384 mA DC and saturation current from 200 to 2,060 mA DC. Coupling is less than 4 percent with 1 mm of spacing between components. The recommended footprint is 0.070 in (1.78 mm) by 0.120 in (3.05 mm) by 0.130 in (3.3 mm). Operating temperature is -55°C to 125°C. Product is supplied on tape and reel.

Piher Introduces Non-Contacting 360° Rotary Position Sensor 
Piher North America has introduced the non-contacting PSC-360 programmable Hall effect magnetic sensor featuring a switch function not found in other 360º absolute position sensors. The switching point can be programmed at any angle allowing maximum design flexibility. It can also be used as an indicator for multi-turn applications. This low current switch design incorporates both on and off positions that provide a secondary position verification for improved safety for mission-critical applications in harsh environments.

The PSC-360 Sensor also offers high temperature capabilities with operational performance between -40ºC to 150ºC and high accuracy over 360º at 0.5 percent.  The bushing/panel mount style sensor features a standard 0.25 inch 'D' Flat shaft in a low profile package of 13 mm, which is advantageous for applications with tight packaging constraints.  

Designed with the permanent magnet as the only moving component, the PSC-360 sensor provides a mechanical life of up to 50 million cycles.  Further durability is incorporated with the fully sealed magnet and the sensor's electronics (sensing system) encapsulated in molded plastic, providing a completely sealed IP67 rated sensor that is totally impervious to humidity.  These features are well suited to harsh environmental exposure where shock, vibration, high humidity and dust are unavoidable.

Piher's technology is not only true absolute - maintaining the sensor's true position even after a power interruption, it also offers full redundancy achieved with a dual core version within the same housing.  The result is a highly configurable sensor that offers a solution for the severe conditions found in industrial, food processing, agriculture and off-highway applications. Specific uses include hand throttle control and throttle position feedback, accelerator and brake pedals, wheel angle for off highway vehicles and tractors, farm implement position feedback, forklift lift and tilt control, suspension height, marine, cranes and airport ground support vehicles.

Other PSC-360 performance characteristics include linearity of ±1 percent absolute (0.5 percent upon request), selectable analog (ratiometric), PWM, or serial protocol, up to 14 bit angular resolution, 40 bit ID number, and self-diagnostics.  With the PSC-360's modular architecture and Piher's custom engineered technology capabilities, Piher can modify electrical characteristics, mechanical characteristics, and connector configurations to meet customer specifications.  For example, Piher can provide the same full scale output over as short an electrical angle as narrow as 15°.  The PSC-360 is priced under $20 each in production quantities with immediate availability.

BI Technologies Develops High Power Density Inductor for DC-to-DC Converter Power Applications
TT electronics BI Technologies, a manufacturer of magnetic components including inductors, transformers and common mode chokes, has developed a high current surface mount power inductor. Designated the HA73 series, the inductor features a high saturation core material and an operating frequency up to 800 kHz, while measuring 19.2 mm by 19.6 mm with a height of 12.2 mm.

“The core material utilized in these inductors enables them to offer high power density with improved efficiency and minimal power losses in an extremely small package,” said Donna Schaefer, application engineering manager for TT electronics’ BI Technologies.  “The complete package design and core materials make these inductors suitable for use in DC-to-DC converter power applications.”

The HA73 series inductors feature a typical rated inductance range from 13.5 µH to 29.5 µH, with a typical rated current range from 6.5 A to 9 A, depending on the device. Heating current ranges from 8 A to 12 A, with a saturation current from 9 A to 13 A. Typical DC resistance for the inductor ranges from 12.8 mΩ to 28.6 mΩ. Operating temperature ranges from -40°C to 155°C, and maximum temperature rise is 50°C.  BI Technologies will also produce devices outside these specifications to meet customer requirements.
Typical pricing for the HA73 series power inductors ranges from $1.40 to $1.58 each in quantities of 10,000 pieces.   Lead time is from 10 to 12 weeks. 

Newport Releases the S-2000AN Non-Magnetic Isolator, New to the S-2000 Vibration Isolator Family
Newport Corp. has introduced the S-2000AN Stabilizer Non-Magnetic Vibration Isolator. The newest addition to the S-2000 Stabilizer family is designed specifically for applications where the measurement of small magnetic fields would be otherwise impacted by traditional magnetic steel isolators. The S-2000AN provides a 1 Hz vertical resonant frequency and a vertical isolation efficiency of 98 percent at 10 Hz and a load capacity of 2,000 lb. It is a suitable solution for isolating optical tables, such as Newport’s RPR-N series tables or platforms that support large vacuum chambers or other heavy instruments used in materials research applications. 

