www.industrialtechnology.co.uk Industrial October 2017
Technology
FOR DESIGN ENGINEERS, MACHINE BUILDERS AND SYSTEMS INTEGRATORS
Industrial IoT for brownfields
Industry news p6 Wireless & RFID p30
Pharmaceuticals report p10 Robotics p32 RoSbEeoRxtVitcOredDmoRleIlfyVoliEcvoPSaetapa-gagtecuetr3ieo4sn
Bearings, slides & lubricants p16 Drives, motors & controls p34
Machine building p24 Hydraulics & pneumatics p38
Machinery safety p26 The sports pages p42
www.industrialtechnology.co.uk
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COMMENT & ANALYSIS
www.industrialtechnology.co.uk EDITORIAL Across Europe, the only
Editor constant is change...
Mark Simms BSc Tel: 01732 773268 Ihad yet another fantastic money-making idea. Could have been an app, could have been a
website, but people would have been queuing up to pay me money for the privilege of
[email protected] using/viewing my product. What could it be, you ask? My plan was to take a century’s-
worth of maps showing the changing borders across Europe, and create a time-lapse
ADVERTISING sequence that would allow you to view the changes, zoom in on any given region and view
developments in devolution and unification, zoom out to view the impact of wars, conquests
Regional Director (Home Counties & South East) and invasions, pause on specific years and take in the wider picture, and more. It would have
been awesome. Fly in the ointment, though; someone’s beaten me to it. And stuck it up on
Mark West Tel: 020 8467 3613 YouTube of all places, so that’s pretty much any hope of monetising that one gone straight out
the window.
[email protected]
I suppose it’s nice to see what my idea would have looked like.
Regional Sales Manager (Midlands) And perhaps if I stuck to being the ideas man and let someone else do
the development, these things would come to fruition much more
David Harman Tel: 01772 462596 quickly and I’d be a much wealthier chap. Hey ho. If you want to see
it for yourself, type ‘changing European borders time lapse’ into your
[email protected] preferred search engine, and check it out.
Regional Sales Manager (North of England, Scotland & Wales) What brought it into focus for me was the recent independence
vote in Catalonia, which, if the time lapse map is correct, seems to
Jan Anderson Tel: 01978 314730 have been a functioning economy centuries before Spain was even a
glimmer of an idea. Similarly, there has often been discussion about Bavaria splitting from
[email protected] Germany. Belgium is divided half and half between the Flemish and the French speaking
Walloons with, seemingly, a corresponding socio-economic divide. There are others, too, and of
Deutschland/Suisse/Österreich Tel: +49 228-2499860 course we can’t forget our own independence vote in Scotland in 2014. Nor, indeed, Brexit. [email protected]
Eisenacher Medien [email protected]
Politicians in the UK have argued that the push for independence in Scotland has driven the
Overseas Tel: + 44 161 374 5615 push for greater devolution across all regions of the UK. EEF reports that manufacturers are
George Bennett MA [email protected] calling for a clear strategy on devolution, and indeed want devolution deals rolled out across all
areas of England. Can you view the drive from devolution to autonomy to independence not as
MAILING ADDRESSES a straight line but as a never-ending spiral?
Press Releases: [email protected]
Advertising Copy: [email protected] Looking again at the changing European borders video, it struck me that ‘stability’ is very
Head Office: Victoria House, 2 Mornington Road much a relative term. Over the centuries, the only constant has been change. What does that
Sale, Cheshire M33 2DA mean for business? On the one hand, business craves stability – change, particularly dramatic
Email: [email protected] change is bad. On the other hand, even dramatic instability, when you take the longer term
Circulation Department: PO Box 85, Sale M33 2BB view, is just a snapshot in time. So what conclusions can we draw? Well, for me it’s all
Email: [email protected] hammered home, yet again, that I’ve simply got to get my best ideas to market much more
quickly. Back to the drawing board once more, I fear.
GENERAL ENQUIRIES
Email: [email protected] Tel: 0161 374 5615 Mark Simms
Editor
Industrial Technology ISSN 0967-5787 As a controlled circulation journal, Industrial Technology is sent
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Technology
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Contents 38 Index to Advertisers
6 Industry news 28 Ace Fabreeka UK .................................... 3
Advanced Engineering Exhibition ............ 44
6 Calls to focus on leaner, cleaner manufacturing 40 Andantex ............................................. 35
8 Apprentices the solution to the UK’s skills gap Automation24 ........................................ 2
On the cover Bowman International ........................... 19
10 Pharmaceutical industry Dold Industries ..................................... 29
Industrial IoT for brownfields EMS .................................................... 37
10 Linear guides enable automated dispensing See centre spread for details Flexlink Systems ................................... 33
ForTop Automation ................................ 29
16 Bearings, slides and lubricants Also in this issue Gudel UK ............................................ 33
HepcoMotion ....................................... 20
16 The heat is on Industry news ..................... 6 IDS Imaging Development Systems ........... 9
18 Five reasons to replace PTFE-lined bearings Advanced Engineering ....... 12 Igus (UK) ............................................... 7
20 Installing Vee bearings and T-rails New products.................... 14 Igus (UK) ............................................. 17
Engineering Update ........... 43 Interroll ............................................... 34
24 Machine building and automation Kingston Engineering ............................. 35
Kistler Instruments .................................. 5
24 The age of the PLC platform is now Lee Products ........................................ 40
26 The importance of the safety of workers LG Motion ........................................... 11
28 Machinery safety in an Industry 4.0 environment Machine Building Systems ..................... 25
30 Accelerating deployment in the Internet of Things OEM-Automatic .................................... 27
32 UK manufacturing industry must wake up to automation Phoenix Mecano ................................... 29
Rotaflow FV ......................................... 43
34 Drives, controls and positioning systems RS Components .................................... 13
Schaeffler (UK) ..................................... 21
34 Servo drives key for high speed robotic camera dolly Spirol Industries ..................................... 7
36 Easy to select, easy to connect, easy to configure Spirol Industries ................................... 13
Staubli Connectors Division ................... 39
38 Hydraulics and pneumatics Tom Parker .......................................... 41
Turck Banner ........................................ 31
38 Can Formula One technology benefit your own processes? Weidmuller ............................................ 5
40 Hydraulics will run and run with proper servicing
42 The sports pages
42 Cutting-edge aerodynamic insights for performance sports
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INDUSTRY NEWS www.industrialtechnology.co.uk
Calls on government to focus on
leaner, cleaner manufacturing
Business leaders are calling on the government to rebalance the UK
economy by supporting a focus on manufacturing resource efficiency
The British Chamber of Commerce, the TUC and “A successful and balanced economy must be both [email protected]
the North West Business Leaders Team are sustainable and resilient. Manufacturers in the North
among the UK’s leading business organisations West recognise our role in securing and optimising our will mean the kind of investment that creates great
which have joined with the think tank Green use of resources. We are working to address fundamental quality jobs, and closes regional gaps in productivity. And
Alliance to urge the government to support more resource questions regarding the reliability of our energy supply, it will help keep British manufacturing competitive in the
efficient manufacturing. They say it is needed to close the sufficiency of food production and the resilience of our global economy, so it can be a source of great jobs in the
UK’s regional productivity gap and ensure good jobs stay water supply. These resource issues not only offer the key future.”
in the UK. The government’s budget watchdog, the Office to future security, but also open up significant
of Budgetary Responsibility, is expected to take a much productivity gains if government and business place these Commenting on the government’s Clean Growth
more pessimistic view of productivity Strategy, Roz Bulleid, head of climate and environment
in future, as it is due to announce opportunities at the heart of our future industrial policy at EEF, said: “Manufacturers have been waiting
that its economic forecasts have strategy.” some time to discover how the government intends to
been too optimistic over the past meet the UK’s challenging 2030 decarbonisation target
seven years. This makes a focus on Steve Evans, director of research, Institute for and will be pleased to see a broad-ranging and well-
productivity and rebalancing the Manufacturing, University of Cambridge said: “Leading structured report, that ties into the wider Industrial
economy even more vital. UK firms are already capitalising on the more efficient use Strategy. It balances the need to offset the costs
of energy and materials to improve performance, but manufacturers face from decarbonisation with greater
Manufacturing contributes 15- many others are not even aware of the resource risks they realisation of the potential opportunities across a range of
20% of the economy in UK regions face or the opportunities for savings that would make product areas.
experiencing low productivity. them a business priority. The government’s industrial
Although this includes some of the strategy should provide foresight and benchmarking for “There is also much appreciated recognition of the
UK’s most productive firms there is a UK manufacturers to realise the untapped potential of need for more government support for industry in key
long tail of poor performers resource efficiency and help build long term areas, including energy efficiency, heat reuse and carbon
contributing to the problem. Around manufacturing competitiveness.” capture and storage. Industry stands ready to now work
half of manufacturers’ costs are on resource inputs. In the with Government to ensure we move from strategy to
past ten years the best manufacturers across the country Mike Spicer, director of research and economics, delivery at the earliest opportunity.”
have cut their energy use by 50%, but the majority have British Chamber of Commerce said: “Manufacturers
only managed a reduction of 10-15%. Between 2003 across the UK tell BCC that they are faced with rising Looking at the focus in the report on energy efficiency,
and 2015 there was a 24 fold increase in institutional input costs that threaten their competitiveness. As the she added: “The focus on energy efficiency is very much
investors asking and acting on information about resource most successful firms know, improving resource and appreciated, particularly the continued commitment to
risks. The government can help manufacturers via the energy efficiency is essential to meeting that challenge. A development of an industrial energy efficiency fund, as
industrial strategy by providing a long term view of these comprehensive upgrade programme for manufacturing, promised in the Conservative manifesto. The power
risks and an understanding of the role of technology in taken forward by the new industrial strategy and sector has received vastly more public support for
improving efficiency, through the use of alternative supported by government would be a welcome step in the decarbonisation than industrial firms, even though energy
materials, optimised processes and recovered materials. right direction.” efficiency can cut greenhouse gas emissions more
cheaply. “60% of our members see the time it takes to
In a joint statement five leading business Dr Joanne Wade, CEO at the Association for the recover costs from energy efficiency projects as a barrier
organisations and the think tank Green Alliance are Conservation of Energy, said: “UK energy productivity and 10% cite access to funds; these can be overcome
calling on the government to use its forthcoming improved by 15% between 2010 and 2016, but this is with more government support.”
industrial strategy to raise the baseline performance of all not enough to ensure that our businesses are fit for the
UK manufacturers on resource efficiency. This has the future. The industrial strategy provides the opportunity to
potential to add £10 billion to the profits of the set out an energy and resource productivity agenda that
manufacturing sector, increase productivity, support will close the gap and help manufacturers across the
growth in the North and Midlands, where manufacturing country to deliver maximum added value to the economy”
is more dominant, and keep good jobs in the UK.
Paul Nowak, deputy general secretary, TUC said:
A report by Green Alliance, “Lean and clean: building “Improving the energy and resource efficiency of British
manufacturing excellence in the UK” proposes a new industry is not only a necessity, it’s a great opportunity. It
manufacturing upgrade programme with procurement
criteria, to encourage and reward more resource efficient
production.
