The Ground Shifts in a New Exhibit at the Museum of Science and Industry, Chicago.

Science Storms at the Museum of Science and Industry (MSI), Chicago lets guests investigate the basic scientific principles behind nature’s most awe-inspiring events in a 26,000-square-foot permanent exhibition. One of the displays lets guests trigger an avalanche in a 20’ rotating disk to reveal the beauty of granular dynamics.

Designed by Architect Jack Pascarosa, AIA, from Evidence Design and environmental artist Ned Kahn, the controllable avalanche disk was engineered, fabricated, and installed by Production Resource Group (PRG). Christopher Wilson, Senior Project Manager of Museum Exhibits for MSI oversaw the 16,500 lb display that provided the safe and educational method of understanding the power of an avalanche.

“The 20’ diameter disk is set at a 23 degree angle to horizontal,” explains Sara Rockwell, I.E. Mechanical Engineer with PRG. “The disk spins between 0 and 8-RPMs; the speed is based on the control wheel that is connected to the disk. Guests use the wheel, similar to a steering wheel, to change the speed of the disk rotation and see how the mixture of glass beads and garnet sand inside the disk reacts to different speeds. It allows an attendee to see how a solid can act like a liquid, which is the concept of an avalanche.”

For the turning mechanism PRG used a 15-HP motor connected to a reducer. A four-foot diameter ring gear is the main component mounted to the disk. There is a spur gear attached to the gear box that turns the ring gear which then turns the disk. “We needed to build in a safety factor because we didn’t want the inertia generated by the disk to back drive our gear box in the event that someone suddenly changed the speed from 8-RPM to zero,” says Rockwell. “We needed to accommodate a full stop in less than five seconds. To do this, we inserted a friction slip hub into the spur gear, which allowed the gear box to slip if the torque we set for the hub was exceeded. When the disk slows down enough then the clutch engages again and is driven normally. The most severe torque on the system typically happens only at start up and shut down.” PRG worked with SEW-Eurodrive, Inc. for the gear motors and Mayr Corporation for the brakes.

For installation in the exhibit hall Wilson was very pleased with PRG’s solution. “PRG’s approach to the avalanche was a game changer for us,” comments Wilson. “We were considering building the avalanche disk as a single piece. The concept of building it in small pieces, bringing it into the hall and assembling it, then pouring a special urethane compound to make the final disk surface was all PRG’s idea and it saved us a lot of time, a lot of money, and allowed us to do a full test in their shop.”

Rockwell explains that the load was an important consideration, “We weren’t to exceed a maximum load of 250 Pounds per Square Foot (PSF) for floor loading. Since we were dealing with dynamic motion within the avalanche, we needed to subtract for the live load, so we really only had 150 PSF, which is not a lot when you think about it.” The avalanche display did not need to be tied into the building structure however, since it is heavy enough and stable enough to sit on the floor without moving. Geiger Engineering worked with PRG on the building impact for the avalanche.


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Symetrix gear is used to coordinate IED military audio simulation at the Mobile Counter-Improvised Explosive Device Interactive Trainer to train soldiers in the intricacies of bomb avoidance, recognition and detonation.

The Mobile Counter-Improvised Explosive Device Interactive Trainer (MCIT ) helps to train American fighters to recognize what is arguably their greatest threat in modern theaters of battle: the improvised explosive device, or IED. Using sophisticated A/V technology, soldiers and officers learn about IEDs, their components, the ways they are deployed, and the clues to recognizing them in the field. Then, using cutting-edge interactive gaming technology, they partake in a simulation that pits a “red team” of insurgents against a “blue team” on patrol. The Symetrix Automix 780 and SymNet DSP units play an integral role in the MCIT, delivering both conditioned, matrixed audio and, for the simulation, “party line” routing and conditioning for the participants’ intercom systems, as well as appropriately-routed simulation audio.