“One of the most exciting developments with our new S-2000 Stabilizer family are the product variations that we have been able to introduce from the core design that provides the same high performance at a very economical price,” said Warren Booth, product line manager at Newport.  “In extreme applications where it is essential that all magnetic materials are removed the S-2000AN is the best choice due to its aluminum and 316 SS construction.  In our tests our AN version induced only a 1.2 nT change in measured magnetic field over a distance of zero to 2 feet. This compares to over a 35 nT change for traditional magnetic steel isolators. What’s also interesting is that our standard S-2000A induced a 4 nT change in the measured magnetic field which means for some ‘non-mag’ applications our standard S-2000A may provide sufficient magnetic immunity allowing our customers to save nearly $10,000 on isolation equipment compared to competitive offerings.”

In addition to improved isolation performance and quantified magnetic impact the S-2000AN features Newport exclusive SafeLock mounting clips which secure the isolators to the bottom of any Newport optical table, improving the performance, stability and safety of the system.  Available in several popular heights ranging from 16 inches to 28 inches, the new vibration isolator is equipped with precision pneumatic re-leveling valves and float-height indicators. 

New Line of Geared Brushless DC Motors Provide Fast Automated Solutions
Crouzet North America has introduced a new line of high performance, geared BLDC motors available with a complete tool kit of selectable gear boxes, controllers, brakes and smart drives.  The concept allows different configurations to be assembled for fast prototyping and provides a complete automated solution tailored to fit individual customer needs.

The new BLDC motors feature a wide selection range for power, speed, torque and size.  Motors include continuous power up to 400 watts, speeds between 1,500 and 6,100 RPMs, and motor constants up to 15 ounce per square root watt (103 mNm per square root Watt). Maximum torque constants feature up to 198 ounce- inches/amp (1,400 mNm/amp). The six new models include two round and four square designs with lengths ranging from 41 mm to 114 mm.  Motors can be ordered with a factory-mounted optical or magnetic encoder and can also be fitted with electro-mechanical fail safe power off brakes.  
 
Compatible gearboxes feature spur, planetary and worm styles with torques from 0.4 Nm to 120 Nm. 

The BDE30 and BDE40 external drives are offered in 6 A or 14 A max respectively.  Internal drives are offered on BLDC motors that feature power ranges from 40 to 100 watts. A wide range of accessories are also available.

Frontier Electronics Announces First Nationally Franchised Distributor
Frontier Electronics Corp. (Simi Valley,CA) has announced their agreement with NRC Electronics (Boca Raton,FL) to be Frontier’s first Nationally Franchised Distributor. Ranked 28th largest in the nation (according to Purchasing Magazine), NRC Electronics continues to stun the world with unique products & unprecedented customer service. NRC Electronics specializes and focuses on designers, OEMs and sub-contractors who require efficient, innovative, components and technologies. NRC will inventory and distribute Frontier Products from their four product categories; Magnetics, Diodes, MLCC, and Chip Resistors.  

Magnet Materials Supply Chain Players Propose Six-Point Plan to Address Impending Rare Earths Crisis
The United States Magnet Materials Association (USMMA), a coalition of companies representing domestic high performance magnet producers and suppliers, have submitted a proposal to the US Departments of Commerce, Energy, State and Defense, Office of the US Trade Representative, and Office of Science and Technology Policy within the Executive Office of the President to create a “whole-of-government” approach to resolving the Rare Earth Elements (REE) supply crisis, a serious threat to the US economic and national security.

Currently, the US is totally dependent on foreign sources for rare earth materials. These elements are essential to numerous renewable energy and defense systems including wind turbines, hybrid-electric batteries, computer hard drives and precision-guided munitions. Currently, China provides over 97 percent of the world’s rare earth raw materials and dominates the world’s rare earth refining, alloying and manufacturing.

USMMA proposes the creation of an interagency working group, with high-level principals identified and empowered by the Secretaries of Commerce, Defense, Energy, State, the US Trade Representative and the Executive Office of the President, charged with implementing a six-point plan to restore a domestic rare earth supply chain to meet economic and national security needs:

• Establish a baseline - Studies by affected agencies to establish a baseline of rare earth usage and dependence and any economic or national security issues that result, as well as an action plan to restore specific holes in the domestic supply-chain, to include mining, refining, alloying and manufacturing [Note: many of these are ongoing]
• Obtain raw material necessary to resume defense critical rare earth manufacturing in the face of a pending worldwide shortage - A program whereby the Defense National Stockpile purchases existing rare earth supply to support the US Government’s critical needs while the domestic supply chain is rebuilt over the next five years
• Government initiated action to ensure fair trade - A government initiated action to investigate potential foreign government market manipulation or dumping in the rare earth market, as a means of leveling the playing field for domestic competitors
• Investment in a globally competitive rare earth supply-chain - A $2B DOE led grant and loan guarantee program to support the reestablishment of mining and refining operations in the US that will support the domestic supply-chain
• Specific focus on defense critical components - Numerous Defense Production Act programs ($10 to 50 million each) to support establishment of domestic manufacturing capability in critical segments of the rare earth market
• Investment to ensure future innovation - Support of innovation, training and workforce development to support the rare earth element supply chain by providing base budget funding for academic institutions, government laboratories, companies, non-profits and industry associations

Currently, there is one US rare earth mine and processing facility (which is not mining), a major US Geological Survey-validated deposit of rare earths in Idaho, two small alloying facilities and one significant rare earth magnet producer, making the nation’s supply-chain for critical renewable energy and defense systems nearly non-existent and leaving the United States dangerously vulnerable to potentially unreliable foreign nations.