Angela Francis, senior economist at Green Alliance,
said: “The German and Japanese governments support
their manufacturers to raise resource efficiency. The UK’s
industrial strategy must help British businesses keep up
if they are to retain their competitive advantage post-
Brexit. There are huge economic opportunities here
which could help to reinvent manufacturing in the
North.” Juergen Maier, chief executive, Siemens UK and
chairman, North West Business Leadership Team, said:
6 INDUSTRIAL TECHNOLOGY • October 2017
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7
INDUSTRY NEWS
CLPA membership Apprentices the solution
passes the 3000 mark to the UK’s skills gap
The global footprint of CC-Link IE and Apprentices are the solution to addressing the UK’s have finished. But apprenticeships don’t necessarily close the
CC-Link have reached a new high, with the skills gap, say 82% of UK SMEs in results obtained door on university – there’s no reason why someone can’t do
number of CC-Link Partner Association from the Close Brothers Business Barometer, a both because higher-level apprenticeships can lead to a
(CLPA) member companies passing 3,000. quarterly survey that questions over 900 UK and RoI foundation degree, meaning going to university at a later stage
With this surge in members, of whom more SME owners and senior management across a range of sectors needn't be off the cards.”
than 300 are offering some 1,700 products and regions. “Skills shortages have made headline news
available for the technologies, CLPA is recently and it’s clearly an issue that SMEs feel very strongly Nationally, 49% of business owners answered ‘yes’ to the
helping to drive the digitalisation of about,” said Neil Davies, CEO of Close Brothers Asset Finance. question ‘if assistance was available either from either the
manufacturing which is central to the goals “Many businesses are very concerned about where their next government or the private sector, would you participate in an
of Industry 4.0. cohort of skilled workers is going to come from and the answer, apprenticeship scheme?’. “At a regional level, there were
they feel, is more apprenticeships. relatively wide variances between those businesses that would
Further, double-digit year-on-year seek assistance and those who would not, most likely because
growth has seen the number of installed “Our research tells us that one in five small to medium of the distribution of industry sectors,” said Davies. “For
devices increase from around 17 million in sized businesses have their own apprentice scheme while 58% example, the West Midlands, which has long been a
March 2016 to over 19 million at the end feel it’s not right for their business; the remaining 22% cite manufacturing and engineering powerhouse ranked towards
of March 2017, and today the installed lack of affordability as the reason why they don’t have one of the bottom of the list but has historically used apprenticeships
base is close to passing 20 million. their own. Clearly, not every business has a need for an to ensure succession planning.
apprentice; however, the fact that for many it’s simply too
CLPA-Europe general manager John expensive shows that more needs to be done. Close Brothers “Businesses in the South East, on the other hand may feel
Browett comments: “The rate of new has long been a supporter of apprenticeships, with two less well equipped to create their own schemes, and as such
installations continues to grow at a double schemes currently underway in the manufacturing and would be more likely to seek outside assistance.”
digit pace as more and more users come to transport sectors.”
appreciate the benefits of our technology.
The industry leadership of CC-Link IE has University alternative
proved to be key, being the first industrial
Ethernet technology to provide gigabit SMEs firmly believe that apprenticeships are a viable
transmission rates with full determinism. substitute to university, with 76% of business owners agreeing
Given the current move towards Industry with the statement ‘apprenticeships are a valuable alternative
4.0 applications and the bandwidth to university’. “The number of school leavers choosing
required for their success, it’s no surprise apprenticeships over university has risen by over 20% since
that its user base is growing so quickly.” 2010,” said Davies.
eu.cc-link.org
“For the industries we serve, this is clearly a positive
Automata slashes the development and for many, one of the main attractions of
cost of robotics apprenticeships is the opportunity to earn while they learn and
because the schemes are linked to businesses, in many cases
Automata is launching Eva, an elegant, it mean they are able to walk into a full-time job after they
simple, affordable robot arm built for
professionals. Eva costs just £4,990 while UK-manufactured drives help Indian
robotic arms of similar size cost over
£20,000. Automata is now taking aluminium finishing mill boost uptime
reservations for Eva on its website.
Six 200kW Unidrive M700 AC variable frequency Seeking to develop a reliable solution to overcome the
Eva has been in development for over drives (VFDs) from Control Techniques are boosting downtime of two finishing mills in its casting house, which
two years and has been through over 18 the uptime of finishing mill operations at a major produce aluminium wire rod coil and billets for the global
versions, rigorous lifetime testing and it is aluminium manufacturing facility in India. Facing automotive and consumer goods markets, Balco turned to
now undergoing final testing. The first ongoing issues with its previous drives, the plant turned to Control Techniques, who recommended a 1200kW AC VFD
customers for these trials include a Control Techniques following the company’s readiness to take standby drive system based on six 200kW Unidrive M700
multinational automotive supplier, a leading full responsibility for the entire project. drives. The drives are required to operate with existing Leroy
producer of laboratory instruments and a Somer SLSHR liquid-cooled induction motors, which are
British components manufacturer. particularly suited to variable speed operation. A further
requirement was that the M700 series drives were to be
Suryansh Chandra, co-founder of configured on Ethernet (on-board real-time Ethernet is
Automata said: “Current industrial robots included as standard on the M700) with a Rockwell safety
are designed for heavy industry tasks that controller.
require extreme power and precision. But
people don’t work like that, and 90% of The drive was designed to operate as an on-demand
automatable tasks in manufacturing such standby for both of Balco’s production finishing mills, offering
as machine tending are still done by people acceleration and deceleration of 1.5 seconds per 1000 rpm.
on a daily basis. Furthermore, the mills had to run in closed loop configuration
and stop and start in 1.3 seconds. The use of DBR (dynamic
“We designed Eva to make automation braking resistor) braking was another requirement of the
simple, quick and affordable, so people can project.
leave the menial work to Eva and focus on www.controltechniques.com
more intelligent tasks.” Eva is Automata’s
first step in achieving the mission of INDUSTRIAL TECHNOLOGY • October 2017
bringing the next revolution in
manufacturing by making robotic
automation affordable and simple.
www.automata.tech
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Industry report pharmaceutical
Linear guides enable
automated dispensing
An automated dispensing
system for pharmacies relies on
linear guidance technology for
its gripping action
In order to save time and accommodate a wider range so that it can reach the packs of medicines. The two asserts that GV3 is one of the quietest linear systems
of products, more and more pharmacies are turning to parallel, induction hardened GV3 slide rails are based at available – a key benefit that appealed to Gollman as the
computer controlled, automated dispensing systems. the top of the system and enable the arm to move systems are in close proximity to both customers and
Gollmann, based in Germany, has developed two smoothly between the roller cabinets. The latest hybrid pharmacists alike. The roller cabinets containing all of the
picking systems for pharmacies, GO.compact and gripper technology on the gripper arm ensures that the different medications also move on a GV3 system, which
GO.direct, with the aim of achieving the largest possible packs are safely inserted and re-stored. Hepcomotion provides a reliable and smooth movement.
storage volume on the smallest footprint.
Go.compact and Go.direct are compact and flexible
automatic pharmaceutical cabinet systems that load, store
and pick individual items of medicine. One of the key
advantages to the pharmaceutical industry is that the
systems can store more items in a compact space,
therefore providing pharmacies with a competitive
advantage to stock a wider range of products. The
smallest picking machine, for example, has a base area of
only 3.12 square metres, yet can hold approximately
4000 items. Additionally, the systems are time-saving as
the pharmacists do not need to be involved in the picking
of medicines.
The simple, compact bearing system combined with
the hybrid gripper technology ensures that the medicine
packs are safely inserted into the system and then
transported from the system to the customer in the
pharmacy. As smooth movement is a key requirement for
this application, Gollmann turned to HepcoMotion. The
company’s GV3 linear guide system plays a pivotal role,
leading the 60kg gripper arm between the roller cabinets
Motion control for respiratory cup printing
Offering a combination of accuracy, precision respiratory cup equipment and rotate through 360 Linux printer via inputs and outputs to control the
and repeatability, LG Motion has designed degrees to orientate with the print head. A linear specialist printing process.
and manufactured a system for the automatic dovetail slide from the UniSlide series is used to mount www.lg-motion.co.uk
printing of detail onto respiratory cups. The the printer output head and index in to the correct
customer’s objective was to achieve an easy to use position. The Linux printer then sends the information to
system that would accurately print maximum and be printed.
minimum water levels and their company logo onto
their circular respiratory equipment. It was important UniSlide features a unique rigid dovetail design
that the system produced accurate and reliable results manufactured in lightweight, high strength aluminium
as the medical respiratory cups are used to aid the alloy. It is corrosion resistant, and can withstand impact
breathing of patients under anesthetic. loads. Low friction polymer bearings are fitted to the
slider to ensure maintenance free long life. The dovetail
The solution uses core motion technology surfaces are precision machined and lapped.
components to provide a simple to use system that met
all of the customer’s objectives. It is built around an The UniSlide and rotary table are powered by
LGR2090 series rotary table, with fixtures that hold the stepper motors that are controlled via a two-axis motion
controller. The motion controller also integrated with the
10 INDUSTRIAL TECHNOLOGY • October 2017
ACTIONS
SPEAK LOUDER
THAN W RDS
The roller cabinets move on The medicines are released from the roller cabinets The aerospace solutions we deliver help
a GV3 guide rail from via an internal conveyor belt, as well as by means of ensure mechanical precision and reliability -
HepcoMotion. The GV3 guide slides or conveyor systems into the cash register area,
system can run dry (without which takes only a few seconds. It is therefore very quick from factory to 50,000 feet.
lubrication) and is self- for the customer to receive their medicine.
cleaning thanks to the V Why not contact us to find out more about our
guide technology. Managing director Daniel Gollmann says: “The motion control systems in the aerospace industry,
Hepco products – we use rollers and rails – work very
Two parallel running well, even for a very long time. So we are very satisfied. from R&D to manufacturing.
induction hardened GV3 We opted for Hepco because we were looking for a track
steel rails lead the 60 kg which can fit into our small space and still has the WE MAKE THINGS THAT
heavy gripper arm (not appropriate guiding qualities to accommodate the loads GO IN AND OUT, UP AND DOWN,
shown) between the roller we have mentioned.” Another reason for using GV3 is
cabinets. that the system can run dry, without lubrication. “We ROUND AND ROUND
needed a dry guide, which does not cause any transfer
The two parallel, induction of grease and dirt into areas where there are sensitive Arrange a visit
hardened GV3 slide rails are medicines,” explains Gollmann. “That was the main and meet the team:
based at the top of the reason for us.” + 44 (0) 1256 365600
system and enable the arm
to move smoothly between Mark Völkers, technical sales manager for Northern www.lg-motion.co.uk
the roller cabinets. The Germany at HepcoMotion, explains another advantage:
latest hybrid gripper “The GV3 slides are self-cleaning. Although this 11
technology on the gripper application may not seem as hostile as many of the
arm ensures that the packs applications out slides are used in, the presence of fine
are safely inserted and packaging dust can create wear. GV3 is very tolerant of
re-stored. GV3 is one of the debris thanks to the geometry between the V guide and
quietest linear systems the V bearings, which has a ‘mill stone effect’ caused by
available; a key benefit that the different peripheral speed inside and outside the V
appealed to Gollman as the form.
systems are in close
proximity to both customers “The difference in speed causes particles of debris
and pharmacists alike. nearer the centre to move outwards towards the
periphery, and to be expelled. So when the trolley
The roller cabinets moves, any fine dust or debris from the pharmaceutical
containing all of the packaging which has accumulated on the rails is simply
different medications also wiped clean by the V bearings moving along the slide
move on a GV3 system, system. This makes them low-maintenance and keeps
which provides a reliable the system running and reliable.”
and smooth movement.
