Search

The entire fleet of San Francisco Cable Cars now have better illumination while reducing the need for battery changes. Historic SF Cable Cars Upgrade to LED Lights The entire fleet of San Francisco Cable Cars now have better illumination while reducing the need for battery changes. Cool Stuff Aug 7, 2025 Opportunity Since 1873, the best lighting the historic San Francisco Municipal Cable Cars had was dim incandescent headlights that did not do anything for illumination. They were merely bright enough to serve as an indicator that a cable car was coming. Plus, the old incandescent lights would quickly burn out or break from the constant vibrations. “The biggest issue was the light on cold, wet, dark nights,” said Arne Hansen, Supervisor of Maintenance at the San Francisco Municipal Cable Car Barn. “We would change the batteries in the cars maybe 10 or 12 road calls in a night. We have better batteries that last much longer now, but still, with the GPS system and cameras, the equipment was draining the batteries pretty fast.” All Cable Car photos Courtesy of San Francisco Cable Cars. After over 140 years, the Cable Cars solved their lighting problems by simply upgrading to LED light bulbs from LEDtronics. Hansen said they ordered LED lights for the entire fleet and are very happy with their choice. Other operators have commented that the LED headlights have increased visibility tremendously. Photo Courtesy: LEDtronics. A19 style LED light bulbs were also installed inside the passenger cabins. Those lights, along with the PAR46 LED headlights, are saving the city money on energy as well as maintenance—especially in the winter when the lights are left on much longer. Between those advantages and the increased visibility, Hansen acknowledged that, “All the operators give it a thumbs-up. They all approved the change, and they all loved it. The project was a complete success.” For more information: LEDtronics San Francisco Cable Car Previous Facebook LinkedIn Copy link Next

Using Kodak film and Panavision lenses, director Gareth Edwards sought to capture the magic of Spielberg's original vision. Here's How Jurassic World Rebirth Captured the Nostalgia of Film Using Kodak film and Panavision lenses, director Gareth Edwards sought to capture the magic of Spielberg's original vision. Joe Gillard Film and TV Jul 8, 2025 Can you believe there are now seven Jurassic films? I still remember seeing the first two in theaters, and they were big moments in my childhood. They were all I could think about. And I’m far from the only one who experienced that joy in theaters. The films are some of the most influential ever made. “All those films you love, that you grew up with, that have that certain look that really hard to describe? It’s because it was shot on Kodak.” – Gareth Edwards, director, Jurassic World Rebirth. Jurassic World Rebirth premiered on June 17th and stars Scarlett Johansson, Jonathan Bailey, Mahershala Ali. Capturing the Spielberg look with Kodak and Panavision technology The Jurassic films are known for pioneering visual effects , but all but one of the films was shot on traditional 35mm film. Jurassic World Rebirth continues the tradition. The past few decades saw a transition into digital to film movies, but there has been a nostalgic resurgence of interest in using traditional methods. Also from EE: The Technology Behind the Rotating Chairs on The Voice You can thank director Gareth Edwards for the decision to use Koday 35mm film and Panavision lenses. “All the films I grew up loving were ... shot on Kodak,” says Edwards in a video uploaded to YouTube. He says he “fought really hard” to shoot Jurassic World Rebirth on Kodak film a Panavision lenses. “All those films you love, that you grew up with, that have that certain look that really hard to describe? It’s because it was shot on Kodak,” said the nostalgic Edwards. But it goes beyond nostalgia. For Edwards, a film can look “better” than reality, even with the right camera technology, because of how colors can appear. “Having the film stock and the film veneer and grain and these really beautiful wide, animorphic, distorted lenses to work with has been really beautiful,” says David Vickery, Visual Effects Supervisor, in the video. “It’s something to help us bed the visual effects and creatures into, how much bowing and distortion and stretching of the image happens towards the edge, all sorts of chromatic aberration that happens to the highlights and make sure that when we add digital elements into the frame that we can sample that and put it all back on.” Panavision lenses preserve the magic In addition to Kodak film, the team also tried to recreate the magic behind Spielberg’s first film by using the iconic Panavision anamorphic lenses to shoot the film. Animorphic lenses work by using cylindrical lenses to compress the image during recording, rather than cropping or matting. Then, an additional lens expands the image back to widescreen proportions. This way, more image resolution is preserved. It's interesting to see film studios lean into the public demand for experiences that feel familiar, even if the technology is older. I suspect we'll see even more of this attitude towards film and TV as too much AI has the potential to overwhelm and exhaust audiences, particularly Millennials and Gen Xers who will likely pine for a simpler time. For more information: Jurassic World Previous Facebook LinkedIn Copy link Next