USMMA believes that urgent and collective action is needed by the federal government in order to head off the impending rare earth crisis. It is estimated that Chinese domestic consumption of rare earth materials will outpace Chinese domestic supply as early as 2012. With a three to five year timeline to reestablish a domestic rare-earth supply-chain, the US is already in a “silent crisis.” It is unclear whether rare earth material will be available outside China in the coming years.

USMMA was founded in 2006 by magnet manufacturers Thomas & Skinner, Inc. of Indianapolis, Indiana; Hoosier Magnetics of Ogdensburg, New York; and Electron Energy Corporation of Landisville, Pennsylvania, to advocate on behalf of the specialty metals clause found at 10 U.S.C. 2533b. US Rare Earths, Inc. joined in 2009 to expand the group’s focus to support the reintroduction of a competitive rare earth supply chain in the United States.

USMMA members have already successfully advocated for inclusion of a congressionally mandated study of the rare earth supply-chain in the FY10 National Defense Authorization Act. More information on the USMMA can be found at http://www.usmagnetmaterials.com.

Department of Energy Announces $100 Million Available for Innovative Research Projects
At the inaugural ARPA-E Energy Innovation Summit, US Energy Secretary Steven Chu announced $100 million in Recovery Act funding will be made available to accelerate innovation in green technology, increase America’s competitiveness and create new jobs. The announcement comes as some of the nation’s top energy leaders and members of the scientific research community have gathered to ensure US leadership in clean energy technologies.

This is about unleashing the American innovation machine to solve the energy and climate challenge, while creating new jobs, new industries and new exports for America’s workers, said Secretary Chu.

The ARPA-E’s third round of funding opportunity is focused specifically on three technology areas: 

• Grid-Scale Rampable Intermittent Dispatchable Storage (GRIDS). ARPA-E seeks to develop new technologies to enable the widespread deployment of cost-effective grid-scale energy storage.
• Agile Delivery of Electrical Power Technology (ADEPT). ARPA-E seeks to invest in materials for fundamental advances in soft magnetics, high voltage switches and reliable, high-density charge storage. 
• Building Energy Efficiency Through Innovative Thermodevices (BEET-IT).  ARPA-E seeks to develop energy efficient cooling technologies and air conditioners (AC) for buildings to save energy and reduce GHG emissions from: (a) primary energy consumption due to space cooling and (b) refrigerants used in vapor compression systems. 

ARPA-E’s first solicitation, announced in early 2009, was highly competitive and resulted in funding 37 projects aimed at transformational innovations in energy storage, biofuels, carbon capture, renewable power, building efficiency, vehicles, and other areas. 
ARPA-E’s second solicitation announced in December, 2009, which has yielded nearly 500 concept papers focused specifically on three areas of technology representing new approaches for biofuels, carbon capture and batteries for electric vehicles. 

A Plan for the North American Rare Earth Value Chain
By Ed Richardson, Vice President • Thomas & Skinner, Inc.

For the last year or so, we’ve all heard a lot about the looming rare earth crisis. You can’t attend a conference or forum on metals or magnetic materials and not hear a slew of dire descriptions of the rare earth industry. Clearly, with China dominating every part of the value chain, reestablishing a healthy and sustainable North American rare earth industry won’t be easy. A lot of things have to go right, and they have to happen over the course of many years. A big part of the challenge is just getting started. There are a lot of ideas floating around about how to get the domestic rare earth industry on its feet again. It can be difficult sorting through the hopes, dreams, claims, plans and guesses.

Read article here.

The Technology World in One Location!
Top design engineers, system engineers and technical managers from multiple markets and industries will be converging in Dallas this fall, October 18-20, to attend six leading technical events that are being co-located for the first time ever. Make plans today to attend!

Battery Power 2010 • Thermal Management & Technology Symposium • REMOTE Site & Equipment Management 2010 • Energy Efficiency Expo 2010 • Antenna Systems 2010 • Electrical Manufacturing & Coil Winding Expo

Download a PDF Copy of the Spring 2010 Issue of Magnetics Business & Technology Magazine

Feature Articles:

Rebuild vs. Replace
A Plan for the North American Rare Earth Value Chain

Columns:

Think Again: In-House Magnetic Manufacturing May be Good for Your Business Health
Hardware vs. Software

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