Low maintenance is another key driver for the
specification of Hepco’s GV3 system, as pharmacists
strive to avoid inconvenient downtime which impacts on
sales. When a Hepco V guide rail shows signs of wear,
the eccentric adjustment facility of the V bearings can be
used to quickly and simply remove any play that has
occurred. When the V bearings reach the end of their
calculated life, they can be replaced individually, and not
as an entire set, so perfectly good components do not
have to be discarded unnecessarily.
Gollmann now equips over 200 of its automated
pharmacies with Hepco’s GV3 system.
www.hepcomotion.com
October 2017 • INDUSTRIAL TECHNOLOGY
EXHIBITION PREVIEW
Advanced Engineering 2017
Advanced Engineering 2017 runs at the NEC, Birmingham, from
1-2 November, and is the UK’s largest annual gathering of
advanced engineering professionals. We present a preview of
some of the innovations you can expect to see at the show
Connecting the entire supply chain of the UK’s also priority access to Universal Robot resources such as suitable for high precision applications, or any application
advanced engineering industry with R&D, applications expertise. At Advanced Engineering 2017, where accuracy is paramount. Said to be one of the
design, test, production and procurement from visitors will be able to take advantage of this know-how quietest linear systems on the market, GV3 offers high
OEMs and top tier industry players, Advanced and learn how Universal Robots are the ideal basis for speeds of up to eight meters per second.
Engineering is a must-visit exhibition. It recognises the cost-effective production solutions that enable humans
fact that UK advanced manufacturing and innovation is and robots to work collaboratively. Hepco will also be showcasing the DTS2 driven track
world class, and provides an event which promotes system – an ideal choice for any application that requires
business, growth and innovation throughout the There are now three flexible and lightweight 6-axis high positional accuracy and a demanding duty cycle.
manufacturing base and the supply chain. robot arms in the Universal Robot range from RARUK Widely used to facilitate high speed automation of
Automation. Each can be used for a wide range of assembly processes, the DTS2 is popular in a number of
Bringing together five co locating show zones, key applications and are categorised according to their industries including the packaging, automotive and
engineering communities are able to drill into the latest payload limits. The models also have reach, weight and electronic industries to name but a few.
developments in their own familiar sectors, whilst footprint differences. The smallest and most recent
crucially introducing themselves to colleagues, suppliers addition is the table top UR3. It is extremely compact and Further products include the SBD Sealed Belt Driven
and technologies from less familiar but parallel sectors virtually noiseless with a footprint of just 118mm. It actuator which provides a higher level of performance in
they otherwise would not see. So let’s look at some of the weighs only 11kg but has a payload of 3kg and, in terms of load capacity and life than other comparable
innovations on display this year. common with other Universal Robots, it has ±360 degree sized linear actuators. A stainless steel band covers the
rotation on all wrist joints and infinite rotation on the end linear guide and belt, which prevents dirt ingress, making
Much of the extensive Elesa range of standard joint. Additional features include a patented safety system the SBD ideally suited to harsh environments or industries
machine elements are designed around the needs of the with 15 adjustable safety functions, a wide range of I/O where there are high levels of debris.
UK’s advanced engineering industries through the five ports, standard communication protocols for easy
sectors of aerospace, composites, automotive, integration and programming via a 12in touch screen. To meet the heterogeneous demands of applications in
performance metals and connected manufacturing. the field of Industry 4.0, Kabelschlepp Metool has
Featured on the Elesa stand will be the company’s IP65- One of the most recent additions the range of developed the new Master drag chains LE60/LE80 with
67 direct dial digital position indicators which include accessories for the Universal Robots is YouRing, a smart the innovative divider system TS3. The reduced wall
new generation electronics for easy installation and programmable collar that gives visual and audible thickness of the divider system lets customers benefit
readout. The IP67 CFSW safety switch and hinge unit is information on robot status. Wireless connectivity and the from more space in the interior: compared to the previous
also on display to demonstrate how it can facilitate safe URCaps plug-in that is supplied with the YouRing makes cable carrier, this achieves a space saving of 50% in the
operation of protective panels and doors of control this neat and clever device easy to install; URCaps is the vertical and 37.5% in the horizontal. At the same time,
equipment. accessory platform that enables full integration into the new Master drag chains are easy to open and fill, for
Polyscope, the UR GUI for robot programming and time-saving harnessing from all sides.
These are joined by the Elesa wireless spindle operation. YouRing can then be freely programmed to
positioning system which facilitates faster and more meet the needs of the application and operator. “The requirements for dynamic cable routing are
reliable machine set up by using a wireless connected becoming increasingly more complex in the age of
profile controller. This unit then displays initial set up Linear motion expert HepcoMotion will be making its Industry 4.0. On the one hand, the packaging space in
values for each of up to 36 electronic position indicators. debut appearance at the Advanced Engineering Show. the machines is decreasing, while on the other hand
Initiation of a program then simply involves choosing the customers want more space inside the cable carrier,”
appropriate menu which will quickly re-set each spindle With over 42 major product lines with thousands Werner Eul, product manager for cable carrier systems at
to its correct start position so that the machine is ‘good to of individual components in various sizes, Tsubaki Kabelschlepp explains. “In addition, the cables
go’. This process saves a great deal of time and takes out Hepco has a wide range of products to differ with regard to function, cross section and sheathing
much of the possibility of human error. meet practically any requirement. Key material.” The new Master drag chains LE60/LE80 with
products on the stand include Hepco’s core the newly developed divider system TS3 can fully meet
A wide range of Elesa levelling feet complement the these requirements.
needs of equipment manufacturers. Many of these are V guide linear system, GV3. This is designed
available in stainless steel for heavy duty application and to serve a diverse range of automation and linear The new divider system TS3 combines space-saving,
to special designs for example those incorporating applications and is widely used in the packing flexible inner distribution with very quick opening. This
vibration damping pads to prolong equipment life, or industry for applications such as a telescopic pick and allows users to easily keep the necessary overview for
others for use in bio-hazard areas such as food processing place gantry, transport system or multi-lane row divider installation and harnessing. The matching dividers allow
and other hygiene/wash down areas. to name but a few. Highly accurate, GV3 is particularly users to always achieve the best possible result with
regard to space requirements, systematic placement and
As a Universal Robot Preferred ease of assembly. For greatest possible flexibility, all
Distributor, RARUK Automation individual components can be combined flexibly and
provides customers with not only a changed or added later on.
higher level
of technical Omron will be featuring its mobile robots – fully
support but autonomous intelligent vehicles that increase throughput,
12 INDUSTRIAL TECHNOLOGY • October 2017
Omron LD series mobile robots reduce machine dwell time, eliminate errors, improve
meet the needs of a wide range material traceability, and allow employees to focus on
of applications. Omron can point tasks that require complex human skills.. What’s
to applications in automotive, more, unlike traditional AGVs, Omron’s mobile robots
semiconductor, food and navigate by the natural features of the facility and
beverage, logistics, light require no expensive facility modification.
products manufacturing and the
hospitality sectors. The OEM mobile platform is available to
developers for custom applications and payloads. It
includes Omron’s proprietary self-navigation software,
which is ideal for use in crowded environments, tight
hallways, and applications where a compact
automated vehicle is advantageous. There are two
basic models: the LD60 for payloads of up to 60kg
and with a maximum speed of 1.8m/s, and the
LD90 for payloads of up to90kg, with a maximum
speed of 1.3m/s
www.advancedengineeringuk.com
The world
never stands still
We’ve been supporting the imagination of engineers
for 80 years, bringing innovative products that inspire
new solutions to tomorrow’s challenges.
With the broadest product range available online for
next day delivery, we make it easy; letting you get on
with what really matters.
Visit RS Online today
uk.rs-online.com
13
What’s M MTransform stepper motors in servo motors
New?
Available in the UK from LG Motion, the Arcus Titan-SVX is a universal, intelligent single axis servo motor driver and
Get ready for Industry 4.0 with controller which can learn patters of motion and anomalies in real time. The patent-pending ‘2nd Sight Technology’ has a
the Rexroth IoT Gateway built-in motion pattern learning and monitoring algorithm with motion healthy trend and fault prediction capability.
Titan-SVX is a real-time closed loop servo driver controller for stepper, BLCD, linear and voice coil motors. The intuitive,
The IoT Gateway is a system of coordinated hardware and software components text-based multi-thread standalone programming software is easy to use.
which networks new and existing machines cost-efficiently, optimising production LG Motion says the new product is packed with innovative features and
processes and product quality. It also provides a fast and flexible connection of represents a breakthrough in advanced motor drivers.
machines to Industry 4.0. www.lg-motion.co.uk
The IoT Gateway makes it easier to connect to the Internet of Things (IoT) without All the kit
intervening in the automation logic. It works by collecting sensor and process data,
and transmitting it to MES, cloud applications or local monitoring systems where
this data can be analysed. The IoT Gateway can be used to increase machine
availability, enhance process quality, save energy and optimise product quality.
Huge time and cost savings can be achieved as the system is web-based and
completely free from programming, helping to ease configuration.
www.boschrexroth.com
Our look at the month’s
L L L
Microstepping drives for Enabling switch for EMS extends Series R
step and direction control wireless functional safety planetary gearheads
Recently announced by Applied Motion Products (AMP) and available Dold has expanded its Safemaster W system for wireless New from EMS is the extended Faulhaber Series R metal planetary
from Mclennan, its exclusive European distribution partner, the STR functional safety with the introduction of a wireless enabling gearheads. The new 26/1R and 32/3R gearheads with 26mm and
series stepper drives for step and direction control are now offered in switch. It meets the needs of engineers who have to work inside a 32mm diameters are said to represent the evolution of the previous
two new AC-powered versions for higher torque applications. dangerous area while the machine is in a special operation mode, 26/1 and 32/3 gearheads, maintaining the same geometrry as their
such as during test, programming and maintenance. predecessors to guarantee mechanical compatibility.
Complementing AMPs existing DC-powered STR series drives, the new
STRAC2 and STRAC8 drives are also aimed at OEMs and machine The TUV approved 3-step radio-controlled Safemaster W enabling Power output for impulsive cycle operation has been more than
builders as a convenient and cost effective choice where PLCs, PACs or switch provides the necessary safety functions. It allows safe doubled compared to the previous generation. Such performance
pulse generating motion controls are used in automation systems. Both operation and safe disconnection in a dangerous situation. It is improvements were made possible through deep design analysis,
the STR and STRAC series microstepping drives include user selectable designed for universal usage and allows maximum mobility and extensive testing and meticulous validation. Also, the 26/1R and
step and direction or CW/CCW pulse control with full-step, half-step and flexibility. In the event of danger, the operator presses the button 32/R significantly improve the input speed by achieving continuous
microstepping resolutions up to 20000 steps/rev. fully or releases it from its middle position; the machine then input speed respectively up to 9000 rpm and 8000 rpm, resulting in
www.mclennan.co.uk goes into its safe state. an impressive 100% increase.
www.dold.co.uk www.ems-limited.co.uk
14 INDUSTRIAL TECHNOLOGY • October 2017
M What’s
M New?