An innovative approach to teaching music brings music education and technology together.  Violins Too Expensive? School Superintendent Turns to 3D Printing An innovative approach to teaching music brings music education and technology together. Joe Gillard Cool Stuff Sep 23, 2025 Here’s a story at the intersection of entertainment and engineering that will tug on your heart strings, so to speak. A school superintendent in Pennsylvania, Laura Jacob, noticed that students from low-income families had difficulty purchasing violins for music, and came up with a solution inspired by something she had heard of an orchestra doing: 3D-printing instruments. In the past five years, Jacob has 3D-printed 200 violins that are free for students in a school where 70% of them are low income. Violins can be very expensive, even relative to other instruments. It can cost hundreds in rental fees for the families of students, if they want their child to have the opportunity to learn violin in school. Jacob started out with two 3D printers. She now says she has 34 of them, and students can learn to use the machines, too. “I’m not a computer scientist or an engineer by any means, but after a variety of failures, I found one that actually printed and it sounded good,” Jacob told CBS News. The violins are made from a template created by a company called Hova Labs. Beyond that, Jacob used real violin strings, a few additional wooden parts, and then added modified guitar pegs. Hova Labs violin template for 3D printers The whole process takes about three days to finish a violin. If the instrument breaks (probably a strong possibility with schoolchildren), they can easily be fixed. As a fun added benefit, the 3D-printed violins can be made in different colors, which might make the instrument more interesting for kids. Prusa 3D Printers The Prusa XL 3D printers are designed for precision. According the company website, “the precision tolerance of a well-assembled Original Prusa printer is 0,1 mm on the Z-axis and 0,3 mm on X and Y.” And the company says that calibrations can be done to further improve the result. “It can be as little as 0,05 mm on all axes, after making additional calibrations such as the Extrusion multiplier calibration and Extruder linearity correction.” Prusa XL 3D printer The magnetic heatbed can hold a two-sided flexible spring-steel sheet, for removal of printed objects from the print surface, according to the product page for the Prusa XL. There are six varieties of sheets for the Prusa XL: smooth, powder-coated textured, PA Nylon, PP, and HighTemp, all of which serve a specific type of 3D-print job. For information: Hova Labs: https://www.hovalabs.com/ Prusa Research https://www.prusa3d.com/ CBS Interview with Laura Jacob: https://www.cbsnews.com/news/pennsylvania-school-3d-printers-violins/ Cover photo: u_l5sf233ead , Pixabay Previous Facebook LinkedIn Copy link Next

Lifting a Bed-of-Nails in a museum display demanded reliable performance, long product life, and simple integration. Bed of Nails Museum Exhibit Lifts with Ease Lifting a Bed-of-Nails in a museum display demanded reliable performance, long product life, and simple integration. Museums Aug 12, 2025 On a Bed-of-Nails lift table application, the question facing engineers was, “How much do you trust your linear bearing technology?” CW Shaw Inc, a designer and fabrication firm that specializes in bringing interactive, fun and educational museum exhibits to life was posed with this question. For linear ball-bearings, any slight contamination of the bearing cages can lead to breakage, stalling, or total machine failure, which results in a low rate of confidence when lying on a spiky table. After considering the design, load, environment, and necessary long-term operation, CW Shaw opted for Simplicity pillow block housings to guide the support rails on the Bed-of-Nails lift table for a museum exhibit. To demonstrate the full effect of the exhibit, the lift table needed to be raised and lowered by 3-inches, handle loads up to 1,000 lb (for safety), and move at a moderate speed of 5-feet per minute. Potential contamination was a major factor CW Shaw considered. Any trace of dust or particulate posed a risk of system failure, raising safety concerns. Therefore, CW Shaw sought a linear motion system that would not fail under contamination (dust and carpet fibers). Since most museums operate on fixed budgets, CW Shaw also held maintenance-free operation as a crucial design prerequisite, which is why the company designers turned to Simplicity linear plain bearings and pillow block assemblies. The Linear Pillow Block Solution Simplicity products from PBC Linear became a proven solution when requiring maintenance-free, worry-free linear motion. Designed and refined for over 25 years, Simplicity technology has been successfully applied in some of the most extreme environments: temperature extremes, high contamination, and shock and vibration. The bearings travel using a proprietary Frelon liner which transfers the load and glides over dust and other particulate without damaging the shaft. Also, since the pillow blocks are precision designed with no rolling elements, Simplicity pillow block housings will never catastrophically fail, allowing for reliable and safe linear guidance of the support rails. Two Simplicity pillow block assemblies were installed at each end of the lift table to support the load and guide the lift rails. CW Shaw noted no problems in performance and, over time, has implemented the design for several nail bed exhibits throughout the country. For more information: PBC Linear Plain Pillow Block Free Product Sample CW Shaw Previous Facebook LinkedIn Copy link Next

The aquarium is partnering with ReBokeh to enable low vision visitors to explore the aquarium using their own eyesight. Georgia Aquarium Uses Technology to Give Low Vision Visitors an Enhanced Experience The aquarium is partnering with ReBokeh to enable low vision visitors to explore the aquarium using their own eyesight. EE Staff Theme Parks Sep 17, 2025 Museums, Cool Stuff Georgia Aquarium is partnering with ReBokeh Vision Technologies to offer free access to ReBokeh’s assistive technology software for people with low vision. The partnership provides Aquarium guests and staff with access to ReBokeh’s app-based software intended to help people with low vision to adjust the appearance of the world around them. Georgia Aquarium is the largest aquarium in the Western Hemisphere, with more than five-hundred species. This partnership will allow “the 90% of low vision individuals who retain functional vision to experience the wide range of animals and