Designing for the future

Eureka’s series of Design Days kicks off on 1 March with the Linear Motion Masterclass. It is the first of six one-day events that Eureka will run this year. Each covers an area of engineering that is fast-moving and complex – or has been identified as one that designers want to learn more about. The subjects covered are: linear motion; designing in plastics; simulation software; lean design; safety and legislation; and automation. All are scheduled to run at the Kaetsu Centre in Cambridge. The format of the Design Day is unique. Each blends technical presentations and workshop sessions to bring delegates up to date with key technologies. In the morning, technical presentations concentrate on real examples of how some of these technologies are being used in industry. In the afternoon, delegates are split into groups in order to attend a series of intimate 30-minute workshops led by the event’s sponsors. Each workshop will handle a different aspect of the subject matter. The session is guaranteed to be practical and educational – these are not sales pitches! Each sponsor will lead delegates through key aspects of the relevant technology – and will answer questions and give advice where relevant. At the end of the session, delegates move to the next session. Linear progression The linear motion event grew out of last year’s ‘round table’ discussion on the subject. The four participants – Aerotech, Igus, Renishaw and THK – will sponsor the first Design Day. It will help participants to understand the latest techniques in designing linear motion systems – whether as a ‘direct drive’ (using linear motors) or with more traditional components such as ballscrews. The keynote speaker is Dr Jiabin Wang, senior lecturer at the department of electronic and electrical engineering at the University of Sheffield. Dr Wang is a leading researcher in linear motion – particularly linear motors. His paper will cover the current state-of-the-art in linear motor technology, including a case study on how a linear compressor can improve the efficiency of refrigerators. He will also take a peek into the potential future of linear motor applications, such as micro-CHP and active suspension units. Dr Wang will be joined at the podium by Dr Will Eve, director of technology at Inca Digital Printers. Inca makes flatbed inkjet printers, which print large images in a series of lines. For obvious reasons, accuracy is critical. Dr Eve will talk about some of the practical measures that were needed to ensure printing accuracy in Inca’s latest generation of products Both Dr Eve’s and Dr Wang’s papers will be approximately half an hour in length. Sandwiched between these papers – and a few networking morning coffee breaks – the four event sponsors will give brief details of the workshops that they will lead in the afternoon. Aerotech, for example, will compare linear motors with traditional designs – arguing that while these new systems may require higher investment, they can offer greater accuracy and lower long-term cost. Bearings supplier Igus plans to talk about the benefits – and potential shortcomings – of linear plain bearings. Encoder manufacturer Renishaw will explain the importance of feedback to any linear system design – including information on laser encoders. And THK, which supplies linear guides, will explain how linear systems can be designed to withstand extreme conditions – such as in the offshore industry. The programme for the Linear Motion Masterclass is complete and can be seen on the Design Days website (www.designdays.co.uk) Plastic fantastic Hot on the heels of linear motion, Eureka’s second Design Day is Designing in Plastics. While some engineering plastics – such as nylon, acetal and polycarbonate – have been around for more than 50 years, they are often seen as ‘exotic’ materials next to steel and aluminium. Many engineering companies are now beginning to embrace plastic materials, knowing that they can save weight and cost – and end up with a better product – if they design it correctly. This event is aimed at companies who want to make that first step towards designing products or components in plastics, but are unsure how to do it. At the same time, it can help those who have begun to use plastics but want to improve the way they do it – such as by increasing their knowledge of material types, design rules and . The event’s keynote speaker is John Hockey, a design engineer by training and now a consultant. John previously worked for, among others, DuPont in the UK. His paper will look at the step by step approach that is needed to achieve a perfect plastic component of product, and is entitled: “Stairway to Heaven: how to succeed with plastics design.” DuPont’s paper – on the subject of metal replacement – will be presented by product specialist Mark Hazel. The afternoon workshop, which will expand on this subject, will cover: a comparison of properties of selected engineering plastics with metals; identify the types of metal component that could be made in plastics; and outline the key design factors to take into consideration when replacing metal parts. In its workshop session, Distrupol will lead delegates through the best way of selecting the correct material for each application. The draft programme for the plastics event is on the Design Days website. (www.designdays.co.uk) Future events Linear Motion and Designing in Plastics are imminent, but Eureka is also planning a range of further events this year on software, lean design, safety and legislation, and automation. Our Software for the Future event, scheduled for April, will look to educate users on the latest cutting edge software – including CFD, FEA and other advanced engineering analysis packages. The latest 3D CAD systems often incorporate CFD or FEA – so a better understanding of either will help designers to unlock the full potential of the software. Potential workshop subjects include FEA and CFD, as well as visualisation, mathematical modelling and virtual modelling. Techniques in Lean Design are helping to slash costs and improve efficiency by identifying and eliminating ‘waste’. This can take many forms: over-engineering of products, for example, or working on designs that are later aborted. Many leading engineering companies have increased profitability by applying Lean Design rigorously. This event, in May, will identify ways of finding waste in the design process – and banishing it. Legislation is beginning to rule our lives. This month, the WEEE Directive – which insists that electrical equipment is recycled by the manufacturer – comes into force in the UK. Add to this the changes in the Machinery Directive, and modern engineering companies need more than just engineering skills to stay afloat. Eureka’s July event on Safety & Legislation will help designers to negotiate key pieces of legislation, and suggest new ways of designing to comply with them. And finally Automation for the Future, scheduled for September, will help designers to create modern, efficient automation systems. Case studies will show how designers are using a range of techniques to save energy, boost efficiency and bring down costs for their customers.