Active redundancy modules for
preventive function monitoring
The new active redundancy modules in the QUINT product range from Phoenix Contact
increase the availability of a system through decoupling and monitoring. The SINGLE
ORING modules run the cable to the load redundantly and separately. In combination with
the new QUINT POWER power supplies, the redundant system is monitored continuously.
Using preventive function monitoring, the redundancy module informs you about the
output voltages of the power supplies, defects in the wiring and the decoupling section,
as well as the actual load current.
www.phoenixcontact.co.uk
you need Complete measurements
and complete portability
The Yokogawa DL350 ScopeCorder is the most comprehensive fully portable
measuring instrument available for capturing, displaying, recording and analyzing a
wide variety of electrical and physical parameters in industry sectors including
automotive, electronics, energy, transport and mechatronics.
Like other models in Yokogawa’s ScopeCorder family, the DL350 combines features of
a general-purpose oscilloscope and those of a high-performance data acquisition
recorder in a single, portable instrument. Unlike alternative portable measuring
solutions such as oscilloscopes and combined oscilloscope/multimeters, it adds
exceptionally high levels of precision and accuracy to field measurements, isolated
inputs for measurements at high voltage levels, and long-memory capabilities that
allow long-term recording for many hours or even days.
tmi.yokogawa.com
most interesting product launches
L L L
Actuator is adaptable to Suspension arm Plugs are designed to seal
a range of applications assemblies from ETA cross port passageways
SKF says its new CASM100 electromechnical actuator offers Uust introduced by ETA Enclosures UK and offered in three Lee Cross Port Plugs are a plugging solution specifically
exceptional flexibility for a broad range of applications. The specification variations subject to weight requirements is a new engineered to seal cross port passageways. This configuration is a
product’s modular design offers a base platform with new modules range of ETR Suspension Arm assemblies. The structure of the variation of the original Lee Plug – a smooth wall design combined
planned for release over time to cater for future needs. The support arm system is defined by machine size, enclosure with the field-proven controlled expansion principle creates a
standardised interface between modules – similar to the concept dimensions and enclosure weight, the number of connection permanent, leak-proof seal, without the need for o-rings or
of LEGO bricks – increases the unit’s flexibility and makes it elements and the profile lengths. Load capacities, defined for a total sealants. Installation is simple, reliable, and requires no
backward compatible. This modularity design also offers the of 1m profile including enclosure, are rated at 400N, 800N and maintenance.
benefit of easy integration and fast assembly. 1200N.
Lee Cross Port Plugs are constructed from 6Al -4V titanium. They
The actuator is said to consume up to 80% less energy than ETA says these new suspension arm assemblies are ideal for have been qualified for proof pressures over 20,000 psi and at
pneumatic alternatives and 50% compared to hydraulic solutions. mounting controls away from the floor space onto the control cabinet temperatures up to 400°F. Configurations are available in 0.250,
It also uses fewer consumables because, in many applications, it is or machine assembly. They are available in Grey RAL7035 with grey 0.281, and 0.343 inch diameters. The plugs are ideal for isolating
virtually maintenance-free. fittings as standard. sections of a fluidic manifold. They are typically used to plug long
www.skf.com www.eta-enclosures.co.uk passageways created by deep hole drilling that are difficult to
access with conventional sealing methods.
www.leeproducts.co.uk
October 2017 • INDUSTRIAL TECHNOLOGY 15
BEARINGS, SLIDES & LUBRICANTS Bearing Installation & Lubrication
The heat is on
Heat, either directly applied or generated in service, plays a key
role in the life of a bearing, being both beneficial and potentially
detrimental at different stages of its lifecycle. Phil Burge explains
how heat can be used beneficially in bearing installation,
and describes the negative effects that excessive heat
will have on lubricants when the bearing is in service
Heat is the inevitable result of friction in rotating heater and yoke never get hot; however, they lubricant, its appli-
machinery, and bearings are in the front line can cause bearings to be magnetised, and are cation and regular inspection
where friction is concerned. Their role is to nowadays equipped with a device that are therefore among the most
reduce it, thereby minimising internal automatically demagnetises the bearing prior important maintenance functions as far
temperature rises and their unwanted consequences such to mounting. as bearings are concerned.
as lubricant deterioration and premature bearing failure.
But heat has a very positive role to play at the earliest Before a bearing is placed in service, the The ‘high temperature limit’ (HTL) of a grease
stage of the bearing’s lifecycle when it is prepared for operating temperature range of the application lubricant is established by its ‘dropping point’ – the
installation on a shaft or within a housing. should be established to ensure that the correct size/type of temperature at which it becomes a fluid. Before the onset
bearing and associated lubricant is specified. Where high of the HTL is a grease’s so-called ‘high temperature
An estimated 16% of all bearing failures are believed operating temperatures are to be expected, either as a performance limit’ (HTPL); at this stage a grease starts to
to be caused by forcing bearings into place when result of ambient conditions or generated within the bearing degrade chemically, the by-products of oxidation having
mounting, and this can have serious knock-on effects. itself, special bearing designs and materials of construction an irreversible, detrimental effect on the lubricant and
Quite apart from the fact that the bearing is very likely to that avoid the heat-induced structural changes that can consequently bearing performance. Oxidation leads to a
fail prematurely due to resultant raceway damage, the chemical reaction producing volatile elements and lacquer
system in which it is installed will run less efficiently or Hot-mounting a bearing – by creating formation, which severely degrades the grease’s
may even undergo catastrophic failure, leading to lost a temperature difference between lubricating properties.
production and costly downtime. the bearing ring and the shaft or
housing – can be achieved using SKF offers a traffic light system to display a grease's
There are various industry-approved ways to mount a several techniques, though some of operating temperature rating: green representing the
bearing. SKF, for example, has developed a variety of the more traditional approaches, temperature range over which the grease will perform
methods for cold mounting, including its proprietary such as oil baths, are no longer reliably; amber indicating the stage between HTPL and
Drive-up, oil Injection and SensorMount techniques; but recommended due to health and HTL where the performance of the grease is likely to be
heat, too, can be particularly useful when mounting safety considerations and unreliable, and finally red – the point at which the grease
bearings. Hot-mounting a bearing – by creating a environmental problems has deteriorated to such an extent that it has become
temperature difference between the bearing ring and the unusable. A similar traffic light system for grease is
shaft or housing – can be achieved using several occur throughout the bearing geometry should be used. applicable to low operating temperatures.
techniques, though some of the more traditional SKF has developed a range of both standard and
approaches, such as oil baths, are no longer customised high temperature bearings that are capable of Lubricants, both oil and grease based, are available in
recommended due to health and safety considerations operating at temperatures as high as 350°C. many grades and viscosities, and in formulations suitable
and environmental problems associated with disposal. for use at both high and low extremes of temperature. The
Bearing temperature should also be temperature rating of the recommended lubricant must be
More modern methods include aluminium heating monitored regularly (or even contin- determined at the earliest stage of machine design –
rings, electric hot plates (for small bearings), heating uously) in service and as close as possible dependent upon predicted temperature rises within that
cabinets and infrared radiators. SKF recommends using to the bearing’s outside diameter, as this machine – and used consistently throughout its
induction heaters, which quickly apply heat evenly to the will indicate any excursions from the operational life.
bearings. Induction heaters are safe to use because the norm, suggesting lubricant problems or
damage to the bearing’s raceways. In Temperature monitoring devices are tools that no
addition to vibration, temperature is also industrial manufacturing plant should be without. A rapid
a prime condition monitoring parameter, rise in bearing temperature may be indicative of lubricant
and many instruments are available that deterioration or a sign that the bearing is developing a
measure and analyse both vibration mechanical fault. So, whether temperature is measured
signatures and temperature trends continuously using thermocouples or during regular
simultaneously to provide reliable, real maintenance checks using a thermal camera, this simple
time machine health monitoring. maintenance task is likely to have a significant impact
on a bearing’s life expectancy.
Critically, elevated temperatures may www.skf.co.uk
also degrade the bearing lubrication,
particularly if the wrong type and quantity Phil Burge is marketing and communications manager at SKF
of lubricant is used, leading to premature
bearing failure. Choice and quantity of
16 INDUSTRIAL TECHNOLOGY • October 2017
BEARINGS, SLIDES & LUBRICANTS Polymer Bearings
Five reasons to replace
PTFE-lined bearings
Robert Dumayne uncovers the top five reasons for replacing
PTFE-lined bearings with engineering plastic options
Many times, high-performance plastic (Right) Corrosion of the metal shell of a PTFE-lined bearing service life/wear brings some interesting findings. The
bearings are confused with PTFE-lined COF of iglidur bearings and metallic PTFE-lined bearing
metal-backed bearings, which are a much these types of environments, metal rusts, corrodes, options were tested as brand new parts, then after 100
older technology. Over the past three and contaminates sensitive areas, while also leading hours of rotation. This test was performed at 0.1m/s
decades there has been a revolution in the advancement to bearing failure. under a load of 1 MPa. Results showed that while both
and use of engineering plastics in bearing applications. bearings exhibited the same COF as new parts, as wear
Plastic bearings are designed to stand up to high speeds Bearings made entirely of plastic are impervious to occurred, the COF of the PTFE-lined bearings increased
and loads, temperature extremes, caustic chemicals, and rust, and engineering plastic materials are available exponentially, as opposed to only a nominal increase in
a wide range of other application requirements and that resist damage from chemicals, oils, and other COF by the iglidur parts.
environmental factors. So let’s look at the five prime caustic media. The trend towards using biofuels has
reasons to replace PTFE-lined bearings with polymer created new issues for PTFE-lined bearings. 5. RoHS compliance: Since 2006, RoHS (Restriction
alternatives. Biodiesels and other biofuels have a tendency to of the use of Hazardous Substances), has steadily
absorb a high level of moisture, which can greatly tightened guidelines set to limit the values of industrially-
1. Thicker wear surface: A PTFE-lined bearing is effect metal bearings. After limited exposure to necessary, yet potentially harmful substances, including
comprised of a metal shell and a very thin coating of moisture, parts of the metal bearing shell can peel lead, hexavalent chromium, mercury, polybrominated
polytetrafluoroethylene, or PTFE, applied to the inside as away from the PTFE lining. biphenyls, polybrominated diphenyl ethers and cadmium
the wear surface of the bearing. These types of bearings in the manufacture of electronics and electrical
typically have a maximum wear surface of 0.05mm. As To combat this problem, plastic bearing materials equipment. With newer RoHS II Standards, a maximum
the PTFE lining is stripped or worn off during operation, have been developed to be used specifically in biofuel value of 0.1% of the total product weight is allowed for
the metal shell becomes exposed, creating a metal on or other high-moisture applications. most of these substances, with the exception being
metal effect between the bearing and the shaft; this can cadmium, which is limited to 0.01%. These standards
cause serious shaft damage, or seizing of the bearing. 3. Weight savings: PTFE-lined bearings weigh much are similar to regulations that are also in effect in North
This issue is most common when bearings are used in more than a full plastic option. When using a heavier America and Asia, so meeting these material standards is
oscillating applications, or where high edge loads are bearing, no matter what the material, more energy is becoming of global importance for manufacturers.