exhibits using their own vision, rather than defaulting to tactile or audio descriptions,” according to a press release. The app-based technology behind it ReBokeh’s technology works through the live camera feed from their mobile devices with overlayed, customized filters that adjust aspects like contrast, color hue, zoom, and lighting to meet the needs of low vision users. An AI feature also offers the interactions with ReBokeh’s AI tool with which guests can ask questions about what’s around them and what they’re seeing. It also works in multiple languages so it can work as a translation tool for signage, information, and visual surroundings. Watch to see how the app's general technology works “Our key mission is to unlock the ocean for all; that includes providing features and opportunities like ReBokeh’s technology for guests so they can experience our larger-than-life animals and the wonder they invoke. This partnership with ReBokeh is integral to our continued commitment to accessibility for all,” said Sam Herman, Director of Guest Programs at Georgia Aquarium. “A day at the Aquarium is an opportunity to see the magic of our oceans and the incredible variety of wildlife that call the sea home,” said Rebecca Rosenberg, the low vision founder of ReBokeh. “Being able to see and interact with each exhibit using your own eyesight can be an incredibly powerful experience for people with low vision. We couldn’t be more excited to partner with Georgia Aquarium to make them the first aquarium on the planet to create these new and immersive experiences for the low vision community.” ReBokeh is extending this partnership opportunity to other museums, zoos, and public spaces. Source: https://www.rebokeh.com/ Previous Facebook LinkedIn Copy link Next

Live production and signage workflow incorporates live social content into lively display screens Social Media Engages Recreational Crowd Live production and signage workflow incorporates live social content into lively display screens Brian Galante Sports Jun 4, 2025 The rallying cry of “Attention all sand addicts, duners, and dirtheads” resonated loud and clear in the YouTube event announcement for Polaris Camp RZR, one of the biggest dune gatherings of the year. It was the first serve in a social media volley that amplified the fan experience throughout the three-day recreation event. The annual event celebrates the sport and the machines, taking place at the Imperial Sand Dunes Recreation Area near Glamis, California. The location is roughly two hours east of San Diego in a region considered the Mecca of North American sand dune recreation. The reputation of the event and the region was enough to draw thousands of enthusiasts this year, driving everything from backyard quads to full-blown desert racers. Overnight, attendees transformed Glamis Beach into a massive campsite as the event prepared to open on Halloween day. Those preparations included the installation of three video walls and a fully loaded digital production facility. Alpha Sports TV, experts in delivering specialized broadcast content for sports and live events, provided the production front-end and handled content creation and delivery. This included playout of sponsor advertisements and more than 30 special features, as well as live content captured on a roving, wireless Sony HXC100 camera with embedded audio. “A lot of what we did involved processing literally terabytes of media files, primarily video, from many different sources,” said Andrew Allan, president of Alpha Sports TV. “We made sure that the high-quality content we processed was rendered in equally high quality with no artifacts, even though outdoor video walls are quite tolerant of high compression. We needed to make sure all the content, whether from an outside source or acquired live on-site, ultimately looked the same in terms of aspect ratio and overall quality.” Allan points out that many production companies can handle this, but Alpha Sports TV, with its history in Olympic Games and other high-profile events, was brought in for its expertise in integrating graphics, video, and data into live broadcasts and events. This was especially important for the social media aspect, which proved to be a major attraction and source of engagement for attendees. The social media gateway was opened courtesy of software from Bannister Lake, a graphics and broadcast automation specialist. Allan integrated Bannister Lake’s TweetOut and TweetOut Nano products into the workflow to keep screen content refreshed and dynamic. Allan ran TweetOut on the Ross Video XPression Studio platform, creating Twitter and Facebook routines for several different graphics layouts including insertion over the prerecorded Polaris features. This included full-page and lower-third layouts, the former of which could take advantage of TweetOut’s inline photo support. This means that the full-page graphics space was mostly reserved specifically for photos taken by attendees with their “feet on the ground.” Those photos were stored in the Flow database along with tweets and other data content, and made available for output into the lower-third layouts. Room to Spread The TweetOut Nano solution essentially offers users a compact form factor for integrating social media content into live broadcasts – especially ideal for temporary facilities where rack space is limited. Allan likens its size to “a few decks of cards,” noting that it’s very quick, reliable, and networkable. “We can conceivably have several different ‘content moderation clients’ networked into the switch, all providing their own social media contributions to the stream,” said Allan. At the Polaris event, the TweetOut software constantly polled Twitter and Facebook content based on search parameters, including several different hashtags provided by Polaris. The production team regularly received hits based on those hashtags. A built-in interface allowed for downstream editing of content that was raw or inappropriate. From there, the content went straight into XPression. That flexibility