The military’s Central Command, together with the Joint Improvised Explosive Device Defeat Organization Joint Center of Excellence, ordered the creation and defined the goals of the MCITs. They contracted University of Southern California think tank, The Institute for Creative Technologies (ICT), to design and develop the content and substance of the MCITs. Isolated Ground, a Los Angeles-based set design firm was brought in to fabricate the MCITs. Isolated Ground hired Technical Multimedia Design of Montrose, California to both design and install the A/V components.

Each MCIT is composed of four mobile, self-contained, forty-foot Conex shipping boxes. They can be moved and used virtually anywhere there is a tennis-court-sized area in which to place them (using either local or generator power). Currently three MCIT systems exist, one at Ft. Bragg, North Carolina, one at Camp Pendleton in California and a third “final prototype” at Camp Shelby in Mississippi. The organizations and companies are currently in negotiation for the construction of additional units for deployment around the country and around the world.

ICT wrote the software for the game, which is based on the VBS2 game engine. A SymNet Express 12x4 Cobra coordinates dialog among and between the teams. Every participant wears a headset, and the SymNet unit is programmed so that members of the same team can automatically talk with each other, in addition to hearing appropriate output from the simulator. The White Team member holds a Symetrix ARC-SW4 wall panel that allows him or her to monitor the teams individually or collectively. In addition, the ARC-SW4 gives the White Team member the ability to speak to any or all of the participants.

When asked why they specified Symetrix, Dave Revel, president at Technical Multimedia Design, was unequivocal, “With Symetrix and SymNet, we get a tremendous amount of processing power for the price point. The programming is flexible and easy – we had the entire MCIT system programmed in half a day!.”

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Energy efficient electro-mechanical motion system uses 5 KWh of electricity and adapts to entertainment, automotive, military, and other applications with unique motion-cueing algorithms.

Cruden B.V., a designer and manufacturer of interactive motion-based simulators, has installed its first two Hexatech 3CTR race car simulators at Weston-Super-Mare Grand Pier. The simulators are the exact same professional equipment as used by racing drivers and engineers in Formula One and other international motorsport championships for training, race car development, and off-track testing.

The Hexatech 3CTR uses full motion or six degrees of freedom, highly accurate force feedback, and realistic g-force simulation. Each simulator has three seats.

The simulators offer guests races in Formula One, rally cross, and sports cars on a variety of tracks, and even though the Grand Pier is completely under cover, drivers can even choose whether to race in the rain. Wannabes Lewis Hamiltons and Jenson Buttons can race against each other when the two systems are linked together. Cruden is able to modify its simulators for the attractions market to exact specifications, supplying open or closed cockpits, fitting car bodywork or mounting actual vehicles into a motion platform. Its software offers a broad ‘pick and mix’ range of options which include vehicle models, tracks and race cars, and various other upgrades, available throughout the long life of the simulator. In addition to realistic noises, smell and lighting can be added to create the desired ambience.

The secret ingredient of the Cruden package is its highly developed motion-cueing algorithms – the complex and critical math which translates driver input into motion and force feedback response via the simulator’s interactive motion platform and control loading. Movement through six degrees of freedom, seat belt tensioners and near 100%  realistic steering feedback provide the exact same feel as a real race car as judged by experienced test drivers. Simulator sickness of below 1% is further evidence of good simulation.

Each simulator can be modified to exact specifications, from the look of the hardware to the feel of the ride and handling. A user-friendly ‘Race Manager’ program allows track and vehicle selection. Cruden simulators deliver unlimited, repeatable performance over their long lifetime. Machines can last for years without major overhaul thanks to Cruden’s expertise in developing durable simulation equipment for the military and professional flight and marine simulation industry.

The simulator’s design includes an energy efficient electromechanical motion system, which typically requires only 5 KWh of electricity to operate. It has seat belt tensioners and realistic steering feedback.

Simulators are fully compatible with Matlab/ Simulink and seamless integration of simulation models through CarSim and VeDYNA.

The simulator’s image generation process significantly reduced motion blur as well as real-time CG shadowing and environment mapping.