present. required to operate the bearing system. This can be
problematic, especially in vehicle applications, such as Though widely used in a vast array of applications,
In comparison, engineered plastic bearings are cars, aircraft, recreational vehicles and bicycles. PTFE-lined metal bearings contain alloys that are not
comprised of advanced polymer compounds, which compatible to these new standards. Manufacturers of
contain particles of solid lubricant embedded in millions In contrast, plastic bearings are extremely lightweight, equipment that needs to adhere to RoHS Compliance
of tiny chambers throughout the entirety of the material. approximately 80% less than a PTFE-lined option. The Standards can turn to iglidur bearings in place of metal
During operation, these particles of solid lubricant are reduced weight can reduce fuel consumption and carbon alloys. All substances covered by the new RoHS
transferred onto the shaft to help lower the coefficient of dioxide output, reducing the overall drive power standards are absent from each iglidur composite
friction and rate of wear, and eliminate the risk of metal requirement. To compare, an iglidur G plastic bearing plastic material.
on metal contact. This allows the acceptable amount of weighs in at 6.5g, while a comparable size PTFE-lined www.igus.co.uk
wear to be determined by the type of application, unlike bearing comes in at just over 34g.
PTFE-lined alternatives which will fail if the wear exceeds Robert Dumayne is dry-tech director at Igus
the 0.05mm lining’s thickness. 4. Constant coefficient of friction: Thanks to the very
low values of PTFE, the coefficient of friction (COF) of a
2. Resistance to corrosion and chemicals: The metal PTFE-lined bearing is usually very good during the
shell of a PTFE-lined bearing becomes problematic in beginning of the bearing’s service life. However, the very
applications where water or chemicals are present. In thin PTFE layer will be worn away over time, creating a
rapid increase in the COF as metal-on-metal contact
(Below) A PTFE-lined metal backed bearing compared to an Igus occurs.
iglidur J bearing
The iglidur plastic bearing materials, on the other
hand, are a homogeneous blend of base polymers,
strengthening fibres, and solid lubricants. With particles
of lubricant throughout the entire bearing
thickness, the bearings have a brief
start-up phase while they mate
with the shaft surface, or bed in,
after which the COF remains
constant throughout the
entirety of the bearing’s service
life.
Rigorous in-house testing
to investigate how friction
between plain bearings and
their shafts change through the
18 INDUSTRIAL TECHNOLOGY • October 2017
BEARINGS, SLIDES & LUBRICANTS Vee Bearings
Using Vee bearings and T-rails
Gerry Smith offers hints and advice on installing linear systems Let’s turn now to the carriage and bearings. First step
is to select the material for the carriage – steel or
Vee bearings and T-rails offer the user a simple preference is to clamp the T-rail to the support material aluminium. The hole centre positions for the bearings
way of constructing smooth running linear and to drill pilot holes through the T-rail into the support. (dimension “A” on the drawing) can be calculated as:
systems with a high load capacity and, in the This means the centres will match. Double check that
case of the stainless steel version, corrosion the T-rail edges are still parallel, then drill through holes A = Width of support + 2xTE + 2xA1
resistance too. So let’s look at how we might build these in the T-rails and drill and tap the support.
components into a linear system. where TE is the offset of tip of the Vee rail from the
Finally bolt the T-rail onto the support. We tend to support material, and A1 is the dimension from centre of
The first thing to do is to decide the width of the track use dome head machine screws; make sure the screw bearing to bottom of Vee.
and then choose what material the T-rail will be attached heads do not interfere with the carriage or rail edges.
to, the support. Importantly, the precision of the system Also make sure that the rail edges are parallel. Drill the holes through the carriage plate. Insert the
is dictated by how accurately the support material is concentric bushes into two bearings and insert the
manufactured. eccentric bushes into two bearings. Firmly secure the
concentric bushed bearings to one side of the carriage
Drilling the T-rail is easy. The flats are not plate and tighten. Loosely assemble the eccentric bushed
hardened, only the tip of the vee, so normal bearings to the carriage plate and slide the carriage onto
drilling techniques can be used. Our the T-rails. Now adjust the eccentric bushed bearings by
feel (or feeler gauge) to achieve the pre-load required.
Slide the carriage back & forth to ensure there are no
pinch points.
It is recommended to use hex cap head bolts and
nyloc nuts through each bearing bush. Importantly, make
sure the outer ring of the bearing is turning on the inner
ring of the bearing and not on the bush. The bearing
should be an interference fit onto the bush.
www.euro-bearings.com
Gerry Smith is managing director of Euro-Bearings
High quality
Low cost
Fast delivery
HLG | Linear Guide System
Tel: 01884 257000
www.hepcomotion.com
20
New KUSE X-life 45˚
Load ratings increased by up to 44% 60˚
and rating life extended threefold 45˚
Advances in linear technology are still possible even for well-established KUSE X-life linear series. Six rows of
products. The New KUSE series achieves even greater accuracies, enabling balls with ° and 6 ° contact angles
use in the highest precision applications - and has been awarded the
Schaeffler X-life quality mark.
Design improvements have increased load ratings for six-row KUSE linear
recirculating ball bearing and guideway assemblies by up to %. Rating life is
three times higher. Pulse amplitude has also been reduced by up to %
Instead of the usual four rows of balls, six rows now support all loads; four rows
support compressive loads while two rows take the tensile loads. The KUSE
X-life series is therefore perfect for combined load directions, having one of
the highest rigidity levels and load carrying capacities based on balls for any
monorail guidance system currently available.
The New KUSE X-life series - for the highest-precision applications in electronics
production, microscopy, optics and applications that require both a high load
carrying capacity and long, trouble-free operating performance.
Schaeffler (UK) Ltd E-mail: [email protected] | www.schaeffler.co.uk
Industrial IoT for brownfields
As a comprehensive performance indicator, looking to implement Industry 4.0, that is simply too long analyse data from machinery and equip-ment that
overall equipment effectiveness (OEE) can play otherwise lacks the necessary connectivity. With its new
an important role in making manufacturing to wait. “So, what you need is a way to bridge the gap for Orange Box concept, B&R has proven that doing so can
assets more productive. Difficulties gathering
the data needed to calculate OEE, be surprisingly easy. “An Orange Box can substantially
however, have often prevented it from reduce downtime and boost the
being used to improve older brownfield availability of existing machines and
systems. Now, there is a solution that lines,” says Blaschke. “That makes
lets you easily tap into the operating your entire operation more productive
data of digitally isolated equipment and profitable.”
and benefit from automated
acquisition, harmonisation and analysis Smartphone notifications
– including real-time OEE monitoring.
The Orange Box can notify machine
Connected manufacturing systems with operators of significant events – like an
access to the latest open safety door – directly on their
technology are able to
collect and evaluate smartphone. This allows
extensive technical and them to react immediately
operational data to and resume production as
implement the type of quickly as possible. When
solutions envisioned for the frequency of
Industry 4.0 and the unplanned stoppages is
Industrial Internet of Things clearly documented, it
(IIoT). It’s easy to expect these features from becomes obvious where
a greenfield project when starting more or
less from a blank slate. For the majority targeted improvements can
of plant managers, though, the reality be made.
is a bit more complicated.
Further potential for improvement can be
“A company can’t just tear down all identified by comparing productivity
of its facilities and start from scratch,” between machines, lines or shifts.
says René Blaschke, B&R’s expert for “Very often, relatively minor
IIoT brownfield integration. When adjustments can have a dramatic
retrofitting legacy equipment to support impact on productivity,” reports
new Industrial IoT solutions, the first step Blaschke. Better synchronising
is to find a way to automate the collection and maintenance and break times is a
harmonisation of its operating data. Then, you need to perfect example.
use this data to calculate the OEE, which reveals
productivity losses and serves as the foundation for Straightforward technology
improving overall performance.
From a technical standpoint, the Orange Box concept is
Automated data acquisition remarkably straightforward. A B&R controller reads
operating data either via wired I/O channels or directly
To this day, it is not uncommon to find machine operators from the machine controller using communication
scribbling down operating data with a notepad and pencil. protocols. The Orange Box reads data from B&R, Siemens
“This data then lands on the desk of an analyst for
processing,” says Blaschke. Not only is this a far cry from the remaining service
the digital-age ideal of real-time analytics, it is unrealistic
to expect every shift to record its data in a consistent, life of brownfield
standardised way. “This has been a notorious problem in
production data acquisition,” notes Blaschke. It also equipment,” says
makes it very difficult to compare performance
across different machines. Blaschke. For plant
Industrial manufacturing managers, this
equipment has a particularly long
service life. With machines means finding a
typically running for 25 or 30
years, one that was installed 15 reliable way to
years ago can easily be around for
another decade. For a company collect and
An Orange Box can transform a production
line plagued by frequent unplanned stoppages
into one where downtime is a rare exception
22
The Orange Box provides a clear overview of
operating data for any manufacturing asset.
or Rockwell controllers via the respective INA, ISO on TCP A few quick settings, and mapp OEE is ready to start functions you need,” says Blaschke. “And, like apps on a
or EtherNet/IP protocols, converts it into OPC UA delivering a machine’s OEE data, for example. “There’s no smartphone, those are the only ones you pay for.” The
messages and processes it. need to write a single line of code,” emphasises Blaschke. software management functionality provided by the mapp
Further, mapp OEE has an accompanying HMI Technology platform allows Orange Box users to install
“The results – such as the OEE value – can be component that works in the background. Together with updates or new mapp components via LAN, WLAN or
displayed right on the machine and/or passed on to mapp View – B&R’s HTML5-based HMI solution – this USB flash drive.
higher-level systems,” explains Blaschke. The Orange Box component can display real-time content on any web-
has an OPC UA server that allows any manufacturing enabled device. The intuitive dashboard provides an at-a- Shaped by customer requirements
execution system (MES) or enterprise resource planning glance overview of all the most important information.