to moderate streams with simplicity also meant that Allan could focus on higher-end production aspects, including live camera feed monitoring and on-the-fly graphics creation. “I like to have all these different components broken out into modular functionalities, which is why we have TweetOut Nano dedicated to managing the raw data,” said Allan. “That way when there is someone on site who can help, we can put them in front of the Nano box to moderate the content. Everything that comes from the Nano into my Ross XPression has been pre-moderated. That relieves me from having to keep my eye on four different machines.” Flow Motion The complete workflow included transcoding tools from Handbrake and Adobe for format conversion, and a temporary site-wide satellite broadband solution for local WiFi device connections so that attendees and participants could engage and connect via social media. The combined output of video, graphics and social media was ultimately output through a Ross Carbonite switcher, which, along with the videowalls, Sony camera and RF hardware – including six antennae spread around the site for camera feed transmission – was provided under a contract with Screenworks. The broadband link was partitioned for private and public use. This ensured that Alpha Sports TV wouldn’t lose its slice of the bandwidth if attendees swamped the network. “Nano doesn’t require much bandwidth at all – it’s purely XML data, and as such doesn’t cause any bottlenecking in terms of data throughput,” said Allan. “It was essentially an input into the Carbonite switcher, networked with one of the laptops running XPression. We used a third laptop for standalone Xpression graphics, which were basically content layouts built in advance so we could quickly post updated event schedules.” Elsewhere, Allan notes that aspect ratio was an interesting challenge. All video content was delivered to Alpha Sports TV in HD 16:9, while the main giant screen was SD 4:3. To compensate, videos were formatted for HD and letterboxed to the screen to avoid loss of content. The screen's huge size allowed the letterboxing to be an acceptable compromise. Ultimately, turning the typical event production into a “SocialTV” experience was an important step. “You can very quickly tell when people catch on to tweets and social media activity on the screens, because the comments quickly increase in quantity,” said Allan. “If you make it clear that you’re looking for photos and things to accompany tweets, it comes fast and furious. That’s really what you want to see out of an event like this, and we had the right tools in place to out as much content as possible.” For more information: Alpha Sports TV Sony HXC100 Camera Bannister Lake (now part of Ross) Handbrake transcoding tools Adobe transcoding tools Previous Facebook LinkedIn Copy link Next

Masque Sound provides audio for touring production of Joseph and the Amazing Technicolor Dreamcoat. Custom Audio Packages for Musical Masque Sound provides audio for touring production of Joseph and the Amazing Technicolor Dreamcoat. Masque Sound Home Stage Events Jun 4, 2025 When Andrew Lloyd Webber and Tim Rice’s enduringly popular musical Joseph and the Amazing Technicolor Dreamcoat embarked on its 2014 U.S. tour Masque Sound supported Co-Sound Designers David Patridge and John Shivers in their quest to bring the contemporary production to the stage. Since Joseph and the Amazing Technicolor Dreamcoat is scheduled to tour through spring of 2015, Patridge and Shivers wanted to make sure that in designing the sound system it would be capable of easily moving and fitting into a small footprint on the truck. “We wanted to provide the best audio experience that we could, in working within the confines of a traveling production’s space limitations,” says Patridge. With space at a premium, the designers opted to utilize the smaller-footprint Yamaha CL5 Mixing Console, along with a Yamaha CL3 for monitoring, both of which worked quite well for the show. The Yamaha Console was ideal for the production not only for its compactness, as it could be picked up and lifted into position by two people, but also because its comprehensive feature set addressed all of the production crew’s needs. In addition, connecting the console together is a fairly straightforward process and can be done with Cat 5 cabling, which is ideal on a show that needs to move quickly and efficiently. For the PA, Masque Sound provided an L-Acoustics dV-DOSC array, a tried and true speaker design that sounds great. The dV-DOSC line array was integrated into existing speaker towers from Masque Sound’s inventory, which gives the show a PA that is quite spectacular. The flexible system that Masque Sound provided is ample enough to fit, but also compact enough for smaller venues, which was particularly ideal for this production tour, as it features various venues of different sizes. “Fortunately Masque Sound has a very deep shelf of available gear, and we were able to put together an excellent audio package with its equipment that stayed within our budget and did not compromise on the quality of the sound at all,” adds Patridge. “In addition, Masque Sound’s modification of existing inventory speaker towers to fit with the L-Acoustics PA was a large cost savings to us. Joseph and the Amazing Technicolor Dreamcoat is a family musical about the trials and triumphs of Joseph, Israel’s favorite son. Retelling the Biblical story of Joseph, his eleven brothers and the coat of many colors, this musical is full of unforgettable songs including "Those Canaan Days," "Any Dream Will Do," and "Close Every Door." Directed and choreographed by Tony® Award-winner Andy Blankenbuehler, this new production features Broadway stars Diana DeGarmo ( Hairspray, Hair ) as the Narrator and Ace Young ( Grease, Hair ) as Joseph. For more information: Masque Sound Home Previous Facebook LinkedIn Copy link Next