Originating from Fokker Aircraft Company, the Cruden company was previously known as FCS Racing Simulation and was renamed Cruden in 2006. In 2003, FCS took its flight simulation know-how and developed a racing simulator that combined a motion base with a detailed dynamic vehicle model, excellent motion-cueing software and professional image generation.

Since 2005, the company has been successful in securing projects both in the entertainment and industrial markets – where it is a supplier to some Formula 1 teams.

Cruden’s team of vehicle dynamicists, software developers, mechanical engineers and project managers are headquartered in Amsterdam, but in 2008 Cruden launched a US operation.

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Art-Net Compatible DMX Lighting Control Software brings simple control to iPad, iPhone, and iPod Touch devices.

Alcorn McBride released its newest App – LightingPad™, which is designed for controlling lighting for small shows or for installing and testing lighting systems. It can also be used to program Alcorn McBride’s LightCuePro™. Users may connect any Art- Net compatible DMX device to a wireless network to create a hand-held lighting console.

The LightingPad is compatible with the iPhone, iPad, and iPod Touch. It controls 512 channels of DMX and stores up to 100 cues with independent fade times. With the Art-Net DMX-over- Ethernet protocol it can automatically search and display any Art-Net device. For the iPhone and iPod Touch, the horizontal screen displays the slider view; users may flick left or right to display more channels. Rotating the iPhone or iPod Touch vertically will bring up a scrolling list of 100 cues. Touching “Save” names the cue and memorizes fade time and slider positions, while pressing the “Go” button allows a user to run through cues in the cue list from a single button.

The iPad version includes all the features of the iPhone version; all sliders and cue lists fit on the iPad screen. The iPad version also has the ability to assign and edit slider names and can copy cue lists to and from iTunes for backup and storage.

“We developed the LightingPad to provide our customers with an easy-to-use and convenient tool for lighting design and troubleshooting,” said Jeremy Scheinberg, Alcorn McBride COO. “The iPad/iPhone platform is a great way to add new features and new products which will help our customers to create incredible experiences, no matter the scale.”

The LightingPad App is available for download via the iTunes store under “Utilities”.


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A tiny drive developed for medical standards has a big impact for animatronics and other applications.

Maxon’s new brushless two-watt dc motor offers continuous current up to 0.95 mNm. It also has a nominal speed up to 80,000 rpm and an efficiency rating of 70%.

The motor is available with or without Hall sensors and with 6 V, 12 V, and 24 V windings. It can be combined with the planetary gear head GP 8A. 1-quadrant amplifiers serve as controllers; the DEC 24/1, directly connected via flexprint and the DEC Module 24/2, a miniature plug-in module.

This motor was produced according to the most rigid Medical Standard ISO 13485 and is ideal for a variety of applications such as animatronics, sampling robotics, portable analyzers, metering systems, and instrumentation, and inspection robots.

There are many other applications that would be appropriate for 8mm motors. Engineers from the company are available to discuss applications and direct designers to the proper motor combination.

Maxon makes CAD components of the company’s motor products available for download, to shorten design times. Free downloads are now available on 2D and 3D data. Detailed information and technical drawings of Maxon’s DC brush and brushless motors, sensors, gearheads, brakes, and control electronics are vailable online.

A multi-CAD capability ensures compatibility with all standard CAD systems: SolidWorks, Catia, Pro/Engineer, Inventor, Solid Edge, TopSolid, thinkdesign, Unigraphics, Alibre Design, Acis, STEP, IGES, DWG, DXF.


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Previously, robot developers were forced to put together complex, custom solutions for robotic joints from numerous individual components.  That's not the case any longer.

The joints in the Robolink system are controlled by cable tension, in a similar way to the human mechanics of bones and tendons. All data cables are routed safely through the jointed arms, which are effectively the robot’s skeleton. These cables convey images, acoustics, and forces, which are the artificial senses of humanoid robots.