(ERP) system to access the data. When used as an edge The Orange Box’s modular software is complemented by
device, the Orange Box is also able to send data into the Pay-per-use its equally modular hardware. The most compact form
cloud. features a 25mm-wide compact controller. “That and
Orange Box is not a traditional product, but rather a mapp OEE are all you need to collect the necessary data
The right mapps for your solution conceptual solution shaped by the unique needs of each and calculate OEE for a machine,” explains Blaschke.
customer and machine. Its specific functions can be
“For the Orange Box to deliver the greatest possible tailored on demand simply by adding the appropriate For more advanced features – such as alarm
benefit,” recalls Blaschke, “we knew it would have to be mapps. Set up an alarm system with mapp Alarm, for management or energy monitoring – the solution can
easy to set up and easy to use.” That’s why the solution example, and use mapp Tweet to alert machine operators easily be scaled up with more powerful controllers and
is built around the modular software components of mapp of relevant alarms via email or text message. additional software components. Customers who want to
Technology. These mapp components – or ‘mapps’ for give the Orange Box a modern user interface as well can
short – are preprogrammed to exchange information Industry standards such as PackML are also neatly add an operator panel with an integrated controller or a
automatically. “Configuring a mapp component is no more packaged in mapps for easy integration into the Orange panel-mounted PC unit.
difficult than setting up an email account.” Box. “As a customer, you can pick and choose exactly the
“All the hardware and software is completely
OVERALL EQUIPMENT EFFECTIVENESS (OEE) interoperable,” notes Blaschke. Plant managers can use
different combinations of hardware and software on
Overall Equipment Effectiveness (OEE) is a key Fully optimising one of these factors – achieving different machines with no added overhead. The Orange
performance indicator used to track the productivity of zero unplanned downtime, for example – would result Box quickly and painlessly lifts brownfield equipment out
manufacturing assets. in a 100% rating for that factor. Multiplying the three of digital isolation to enjoy all the benefits the age of
factors gives you the OEE value. Since there is no Industrial IoT has to offer.
The three underlying factors used to calculate OEE universally accepted method for defining the optimum
are the ratios of good units to total units (quality level for each factor, comparing OEE ratings across B&R
factor), production speed to designed speed different lines or facilities only makes sense if the Bakewell Road, Broadoak, Southgate Park
(performance factor) and actual uptime to scheduled factors are calculated consistently. Peterborough PE2 6YS
production time (availability factor). Tel 01733 371320
www.br-automation.com
23
MACHINE BUILDING & AUTOMATION Programmable Controllers
The age of the PLC
platform is now
Can an automation system be more than just the sum of its
parts? Barry Weller argues that it can and that the age of the PLC
platform is now bringing a host of benefits that extend far beyond
ease of programming and simplicity of integration
Replacements and upgrades aside, it is rare and can also inform its operators about how to make production management systems and PLCs but also
today that automation components are improvements in efficiency, helping to coordinate between those higher level systems and other devices.
purchased in isolation. More commonly, a mix manufacturing, processing and logistics operations far This significantly reduces system configuration costs as
of controllers, PLCs, inverters, servo beyond the walls of the machine, or the factory unit it is communications can be established without having to
components, networking cards, HMIs, I/O modules, will located in. worry about network hierarchies and boundaries.
be purchased as a total solution, building a system for
machine control, process control, positioning, production Using the cloud it can also extend data storage and A further key benefit of a true automation platform is
line automation and even factory-wide coordination. processing to the virtual world, recording essential an integrated engineering environment, delivering further
production trend information and delivering moment-by- reductions in total cost of ownership. This single
Of course, this should come as no surprise. Most moment condition monitoring and asset optimisation engineering environment provides tools for system design,
automation vendors will argue the benefits of buying updates. Additionally it can think independently of a programming, debugging and maintenance, ensuring
multiple components from one vendor, citing the physical action, delivering production environments that consistency of the complete lifecycle of the system.
elimination of compatibility issues and the availability of can self-optimise. It enables manufacturers to take a
common programming platforms. Indeed these are all holistic view of their operations, driving huge gains in As an example, Mitsubishi Electric’s iQ-Works
perfectly legitimate arguments to focus on one brand. productivity while significantly reducing total cost of software suite provides tools to address the challenge in
However, even a system of closely matched components ownership (TCO). engineering to develop and efficiently maintain advanced
can only take you so far. The real benefits come once you production lines over the whole product lifecycle. Rather
look at the possibilities of a complete automation The automation lifecycle than having to rely on separate software tools for different
platform. products, engineers using iQ-Works benefit from complete
With the PLC at its heart, the true automation platform integrated engineering software suite for Mitsubishi
The evolution of the modern automation platform, minimises TCO at all phases of the automation lifecycle Electric’s PLCs, servo systems, motion controllers,
commonly with a PLC at its heart, delivers a system that by improving development times, enhancing productivity, variable speed drives, HMIs, PC-based controllers, robots
is much more than the sum of its constituent parts and reducing waste and maintenance costs and making and CNC systems.
addresses important emerging trends and industry information more easily accessible throughout the plant.
challenges. In particular, it provides the enabler that will We can see, then, that the PLC-based automation
allow manufacturers to drive forward on the journey As an example, Mitsubishi Electric has enabled all of platform has much to offer manufacturers of all scales and
towards digitalisation and Industry 4.0. these benefits through its iQ-Platform, which realises at all points on the journey to an Industry 4.0
consolidated controllers on a single platform. Multi- environment. The integrated control components within
For example, when we talk about the importance of function controllers responsible for different aspects of the iQ-Platform offer the system designer the option to
communications today and within the Industry 4.0 automation control can be used together on one high- implement an optimised control system that integrates
environment of tomorrow, a true automation platform is speed system bus. The various control CPUs utilise high- different control processes onto one common platform. The
an enabler not only for integrated communications speed data communication via the backplane, further high-speed system bus enables fast data communication
throughout a factory but beyond to a complete ecosystem reducing cost as additional networks are not required and between these processes and ensures that the high
of global facilities, allowing businesses to optimise their improving performance due to the platform’s large data accuracy requirements of the application are satisfied.
production processes on a worldwide scale. bandwidth capability.
When processes require control systems to be
Further, an automation platform can analyse its own Alongside the logic CPU, dedicated function CPUs separated, the seamless network architecture of the iQ-
health and performance, and offer predictive include CNC CPUs for complex machine operations, Platform offers a best-in-class multiple hierarchy, with
maintenance. It can also save energy by safely turning off motion control CPUs, a dedicated integrated robot control seamless communication between the various network
idling machines and processes or put them on standby CPU and a process CPU. Mitsubishi Electric also offers a layers at fast communication speeds. Finally, the
C Controller, providing a reliable, open platform for engineering environment complements the hardware
executing C/C++ applications. All of these CPUs operate integration by enabling various project management
on the same high-speed bus, enabling complex machine features to be shared across the individual programming
control to be realised without compromising the operation and design software tools.
speed. At the same time, a number of edge computing
solutions directly integrated within the automation For a significant proportion of manufacturers – those
platform deliver IT information to and from the plant floor, looking to take a holistic view of their operations and push
offering further opportunities to optimise processes and efficiency, productivity, speed of development and
offering improvements in traceability through direct reliability of their production processes to new levels – the
connection with the enterprise. automation platform provides the very best foundation to
work from to achieve smart manufacturing and move
Of course, not all data transfer between the plant floor towards Industry 4.0.
and higher level systems need to be managed within the gb3a.mitsubishielectric.com
PLC and a further benefit of a true automation platform is
that seamless connectivity is possible not only between Barry Weller is PLC specialist at Mitsubishi Electric
24 INDUSTRIAL TECHNOLOGY • October 2017
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MACHINE BUILDING & AUTOMATION Machinery Safety
The importance of
the safety of workers
John Uber highlights the importance of designing right the first entirely removed. Third, you must advise or notify
time, and of communications between the user and the supplier operators with regard to hazards and risk via labelling.
And finally, you must train and instruct effectively. That is
While consumer safety and protection is of 6mm from the surface of the belt, so it is difficult to get the progression to follow in order to design a machine to
paramount importance when manu- the finger trapped underneath. Gaps between rejector ‘an acceptable level of risk’.
facturing consumable goods, the safety of plates and fixed supports are also examined. There is a
those working on the production lines must gap of 25mm or 50mm between the back of the pusher Safety professionals use this phrase, as the term safe
also be considered. There are legal and moral plate and the support structure. The 25mm gap is larger is often used too freely, and frankly is unattainable.
responsibilities to protect workers which go beyond safety than a finger would be for a small plate, and the 50mm Machines, regardless their function, can never be 100%
for the sake of compliance. It is safety for the protection gap is larger than a hand when larger plates are used. safe. Suppliers strive to reach a level of acceptable risk,
of people first and foremost. and this should be reviewed openly with the user. That
Transfers are also often overlooked. In product can mean gap control between guards, or maintaining
In spite of the fact that the Machinery Directive makes inspection, transfers are critical for performance. This is certain operating parameters.
it a requirement for the instructions to include the particularly true with checkweighing, where you need a
intended use, foreseeable misuse, safeguards applied, smooth transition to maintain package stability for For instance, if you have a system which has been
and residual risks – all fundamental parts of a risk weighing. Stability of the package is something that you designed and you do not want the pusher plate to go
assessment – some suppliers are still reluctant to provide want with every form of inspection, as the more stable the beyond the edges of a conveyor, you design it with an air
that information to users. It is European law. For the US, package, the more reliable the inspection. cylinder with only enough travel to perform the required
there isn’t such a direct legal requirement, but the ANSI function. It is mechanically constrained so that it cannot
B155 standard has long recommended the sharing of the Interactions between machines create a more hazardous condition. We also think
supplier’s design-based risk assessment with the user, as “adjustment can be mis-adjustment.” Any time we can
a solid starting point for the user's task-based risk Transfers within machinery are governed by the same design with a fixed position, we do, in order to reduce the
assessment. motor control, and related risks can be designed out. chance that someone will adjust the machine to an unsafe
Between machines and other machinery, the transfers are position.
One area that presents a significant challenge is outside our control. Someone has to have an overall view
integration. There are many things to consider: Are you of the interactions between machines. In the EU, the Design and risk assessment should be concurrent.
transferring product on to or off of the inspection device? Machinery Directive makes the obligation clear. The user, There is little point waiting until a machine is at the
Are you rejecting packages? How are you accumulating or the user’s integrator, has responsibility for the safety of installation stage to run a risk assessment. By then it is
packages? How are you addressing the non-mechanical the various areas of integration, and for the safety of the very difficult to make changes if necessary. The
areas, such as electrical energy, communications and “assembly of machinery” – to the point that the Directive assessment must be carried out parallel to the design
signals, safeguarding and safety circuits? All of these makes it a requirement for the user or the user’s integrator process. This reiterates the point that the first stage is to
questions should be answered and addressed at the to produce a Declaration of Conformity for that assembly design-out the hazards. Consider the potential hazards
design stage, and reviewed at each stage of the order of Machinery. during the design and you will have a much lower-risk
process. machine in the end.
There are four key stages to the safe-design process.
The most common risks faced in a manufacturing The first emphasis – the priority for achieving an Another aspect of designing-out from the hazards is
environment with regard to equipment safety are acceptable level of risk – is to design out the hazards. The related to hygienic design. You cannot put a guard on a
electrical. And there is more concern about electrical second is to guard against those hazards that cannot be microbe, so if you have a hazard relating to liquid pooling
energy than any other area, as it is potentially the most for example, this has to be designed out before a machine
severe. These areas are generally well-guarded, and there is put into production. There is a minimal risk to the
are established protocols for accessing hazard areas,
supported by well-defined standards on design and
guarding for these hazards. To take an example, in the US
there is great industry awareness for ‘arc-flash’ – where
potential energy could be delivered from interaction with
a high-voltage source. Arc-flash hazards can cause
serious injury or death. If electrical energy is considered
potentially harmful, then technical personnel are required
to wear protective equipment, such as face-shields,
gloves, and cotton-only clothing before accessing panels
where voltage exceeds 50V.