It takes a creative approach to develop the controls for a museum exhibit that simulates a bat’s echolocation. Museum Exhibit Technology Simulates Echolocation It takes a creative approach to develop the controls for a museum exhibit that simulates a bat’s echolocation. By Jay Rees, PE, Rees Engineering Corp. Museums Aug 18, 2025 Cool Stuff Over my years working as an Automation Systems Integrator, I occasionally get projects that are different from the normal industrial process and manufacturing systems, such as developing the controls for a unique museum exhibit to simulate a bat’s echolocation. This project was for the Children’s Center of Sofia, in Sofia, Bulgaria, which prompted the name “The Bulgarian Bat Detector.” In a near dark environment, the museum visitors rotate a viewfinder toward a display depicting an environment for bats. A couple of bats located in the display are the targets for the detector. As the viewfinder approaches the bat’s position, the sound level of an audio track increases in volume with a maximum level when pointed directly at a bat. The volume level decreases as the viewfinder leaves the bat’s position. Photo courtesy of Rees Engineering. The control solution required that the bats are actually detected, which meant that the controls must compare the direction of the viewfinder to the location of the bats in the display. The volume of the audio track is set based on the position of the viewfinder relative to the bats with volume increasing when approaching the bat and decreasing when leaving. The biggest hurdle encountered was how to control the audio volume without excessive development and testing while also keeping costs low. As an experienced automation systems integrator, I did not have a volume control solution in my bag of tricks, and it quickly became apparent that some type of hybrid solution was needed. The position detection and process logic would be handled with an AutomationDirect CLICK® PLC, the audio playback would use a commercially available digital audio repeater, and the volume adjustment solution would need to be built using electronic components. The viewfinder’s position is determined using a touchless Hall Effect encoder attached to the rotating shaft of the viewfinder to determine the rotational position of the magnet. The encoder output of 0.25V to 4.75V DC represents 0 to 360 degrees. This output range is perfectly suited for the CLICK’s built in 0V to 5V analog input. The PLC also has a built-in scaling configuration for the analog input providing the position’s 0-to-360-degree value. For the audio playback, I used the QuikWave™ EM38A, which is often used by museum exhibit developers. It allows MP3 audio files to be played in a variety of ways. For this application we used a playback script to run a single audio file in a continuous loop. Here's what a bat's echolocation sounds like. Audio Volume Solution One of the more challenging parts of the project involved how to control the audio volume from a PLC output. My customer, Andrew Tomasulo of Connect Interactives, came up with a solution that used Light Dependent Resistors (LDR), which consists of an LED and a photoresistor as a single device. The intensity of the LED regulates the resistance of the photoresistor. Because the only connection between the LED and the photoresistor is light, the photoresistor is an isolated and passive device. The PLC’s 0-5V analog output signal is used to vary the device’s resistance. In order to use the LDR solution for volume control, two LDR units are set up as a voltage divider. Two separate 0-5V analog outputs from the PLC provided opposite voltages to the devices (0-5V and 5-0V). The resistance of the LDR’s is from 1,200 ohms down to 60 ohms, which provides a full volume control range. The setup adjustment control uses four potentiometers to set the target locations for the bats in the display. The audio output volume increases and drops within +/- 10 degree range of the target. A 5V power supply voltage regulator (LM7805) was added to the circuit board to power the potentiometers. The outputs of the potentiometers are sent to an analog input module of the CLICK PLC. Photo courtesy of Rees Engineering. Packaging the System All of the components were packed into a 12- x 10- x 5-inch non-metallic enclosure. Field connections are made using Micro (M12) connections and the power cord uses a European Schuko plug (remember this unit is going to Bulgaria). The custom circuit board was hand assembled and mounted on stand-offs. Almost all of the components came from AutomationDirect except the audio playback unit, custom circuit board, potentiometers, and the power cord. Photo courtesy of Rees Engineering. This was a fun project with its share of challenges but in the end it all worked out (and no bats were harmed in the process). I’m thinking of adding a trip to Sofia, Bulgaria, to my bucket list so I can see and hear the unit in operation. For more information: Rees Engineering AutomationDirect CLICK PLC QuikWave Audio Player Previous Facebook LinkedIn Copy link Next

Multiple industries including broadcasting, medical, military, consumer, and others require heating and cooling depending on their application. Thermal Management for Concert Lighting Multiple industries including broadcasting, medical, military, consumer, and others require heating and cooling depending on their application. Terry Persun Stage Events Jun 11, 2025 Cooling fans are a staple product in many industries, such as large data centers, broadcasting, medical, commercial products, military and defense, and multiple large-scale operations whether in lighting or temperature management in office buildings. As a design and manufacturing company, Pelonis provides a wide array of products that deliver the necessary thermal management required by users. When the right product isn’t available off-the-shelf, they provide custom and semi-custom solutions. Here are a few examples: A high-end concert lighting company required exceptionally good airflow blowers to maintain temperatures on a series of high-temperature emitting lights. Pelonis was able to meet the challenge by first evaluating the environment and