Dr. Rudolf Bannasch is Managing Director at the Berlin-based company EvoLogics, a high-tech company working in the field of bionics and humanoid robots. He provided both the motivation and developmental support behind igus' Robolink component.

“During the development of humanoid robots, we spend an enormous amount of time on the mechanisms,” says Dr. Bannasch. “We had been dreaming of a straightforward, modular system for quite some time.” The reason was to reduce development times so that artificial-intelligence programmers could be involved earlier in the process.

The Robolink unit was primarily designed for robot developers and laboratories that work with humanoid systems, as well as with lightweight engineering solutions for handling and automation. igus’ development objective was to keep the moving mass as low as possible, so that the actuators could be separated from functioning tools, such as grippers, hands, suction cups, and so on. Particular attention was given to enabling a quick assembly and user-friendly design, as well as using tribo-optimized plastics to provide both freedom from lubrication and a low weight.

Robolink is comprised of a drive-and-control unit, joints in different lengths, and arms in different sizes, including a duct for additional control cables. At the end of this jointed system, igus offers the option to connect to different types of tools. Since the system is modular, it can be constructed in a variety of humanoid robot configurations, ranging from jointed arms through fourlegged creatures-like systems. Joints can be easily combined as required.

The drive-and-control unit was purposely designed as a black box to allow robot developers the option to work with pneumatics, electro technology, or hydraulics. The jointed arms are made from carbon-fiber reinforced plastic and other lightweight materials.

The bionic core of the robot’s skeletal parts is the injection-molded plastic joints. They are controlled via cable pulls that transfer tensile forces, just as tendons function in humans. The cable sheath is held and the inner cable moved. The cable pulls are routed from one joint to the next. Only four cables are required for each plastic joint to be able to rotate and swivel freely.

The cables are made from technical synthetic fibers and are extremely strong, hardly stretch at all, are resistant to chemicals, and are lubrication-free and wear resistant. When compared to steel, their light-weight also makes them much more energy-efficient.

“We are pleased to be breaking new ground with our tribo-plastics,” says igus Managing Director Frank Blase. “The new modular system brings the developers of humanoid robots real benefits: lightweight, readymade mechanical solutions for the future.”

igus is currently looking for beta testers for this new product.


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Optical Virtual Camera System Enables Live-action Camera Work for CG Filmmaking at a Competitive Price; Compatible with all Optical Motion Capture Systems.

Filmmakers and game cinematographers are increasingly turning to real-time virtual production technologies to blend real-world tools with their virtual world. At the heart of this development is the virtual camera. James Cameron revolutionized digital cinematography with his innovative control of the virtual camera using motion capture. This “Virtual Vérité” technology is now being offered for a fraction of the cost, with OptiTrack and Insight VCS.

“Our goal has always been to offer full-featured motion capture systems at a price that production companies of every size can afford,” said Jim Richardson, NaturalPoint®® co-founder and lead engineer for the OptiTrack motion capture line. “With the Insight VCS, we’re expanding this vision to include the bleeding-edge virtual camera technology that Cameron made famous with “Avatar” - as usual, at an exceptionally low price. OptiTrack now delivers high-performance body, face and virtual camera mocap for less than anyone else in the world.”

To ensure complete compatibility with a variety of production pipelines, the Insight VCS has been engineered for interoperability with any existing optical motion capture system - including OptiTrack, Vicon and Motion Analysis - that can track marker-based rigid bodies and stream data to Autodesk MotionBuilder or Autodesk Maya.

Developed in close collaboration with Los Angeles-based previsualization company Halon Entertainment, the Insight VCS is the ideal virtual camera solution for a broad range of applications ranging from film and commercial previsualization to digital filmmaking. Throughout the development process Halon tested design iterations in the field, utilizing pre-production versions of the Insight VCS to create content for high profile projects and directors. Halon Entertainment has provided mobile teams of artists for short and long term projects with such acclaimed Directors as Steven Spielberg, George Lucas, and James Cameron.