Reject areas also present risks. Rejectors are
automatic ejection devices, and as such, they are not
considered a “point of operation,” as OSHA defines that
term. They do operate intermittently and without warning,
so those are designed to further minimise the potential
injury should a worker reach into a reject area without
first de-energizing the system. Potential contact areas are
examined to reduce the risk from finger traps. The rejector
plates/contact areas, for example, are never more than
26 INDUSTRIAL TECHNOLOGY • October 2017
Machinery Safety MACHINE BUILDING & AUTOMATION
workers here – more to the consumer – but loss of brand machine is designed; what safeguards are present; and very top level set the tone and establish best practices for
reputation through microbiological or cross-contamination what residual risks are transferred to the user. That is the how to communicate with customers to make sure firstly
could lead to plant closures. If that happens there is no risk assessment essentially – which should be the basis of that the supplier provides all the necessary information,
worker safety issue at all – but of course that is very far a conversation between the user and the supplier. and secondly that the user has that information to apply
from the ideal scenario. when they integrate the system into the line.
On a larger perspective, companies from the supplier
Highlighting potential risks and user side should be encouraged to collaborate and When it comes to training to ensure machines are
work in industry groups. Participation in industry operated safely once installed, of course suppliers can
Suppliers have a responsibility to highlight and help standards leads to the development of soundly structured train customers on the hazards that are present in the
safeguard against potential risks. On an application basis, best practice guidelines. Industry groups such as ANSI system. But the bigger side of ensuring adequate training
suppliers should explain to the user the following: how the and OpX are good examples. These interactions at the is for the user to conduct a task-based risk assessment.
Users know how their operators are going to interact with
the equipment, and the interfaces of all the machinery in
that area. The frequency of interaction positions, where
personnel are accessing different parts of the system –
these are variables that the supplier cannot control.
From an integration perspective, safeguards at
machine interfaces should be provided by those who have
control of the design in those interface areas, and have
knowledge of hazards that may be present or may be
introduced through the assembly of machinery. ANSI
B155 identified five categories for integration
consideration – mechanical, electrical, communications
and signals, safeguards, and safety circuits. To assist the
user in this important task, Mettler-Toledo Product
Inspection provides safety and interface information to
allow the responsible persons to plan and execute the
safe integration in an efficient manner.
www.mt.com/pi
John Uber is product management leader at Mettler-Toledo and
Chair of the ANSI B155 (Safety Requirements for Packaging
and Processing Machinery) 2016 Revision Committee
Safety Solutions
OEM Automatic offer a full range of safety products
and solutions from leading manufacturers
Supported by a dedicated, highly knowledgeable team of product
specialists, sales engineers and customer support staff we are able to
offer a high level of technical support to our customers.
With a large warehouse, located centrally in Leicester, holding more
than 8000 articles in stock we also have an added value workshop
offering modifications and safety edge assembly to customer
specification.
Our Safety offering includes:
O Safety Light Curtains
O Safety Relays
O Non Contact Safety Switches
O Resistive Safety Edge
O Rope Pull Switches
O Mechanical safety interlock switches
O Mechanical interlocks with solenoid guard locking
O Trapped key interlocking with key exchange
O RFID coded magnetic door interlocks
O Safety limit switches
O Emergency stop stations
www.oem.co.uk [email protected] 0116 2184 59296040
27
MACHINE BUILDING & AUTOMATION Machinery Safety
Machinery safety in an
Industry 4.0 environment
How do we tackle Industry 4.0 different language. How can we facilitate smooth and vulnerabilities, risks and liability issues. Based on its
dynamic interoperability among odd components? complexity, a dynamically reconfigurable system requires
concerns from a machinery an integrated approach to safety assessment.
The solution is an electronic reproduction – a so-called
safety perspective? Paul Taylor ‘digital twin’, or ‘administration shell’ of each physical These flexible system architectures and self-
component. The digital twin contains the complete set of configuring systems of Industry 4.0 will call for a new,
offers guidance parameters of its physical sibling, as well as adaptive modular method of certification that delivers integrated
algorithms for decentralised self-optimisation and safety support for machinery end users as they progress towards
The main cornerstone of Industry 4.0 is the measures. Acting as an intermediary, the digital twin Industry 4.0. The key benefit of modular certification is
convergence of enterprise IT and operational functions as a standardised interface between the smart the major cost and time savings it contributes to the
technology (OT). Industry 4.0 is a major components, facilitating flawless interoperability and operation of adaptive self-configuring Industry 4.0
paradigm shift for industry, with technological delivering a dynamically reconfigurable system. production systems. Our experts are therefore developing
enablers such as the Internet-of-Things (IoT) and Big Data a modular certification scheme for smart factory
being increasingly deployed. New generations of complex The connected dimension components, addressing issues such as interface
networks are being created as the boundaries between standards, interoperability, functional safety and IT
these two areas, previously largely separate, become Currently, industrial automation is a consolidated reality, security.
increasingly indistinct, and IoT devices and new with approximately 90% of machines in factories being
automation technologies are rapidly introduced. The unconnected. These isolated and static systems mean The digital transition is an enormously challenging
challenge for machinery end users is to maintain secure that product safety (functional safety and security) can be time for industry, confronting it with the issue of how to
functioning of their automated processes, while protecting comfortably assessed. However, the connected world of maximise the opportunities offered by Industry 4.0, the
their networks from unauthorised access or even attack. Industry 4.0’s smart factories adds a new dimension of ‘fourth Industrial Revolution’, while at the same time
complexity in terms of machinery safety challenges. IoT reducing the risks involved in increasing interoperability.
Interoperability describes the extent to which systems connects people and machines, enabling bidirectional By combining the strengths of the physical and virtual
and devices can exchange data, and interpret that shared flow of information and real-time decisions. Its diffusion is worlds, cyber-physical systems have the potential to
data. For two systems to be interoperable, they must be now accelerating with the reduction in size and price of significantly enhance industry performance, facilitate new
able to exchange data and subsequently present that data the sensors, and with the need for the exchange of large products and spark innovative business models. Today,
such that it can be understood by a user. Advanced amount of data. industry depends on human supervision and decision-
sensors are already finding their way into modern making, but tomorrow’s smart factory machines will have
manufacturing lines, facilitating informed decision- As we prepare for Industry 4.0, it is therefore vital to the ability to interpret their environment and
making. But this is just the beginning. Further innovations consider the shifting landscape of risk. A smart factory autonomously react to it.
will unlock the full potential of smart component will see reduced risk in several areas, such as fewer www.tuv-sud.co.uk
technologies. worker injuries as machines take over hazardous tasks.
However, the increasing number of physical and digital Paul Taylor is manager for machinery safety
Standing on the threshold of Industry 4.0, what is interfaces, including interconnected devices controlled by at TÜV SÜD Product Service
required to reach maturity and reap the full benefits of intelligent dashboards, introduces a new set of
smart manufacturing? Industrial manufacturing will face
massive disruption as developments move towards fully
connected, self-organising intelligent factories. This will
trigger significant potential for efficiency improvements,
including energy consumption reduction and downtime
prevention.
The smart factories of tomorrow will be based on
modular architectures, with standardised interfaces and
state-of-the-art information technology that permit highly
flexible, automated ‘plug and produce’ manufacturing. In
the longer term, advances in autonomy and flexibility will
drive a shift in the economic principles of production. For
example, it will be possible to manufacture small lot sizes
cost-efficiently, meeting an increasing demand for
customised products.
This ongoing digital transformation is driving
innovation across a wide range of industries, which will
face significant challenges as technological developments
move towards fully connected, self-organising intelligent
factories, where manufacturing devices will autonomously
self-optimise.
Technology components can theoretically be
combined to form a mature smart factory in the vision of
Industry 4.0. However, each manufacturing device enters
the production line with its own set of proprietary
interfaces. In other words, the components each speak a
28 INDUSTRIAL TECHNOLOGY • October 2017
TECHNOLOGY
IS IN OUR DNA
Whether it is safety, vision, wireless, Contact fortop
signalling or energy: we have a solution for your questions
for you application. We see it as our in the fields of
job to help choose the correct products automation and
for your application, no matter how energy control.
hazardous the environment.
a few of the brands we represent
[email protected]
shop.fortop.co.uk
+44 (0) 1684 585148
29
MACHINE BUILDING & AUTOMATION Wireless
Accelerating deployment
in the Internet of Things
Neil Bosworth outlines the opportunities that today’s new levels compared with a wholly bespoke design, a Gemalto
of connectivity bring, and helps demystify what it takes to deploy terminal could be deployed within six months, a good
an enterprise-wide Internet of Things solution year ahead of the bespoke solution, and with considerable
time savings. The key benefit of the Gemalto terminal is
If 2016 was the year that the Internet of Things broke performance in real-time and send alerts and diagnostic that everything required is limited to the software level.
into mainstream consciousness, 2017 will be the one information as soon as a fault is detected or, ideally,
where it starts to prove its worth. While consumers before it happens – and potentially provide a route for With the footprint of a credit card and encased in
are being wowed by virtual assistants that turn on the remote troubleshooting as well. robust plastic housing, the miniaturised Cinterion EHS6T
lights, those in enterprise are discovering how to M2M terminals work in virtually any scenario providing
demonstrate real value to their business. Developing a bespoke solution for doing this can be a secure connectivity. They also have on-device debugging,
time consuming and costly exercise. But to address the multi-threading programming and program execution.
The initial hype has been overcome, the technology problem, Gemalto has developed a range of simple and These cellular terminals allow to quickly connect your
and connectivity is here and sensors are bringing in data reliable plug-and-play M2M terminals. They ship with industrial applications with virtually zero design time, no
that is robust. Now this foundation stage is complete, embedded Java allowing for easy and fast application hardware skills, minimal integration effort and no costly
attention can turn to the more exciting task of rapid development. approvals.
experimentation and eventual widespread adoption.
The workflow of IoT deployment The future is clearly a connected world. Waiting for a
Many companies have completed proof of concept product or machine to fail and then attending to it is
ideas and tinkered with small scale tests. But to be truly Assessment is the bedrock of any IoT project. The goal inefficient. Instead we can monitor its status and diagnose
useful, these projects must mature quickly. It is this and the constraints must be known, including costs, issues before they become severe. This alone could have
challenge that organisations must address as the need to deliverables and timescales. Once a company has far-reaching ramifications for dozens of industries,
scale rises in prominence. confirmed these parameters, there are a further five reducing downtime for customers, lowering support costs,
stages before deployment. These are concepting, and optimising productivity. And by adding connectivity,
The fascinating aspect of this new world of prototyping, pre-production, approvals and certification, you open up possibilities for innovation that cannot exist
digitalisation combined with connectivity is its limitless and production. when devices and machines are offline.
possibilities. Each company has its own objectives and its
own advantages. The reason for bringing previously When approaching design of an IoT device, the We are approaching a point where the barriers to entry
disconnected devices and machines onto a network will temptation will naturally exist to craft something bespoke. are rapidly diminishing, allowing companies to take
differ in every case. But the goal will invariably be the This has its advantages in that it will cater specifically to accelerate their progress in the Internet of Things. Critical
same: to drive the company to new heights. its purpose. However, there are hidden drawbacks that to this acceleration is understanding the nuances of the
mean a purpose-built solution like a Gemalto terminal is ways in which IoT projects evolve from prototype to
It can be daunting at first. Those on the front-lines of ideally suited for the majority of IoT enterprise projects. If production, and the ways in which you could
operations and those at the very top of management we look at a breakdown comparing what it takes to accelerate that process.
understand the transformational potential of the IoT. But complete an IoT deployment using a pre-built solution www.gemalto.com/m2m
achieving company-wide buy-in can be a challenge both
in terms of internal investment and overcoming the risk of Neil Bosworth is UK manager for Gemalto M2M
doing something new for the first time.