calculating the overall needs of the system. For motorcycle rider comfort, one motorcycle manufacturer called on Pelonis to supply off-the-shelf cooling fans. In a similar operation, the company supplied fans for delivery vans to cool the driver. Each application required the company to understand the needs of the system to select the most affordable and reliable product for the customer. A consumer electronics company who required ultra-thin flexible heaters for their latest line of portable devices selected Pelonis to help them solve the challenge. Pelonis engineered low-profile heating elements that not only maintained optimal device temperatures but did so without compromising design aesthetics. A robotics manufacturer needed a compact, yet highly efficient cooling system for their automated machinery. Overcoming multiple proprietary design challenges, Pelonis was able to provide customized axial fans that improved thermal management, ensured longer operational life of the equipment, and reduced overheating risks. A commercial HVAC company sought an energy-efficient blower solution to enhance airflow in a large-scale ventilation system. To provide the right system for the project, Pelonis had to design and develop a cross-flow system of fans that could deliver consistent air distribution while reducing power consumption to help save energy. For more information: Pelonis Technologies, Inc. Previous Facebook LinkedIn Copy link Next

Space flight is challenging enough without having to worry about the operational limitations of the components used in the devices going to space. Stepper Motor Design Challenges for Space Flight Applications Space flight is challenging enough without having to worry about the operational limitations of the components used in the devices going to space. Terry Persun Cool Stuff Jul 9, 2025 The harsh environment of vacuum and microgravity applications pose many issues with component capabilities that don’t commonly have to be dealt with here on Earth (Figure 1). That is especially true when it comes to components where movement is their primary function—such as motion control systems. Motors specifically introduce many inherent problems to the environment mainly due to the fact that they require considerable amounts of power to operate, can generate excessive heat, can introduce unwanted vibrations into the system, and can become a source of contaminants. Also from EE: Robots Used in Food Preparation, Serving, and Delivery Figure 1: Specifically designed to be used in satellites and space craft, vacuum rated motors can be used for communications antennas as well as vehicle controls. (Photo courtesy of NASA.) Dealing with these issues comes at a substantial cost. Higher power requirements necessitate larger power generation systems, more heat generated requires bigger cooling systems, dealing with unwanted vibrations requires more robust damping systems, and contaminations can cause havoc on instruments and other on-board components. Lin Engineering has designed their space hybrid stepper motors to work in these harsh environments. Their motors are assembled in accordance with Aerospace AS9100 standards in a fully compliant facility in California, where each component origin is traceable to maintain strict control over the manufacturing process as well as the final product specifications. In space applications, every watt that is wasted by a system that has not been fully optimized for space costs precious resources. Optimizing for power consumption includes customizing motor windings (Figure 2) so that they are able to deliver a peak amount of dynamic torque at the desired operating speed—which takes the proper integration of high-precision components, such as low inertia rotors operating at their highest efficiency. Using proprietary, and proven, algorithms, Lin Engineering is able to optimize torque and speed, noise reduction, heat generation or loss, and/or power optimization. Figure 2: Windings can be customized for high and low speeds, torque output tailored to a specific application requirement, and for high and low temperatures. Temperature Management Two critical concerns related to temperature affecting the performance of hybrid stepper motors in space include the temperature range in which the motor operates and the amount of heat the motor generates. Satellites and other spacecraft operate in extreme temperature ranges. Externally mounted systems expected to function in these extreme temperature variations can cause operational issues if not designed properly. For example, heat affects the magnetic strength of permanent magnets embedded in the rotor. As heat increases, motor performance decreases. The solution to this challenge is to incorporate permanent magnets that are constructed from an alloy that provides greater magnetic power at higher and lower temperatures. For example, either rare-earth samarium-cobalt or neodymium are both used for this purpose. Heat also affects the life of the bearings used in the motor and therefore shortens the lifespan of the entire system. To alleviate this problem, it is necessary to use bearings with oil or grease that can withstand high dynamic temperature ranges—from -80C to +200C. High-temperature, non-outgassing bearings can be designed in as well. Although all motors generate some heat, in a vacuum environment, this can become a major problem because there is no atmospheric medium through which heat can dissipate—from the motor or the vehicle. On Earth, air acts as a conductor, which dissipates the generated heat, while in space, heat needs to be dissipated by other means. By optimizing the winding of the stepper motor, the amount of heat generated can be reduced considerably. In addition, the incorporation of conductive pathways in the motor design also assist in temperature management. These pathways include thermally conductive materials that allow for heat dissipation between the insulator (glue) and motor end bells. Vibration Management Getting a spacecraft into orbit is a violent ordeal. Components