“In working with OptiTrack to develop the Insight VCS, Halon helped build a tool that puts film directors and directors of photography in a virtual world they more closely understand,” said Justin Denton, technical developer and previs supervisor at Halon Entertainment. “The value of being able to walk out into a space and explore a virtual world by physically controlling a camera, finding the perfect angles and then shooting multiple takes is truly remarkable. All of this is achieved in a fraction of the time it takes to keyframe a single camera take, and the results are more natural. The Insight VCS has proven invaluable on multiple high-profile film and commercial projects for us here at Halon.”

The Insight VCS is a two-part system, consisting of a hardware camera rig and software interface. As the hardware rig is tracked throughout the motion capture volume, absolute 6 DOF position and orientation data is streamed live via the software plug-in to either MotionBuilder or Maya to drive the virtual camera within the 3D application. Real-time reference video is streamed out of MotionBuilder or Maya back to the VCS display, creating a low-latency visual feedback loop, akin to the viewfinder in an actual digital camera.

Different versions of both the hardware rig and software plug-in are available to fit a variety of existing pipelines and production requirements. Components include:  Virtual Camera Rigs: The Insight VCS offers two different hardware rigs for controlling the virtual camera: The VCS: Pro is designed for professional production work, the VCS: Pro replicates the organic cinematographer’s experience with exceptional fidelity. The professional model includes a 1280x768 HD LCD display for real-time feedback, mappable buttons and joysticks for extensive camera control, and a robust Redrock Micro shoulder mount kit. Markers and posts are included for a variety of marker configurations.

The VCS:Mini provides low cost, lightweight and highly flexible access to the virtual camera pipeline. The kit includes an anodized aluminum mount preinstalled on a wireless Xbox 360 game pad, as well as markers and posts.

Software Plug-ins: Comprehensive, customizable plug-ins are available for camera work in MotionBuilder and Maya for control over scripts, button mapping, scaling and camera properties. Universal versions of each plug-in are also available for use with non-OptiTrack motion capture systems.

Demonstrations of the Insight VCS will be available at SIGGRAPH 2010, July 26 - 29, at the OptiTrack booth #701.

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The fastest track on the NASCAR circuit is the Talladega Superspeedway. In order to measure lap speed accurately, the camera has to be very steady.

The average speed of a NASCAR car varies from one racetrack to another. The speed is calculated based on the winner’s lap speed through the entire race. On the Talladega Superspeedway the recorded average speed is about 188 miles per hour (303 kilometers per hour).

In order to capture video images of the cars as they hammer along the track at these phenomenal speeds, a camera needs to resist the wind turbulence generated by the passing cars, especially since the camera is mounted to a gantry that is only ten inches above the track.

Doggicam Systems (Burbank, CA) adapted its patented movie camera system to create the Super Slide, a high-speed, light-weight, and super-rigid rail system, which allows the camera to be moved at tremendous speeds and accelerations while maintaining high precision.

One of the key components to the Super Slide that allows the Doggicam Systems’ Super Slide to deliver high-speed precision while moving safely within inches of the subject, are the Intech Power-Core™ rollers. These rollers ensure a smooth, vibration-free rolling transit of the camera system along the rail. With minimum resistance, the rollers allow the camera to accelerate from zero to 24 feet per second in just one second, and to reach a top speed of 25 feet per second.

Intech Power-Core™ rollers eliminate rail wear as well as the need for lubrication. These features are ideal for a long-lasting solution in demanding conditions like high vibration, torrential rains, and extreme heat to freezing temperatures — all environments that the Doggicam Super Slide is exposed to. Intech guide rollers are also used in mechanisms that move cameras in TV studios or on film sets, where smooth, vibration free and quiet camera operation is paramount.

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Hall-effect proximity sensors used as wheel speed sensors.

The University of Wisconsin Formula SAE team competes against over 130 universities from around the world in an annual competition held at Michigan International Speedway. The competition is based on the design and manufacture of a small scale open-wheel, open-cockpit racecar. Teams are usually comprised of engineering students who, in the fall semester, design the car using Computer-Aided-Design programs and, in the spring semester, manufacture these designs to create a competition-ready vehicle. In 2007, Wisconsin Racing took 1st Place at the international competition and in 2008 came away with 4th Place and the top United States team. The team also competes at Virginia International Raceway where, in 2008, the team took home 1st Place at the inaugural competition.

In 2009, the team made a drastic switch from a four cylinder Suzuki GSXR600 motorcycle engine to a single cylinder KTM 525. The main reason for the change was a new rule which made fuel economy worth double the points it was previously. This change also brought about the implementation of a turbocharger. The team uses an IHI turbocharger to increase the vehicle’s performance. Unfortunately, this was a major change made by the team and the vehicle failed to finish the endurance event due to an engine failure. The team was on pace to a top 10 finish, but with the engine failure, dropped all the way to 35th. The 2010 car has focused on increasing the performance while maintaining reliability so that another engine failure does not occur.

Two important aspects of the vehicle are the control strategies used and data acquisition analysis.

One way the team incorporates both of these is with the use of Hall effect proximity sensors (AutomationDirect part number PY4-AN-3A), used as wheel speed sensors by sensing an encoder wheel located within the upright assembly.

One important use of wheel-speed sensors is for the traction control system. Traction control is a useful system which reduces the torque output of the engine in the  event of traction loss. Traction control requires feedback from the wheel speeds on all four wheels, and it uses this feedback to determine the amount of wheel slip on the rear tires in comparison to the front tires. It then takes this wheel slip percentage and retards the spark advance to reduce the torque output of the engine.

This traction control system is very effective in reducing wheel slip and decreasing lap times; it decreases wheel slip a stunning 63 percent. The traction control system reduces lap times by an average of 0.8 seconds over the course of a 30 second lap, and greatly increases the consistency of lap times. This traction control system allows the drivers to focus more on the track rather than focusing on trying to maintain optimum traction.

Another way the proximity sensors benefit the team is through the use of data acquisition. With data logging hardware, the team can analyze each lap by comparing parameters such as the vehicle’s speed. This is beneficial in the development of the vehicle and also in the development of the driver. Monitoring the car can prevent potential failures, and aid in troubleshooting any problems that might occur.


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Microsoft’s new Kinect plugs into Xboxes and lets players control games with body and hand gestures. No controller. Microsoft previously referred to Kinect by the name “Project Natal.”

The new system uses cameras to read player movements. It then translates those actions onto the TV screen and into the game.

Microsoft first showed off this technology at the E3 trade show www.e3expo.com/ in 2009, but did not reveal many details about the system.

Kinect is a three-camera system that plugs into Xbox and allows for hands-free games and controlling the console with voice commands. In addition to watching player motion with cameras, Microsoft Kinect for Xbox 360 also uses a microphone to listen to player voices.

Kinect can be used for video chats as well as to listen to music and watch movies with friends in other locations. The command “play movie,” for example, makes the system start playing the film a user has selected. The new platform is said to take gamers a step beyond Nintendo’s Wii.

Nintendo, which pioneered motion-sensing gaming through an all-purpose controller with its Wii system, is expected to soon release more information on its 3D games system that require no glasses.

Sony also has a new motion-controlled gaming system in development called Move, but like Nintendo’s Wii, it requires players to hold remotes in their hands.

Kinect’s ability to read a players’ body movements without the aid of remotes uses a technology developed by Microsoft Research.

Microsoft announced six games for the system, which will be available when Kinect launches in November, 2010.
Upcoming titles for Kinect include a Lucas Arts game in which Jedi Knights do battle with light sabers. One game called Kinectimals lets youngsters play with virtual wild animals.

The new Xbox 360 will not be able to read player motions without the Kinect add-on.

To learn more about Kinect, visit http://www.xbox.com/en-US/kinect or www.xbox.com/en-US/community/events/e3/kinect.htm.

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