are exposed to high amplitude vibration, low amplitude vibration, and shock from several different directions during the launch. Then there are the vibrations generated by the stepper motor during its normal operations. The optimization of the motor windings is a practical way to minimize the resonance frequency that develops at specific operating speeds. By using high quality components, which are specifically machined to high concentricity and dimensional accuracy, it is possible to ensure that components such as rotors or shafts do not introduce unwanted vibrations into the system. In space, however, vibrations need to be avoided at every turn. Low-level oscillations can affect measurement sensors as well as the quality of imaging devices. Dampening vibrations in a microgravity environment is challenging since the craft or satellite is suspended in space where there is nothing to transfer the energy to. Every component has to withstand these challenges, which is why every stepper motor designed for space must use the proper materials to create the structural integrity to handle any and all expected forces it may encounter—without altering dimensional accuracy or mechanical integrity. Lin Engineering has incorporated such materials in their standard motors, which makes them sufficiently robust for space applications. Figure 3: Lin Engineering designs and manufactures a complete line of vacuum motors capable of operating in space. Overall, the longevity of components that go into space is a factor of the time and effort put into the proper design of the components and their final assembly using the latest materials while manufactured in a clean room facility (Figure 3). Space flight and satellite applications require a keen sense of the challenges associated with their operating environment. For more information: Lin Engineering Previous Facebook LinkedIn Copy link Next

Leveraging the power of spatial computing with manufacturing’s digital twin technology leads to more capabilities for engineering collaboration, from product design to manufacturing. Spatial Computing Allows Engineers and Designers to Bring 3D Designs to Life Leveraging the power of spatial computing with manufacturing’s digital twin technology leads to more capabilities for engineering collaboration, from product design to manufacturing. Terry Persun Cool Stuff Nov 3, 2025 From a recent release, Dassault Systèmes announced that 3D UNIV+RSES, which is powered by the 3DEXPERIENCE platform, will use spatial computing capabilities to provide a new dimension to virtual twins, with the use of the “3DLive” visionOS app. According to the release, Dassault Systèmes partnered with Apple to integrate Apple Vision Pro into the next generation 3DEXPERIENCE platform. This deep engineering-level collaboration between Dassault Systèmes and Apple has brought together the best of both platforms to deliver what Dassault Systèmes considers a magical experience. With 3DLive, virtual twins created on the 3DEXPERIENCE platform will appear to leap off the screen and into a user’s physical space, enabling real-time visualization and team collaboration in lifelike environments. Apple Vision Pro incorporates advanced cameras, sensors, and tracking to allow virtual twins to interact with the physical world around them in 3D UNIV+RSES with scientific accuracy. According to the release, this unique and powerful way to model, simulate, manufacture, train, and operate delivers value across all industry sectors and roles, enabling customers to harness the full potential of 3D UNIV+RSES and spatial computing to adapt quickly to market demand, ensure scientifically accurate product quality, accelerate workforce training, and collaborate and share knowledge and know-how. Elisa Prisner, Executive Vice President – Corporate Strategy & Platform Transformation, Dassault Systèmes is quoted as saying, “Our engineering collaboration with Apple represents a bold advance that reveals the power of 3D UNIV+RSES, where 3D is a universal language for a new world combining real and virtual. The wide and growing adoption of the 3DEXPERIENCE platform by our clients makes this cooperation a unique value for our highly diversified customer base, seeing the high potential of 3D UNIV+RSES to collaborate and train our next generation AI-based experiences on their own virtual twin data set.” Mike Rockwell, Apple’s vice president of the Vision Products Group said, “Apple Vision Pro continues to push the boundaries of what’s possible with spatial computing and is changing the way people work across key industries. We’re thrilled to be collaborating with Dassault Systèmes to supercharge the 3DEXPERIENCE platform with spatial computing capabilities that will enable engineers and designers to easily bring 3D designs to life in ways not previously possible.” Enterprise customers can download Dassault Systèmes’ new 3DLive app for Apple Vision Pro. In addition, the release said that Dassault Systèmes has released a new Apple Vision Pro app—HomeByMe Reality—that allows users to imagine, explore, and visualize home interior options from the comfort of their own home, a furniture store, or in a showroom. All images courtesy of Dassault Systems. For more information: Dassault Systèmes 3DLive HomeByMe Reality Apple Vison Pro Read more about virtual reality >>> Previous Facebook LinkedIn Copy link Next

A student team gained valuable STEM experience by developing an underwater remote operated vehicle using commercially available industrial-grade components. Industrial Devices Used in STEM Project A student team gained valuable STEM experience by developing an underwater remote operated vehicle using commercially available industrial-grade components. Geoff Gardener, North Paulding High School Cool Stuff Jul 9, 2025 Exploration of both the deep sea and of outer space share a lot in common. Both are extremely unforgiving environments where it is very expensive to create manned vehicles to carry out missions. As automation has become more capable, robotics and unmanned remote operated vehicles (ROVs) are used to execute much of this work. Underwater ROVs operate in challenging environments, which means that industrial-grade automation products are a natural fit to support these designs. Also from EE: Escape Room Experience Uses Automation Tools Although, ROVs are controlled remotely by human operators, most have some degree of on-board automation, combining mechanical, automation, and other skillsets. To develop young talent to support this field, Monterey Peninsula College—via a grant from the U.S. National Science Foundation—has established a program called the Marine Advanced Technology Education (MATE) Center. MATE promotes marine engineering by inspiring and challenging students to learn and creatively apply STEM skills for solving real-world problems. Part of the program is the MATE ROV Competition, which offers five different contest classes, each based primarily on skill and not strictly by age group. At North Paulding High School in Dallas, GA, a number of students make up the “WhaleTech” team. Some of them have participated up to seven consecutive years, starting in middle school. Each year, the competition organizer publishes challenges and mock mission profiles simulating real-life conditions, with various restrictions. For example: dive to a pipeline simulation at a given depth, strategically remove a “bad” pipe segment, replace it with a new section, and bring the bad portion to the surface. The team builds a ROV to meet those challenges, and along the way they must act and present themselves as a professional company by developing technical documentation, conducting research, and selecting products. Throughout the process, the team must learn and follow safe practices, assemble and test the ROV and subcomponents, and even do a bit of marketing. The Details Many ROVs look a lot like aerial drones, with propellers arranged to provide thrust in various directions. Just as aerial drones use propellers to provide constant lift and control motion, an underwater ROV does the same, but it can also use an additional mechanism to adjust its buoyancy. Cameras and lights are common on ROVs, and many also have robotic arms and manipulators to perform tasks. Many of the monitoring and control needs mirror the types of functionalities needed by industrial automation control systems. AutomationDirect has a long history of supporting student STEM efforts, and this underwater ROV project exemplifies just how important it is for industry to support education. For the 2024 competition, the WhaleTech team needed to develop a well-controlled ROV with an extensible gripper. The buoyancy mechanism, gripper, cameras, propellers, and other components would need to be supported and arranged in a chassis, which meant that some design effort would have to be in parallel and iterative to achieve the functionality and create an integrated form factor. As part of the process, the team used cardboard mockups and 3D printing, and then they created many structural elements cut out from high density polyethylene (HDPE). The buoyancy engine is used to actively alter the buoyancy of the vehicle so the ROV can rise, descend, or stay at a fixed depth (Figure 1). A sealed cylinder compresses the fixed air volume, displacing it with water, which results in changing the overall density of the apparatus. Figure 1: The buoyancy engine consists of a specially modified pneumatic cylinder, driven by a stepper motor and an AutomationDirect SureStep stepper drive, to provide accurate control with minimal power consumption. (Photo courtesy of North Paulding High School.) After selecting an industrial-grade cylinder, the team needed a powerful yet controllable way to actuate the piston portion via a linear screw drive mechanism. After some trial and error, and investigation of technologies readily available from AutomationDirect, the team found that a stepper motor could do the job admirably. A stepper motor can continuously turn in either direction and be commanded in increments as small as 1.8 degrees per step, driven by an AutomationDirect SureStep stepper drive commanded by an Arduino nano. A stepper motor draws no power when idle, it works well within the available power budget, and there is no rebound when the target position is achieved. The buoyancy engine is also outfitted with a pressure sensor used to store depth data into the on-board computer, and a wireless transmitter to communicate this information to the surface computer for a graph display when the ROV surfaces. Similarly, the gripper assembly incorporates an AutomationDirect SureStep rotary stepper motor driving a screw shaft to provide the motion required to extend or retract a mechanism, which in turn opens or closes the gripper (Figure 2). Because this assembly must articulate, it is connected to the controller using a watertight flexible cable. Figure 2: The WhaleTech project team found the right cable assembly for the gripper by researching the AutomationDirect catalog where they found cut-to-length cable solutions that met their technical needs. (Photo courtesy of North Paulding High School.) In previous competitions, the team had experienced issues with umbilical cables—running from the ROV to the surface—that were not flexible enough to allow precise movements in the water, or were insufficiently shielded and therefore susceptible to electromagnetic interference (EMI). To solve these issues, the team researched cables on the AutomationDirect website and found products with better flexibility and improved resistance to electrical noise. Further, the team occasionally used AutomationDirect’s phone support to iron out details. As a result of their design and execution efforts, the WhaleTech team won first place in the Ranger class of the 2024 MATE ROV Competition. While some members are graduating and moving on to new work and educational endeavors, a new crew will assemble next year and work to build upon their successes. For more information, visit AutomationDirect . Previous Facebook LinkedIn Copy link Next