If building and deploying IoT solutions in the
enterprise is to be a success, there must be recognition
that each use-case is not the same. A large-scale project
that aims to connect tens of thousands of endpoints is
markedly different to one in the low hundreds. While
those looking to connect large, complex infrastructures
together may have to create a bespoke solution, there are
alternative options for those with smaller scale objectives.
This is where opting for a partially pre- designed and pre-
certified endpoint solution can result in significant
savings, both in terms of costs and time.
Two common application scenarios for the Internet of
Things are predictive maintenance and remote
monitoring. There are countless machines that the digital
revolution has hitherto passed by, but adding predictive
maintenance and remote monitoring to a company’s
toolset can have a dramatic effect on its productivity.
What many industries have in common is that non-
connected devices are often deployed remotely and
manned (if at all) by employees who generally have
limited technical skills. Thus, when something
malfunctions, there can be high associative costs for
problem identification and resolution. The obvious
solution is to install something that can monitor
30 INDUSTRIAL TECHNOLOGY • October 2017
Wireless MACHINE BUILDING & AUTOMATION
Balluff introduces long range
RFID reader
RFID systems help users to get a handle on the also ideal for
stream of information in a modern factory. traceability solutions due to its
Objects can be automatically identified and multi-tagging capability which allows up to 50 data carriers to
traced using RFID – a data carrier that functions be detected at once. A highlight is the integrated Power Scan
as a memory is attached to the object and allows it to be function, providing auto set-up at the touch of a button. It
identified. Data is transferred between the data carrier and offers automatic matching to the UHF data carrier being used,
read/write head, via the processor unit, to the controller. and ensures optimal configuration in any application without
cumbersome manual setting of parameters. This is possible
Balluff offers a broad selection of RFID products, and with the touch of a button on the device itself. Balluff claims
now the company has added to its BIS V RFID platform the BIS VU-320 is the only device in its class in the world to
with the introduction of the BIS VU-320 reader, which have an auto set-up function. The read/write head
adds UHF functionality. Featuring BIS V multichannel automatically adjusts itself to the local conditions, which
processor technology, the BIS VU-320 can accept readers minimises start up times.
in the low, high and ultrahigh frequencies simultaneously.
The company explains that this would be useful in The read/write head can be mounted in various ways to
applications where there may be a mixed environment of tag provide optimal orientation with respect to the data carriers.
frequencies, with the BIS V system helping to simplify the The rear-side mounting holes (4x M4 and 2x M5) can be used
RFID architecture. to directly attach the device to a carrier or using a three-
dimension rotating mounting bracket. The built-in antenna of
“A driving force behind the development of the VU-320 the BIS VU read/write head with its circular polarisation
reader was the need to read tags at 1 to 3 feet away,” said allows it to interface with the data carrier in nearly any
Wolfgang Kratzenberg, marketing manager for industrial orientation. It is simply necessary to ensure that data carriers
identification at Balluff. “Typical read range of LF and HF which are linear or circular polarisation are oriented
readers is just a few inches and with UHF readers the read parallel to the front of the antenna.
range can extend out to 20 feet or more making it virtually www.balluff.com
impossible to single out one tag on a production line. This
reader is going to be perfect for those flexible manufacturing
applications where the read range will vary based on the size
of the product being manufactured.”
Harsh operating environments
As with other Balluff RFID readers, the VU-320, is built to
withstand tough manufacturing environments, offering a
protection rating of IP67. Four highly-visible LEDs simplify the
trouble shooting process, eliminating the need to access a
webserver or PLC to determine if a tag is being read or if the
antenna is sending a signal. Because the VU-320 is a part of
the BIS V portfolio, it can communicate via Profibus, Profinet,
Ethernet IP, CC-Link or Ethercat. A full line of mounting
accessories and cables is also available.
With a typical reading range of 1 m, the UHF system is
especially suited to monitoring production processes,
controlling material flow and for use in assembly plants. It is
MACHINE BUILDING & AUTOMATION Robotics
UK manufacturing industry
must wake up to automation
Will Bourn looks at the UK’s have 49 robots per 10,000 employees, but the robot (Above) Statistics from the IFR in September 2016 show the
population there continues to grow fast, boosted by the UK continues to perform poorly in the uptake of robots
past record of investment in government’s aim to become one of the top technological
nations. Their stated aim is to hit 150 robots per 10,000 demonstrated above, that investing in automation brings
robotics and automation and employees by 2020. This is against the background that about a corresponding improvement in productivity and
China’s economy was built up on the basis of low wages. hence market share, then the question becomes why on
the positive impact that future earth is the UK not doing this?
China’s approach is mirrored by Poland and the Czech
investment in automation and Republic, also traditional low-cost economies, which are The UK has a historical reluctance to invest in
the two highest climbers in Europe in terms of robot manufacturing, with a government which seems to
robotics can have on UK installations. The Czech Republic’s robot density climbed believe that the service economy is the key to all, but with
40% between 2010 and 2015. Brexit on the horizon many of these jobs are threatened.
competitiveness Indeed we are already seeing several of the major
Robots don’t cost jobs international financial institutions setting up offices
The UK is currently in the midst of some of the outside London in preparation for Brexit, so we need to
most significant political and economic changes The really interesting part of this though is the correlation replace these good quality jobs with others – why not in
seen in a generation. As we move towards what between robots and jobs. In the US between 2010 and manufacturing?
could be an uncertain future, there is however 2015, 80,000 new robots were installed, and in parallel
little doubt that manufacturing industry will play an with this the number of jobs in their automotive sector This is something which is widely recognised across
increasingly important part in our economy and future grew by 230,000. This same effect is seen in Germany the whole of the UK robot and automation sector. As an
prosperity. Against this background, it is clear that a where over the same time period their robot stock grew by industry, all of the recognised robot suppliers, machine
dramatic increase in investment in robotics and 3% and their automotive workforce grew by 2.5%. The builders, and system integrators, together with
automation will be essential if we are to remain reasons for this linkage are quite straightforward. When associations such as BARA and PPMA for example,
competitive and achieve the productivity levels required to you automate you bring down the overall cost of the goods continually campaign to raise the awareness of both the
attain the growth needed to sustain our economy. you make and you improve their quality. You are therefore need for investment in automation and robotics, and the
more competitive, so you sell more and you gain market benefits that can be obtained by UK manufacturing
For a country with an impressive manufacturing share. industry.
heritage, the UK’s record when it comes to investment in
manufacturing industry is quite depressing. There are Of course, looking at robot statistics is only one Pledges from the Government in the latter part of
regular articles in the news regarding our productivity indicator of the reason why we have relatively low 2016 to invest an extra £2 billion in science and
compared to the rest of the world, and they don’t make productivity in the UK. Other reasons are more structural, technology research and development are obviously
comfortable reading. According to figures from the office welcome, but these strategies are generally for the mid to
of national statistics, amongst the G7 countries only such as education and long term. We already have the robot and automation
Canada and Japan are less productive than the UK. training, transport infra- technologies available today that can make a positive
Germany is at the top of the pile, being 26.7% more structure and the tax impact on productivity, performance and profitability in
productive per man-hour worked than the UK. Even Italy regime. It is very difficult our manufacturing plants. What is needed in the short
with all of its current economic problems is 10.5% more for individual companies to term is a change in the way investments and payback
productive than us. And why is this? In my view the do anything about these periods are calculated in the UK to encourage these
principal reason is lack of investment. factors, but what they can vital automation projects.
do is invest in automation. www.gudel.com
This can be illustrated very simply by looking at robot
numbers per head of the working population. The Money for investment Will Bourn is UK sales manager for Güdel (UK)
International Federation of Robotics (IFR) recently is at a historically low cost,
published figures which show the UK near the foot of the and with the links
table with just 71 robots per 10,000 employees in
manufacturing industry. Our European cousins rate much
higher, with France at 127, Spain at 150, Italy at 160
and Germany, which has more than four times that of the
UK, boasting an impressive 301 robots per 10,000
employees in manufacturing industry.
The overall robot density in the large Western
European economies is still currently ahead of China, who
32 INDUSTRIAL TECHNOLOGY • September 2017
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33
DRIVES, CONTROLS & POSITIONING Servo Drives
Servo drives key for high
speed robotic camera dolly
Advanced servo drives are at the heart of a
robotic camera dolly system, developed to
capture extreme high speed live-action footage
When writer/director Howard McCain and Kuklish founded Mega Trax, would need to be capable of. At the heart Studio II (EASII) motion design software.
McCain outlined an idea he and the two entertainment mavens created of the MX 500, they employed Elmo McCain says: “Elmo has a great reputation
had for an extreme action the world’s first semi-autonomous, high- advanced, high-voltage Gold Drum servo for precision motion control, which gave us
shot, the studio told him it speed, robotic dolly system. The drives, tuned with Elmo’s Application a high level of confidence in the company.
could only be done using computer company’s flagship product, the MX 500,
generated imagery (CGI), and would cost is revolutionising the filmmaking industry
over $1m, he was convinced there had to by creating high-speed, live-action shots
be a better way. Together with VFX for movies, television, commercials, sports
supervisor David Kuklish, he explored and live event venues that were previously
conventional dolly systems, crane systems, only possible with CGI.
helicopter shots and drones, but couldn’t
find anything that would get the job done. With credits spanning large-scale films
(Outlander), franchise films (Underworld),
To address the problem, and so provide televisions shows (Conan) and theme park
a solution to the ongoing creative-meets- attractions (Universal Studios), McCain
financial-and-technical-limitations and Kuklish know a thing or two about
dilemma in the entertainment industry, extreme live action, and what the MX 500
Discover a wealth of advantages
Extra long lifespan Wider speed range Short & reliable Faster installation
delivery times & maintenance
Thanks to stronger shafts Thanks to the extended
and ball bearings number of gear stages Thanks to modularity of Thanks to innovative
new drum motor generation plug-in connection
Ultra-hygienic
All variants with IP69k
degree of protection
Interroll’s next-generation drum motors
Flexible, robust and ultra-hygienic
Interroll’s industry-leading drum motors drive belt conveyors around the world. Aside from
general material handling applications, the motors are mainly used in the packing and food
industries, as well as in airport luggage conveyors.
Interroll Limited · Unit 1a Orion Way, Kettering, Northamptonshire, NN15 6NL
Tel: +44 / 15 36 31 27 70 · Fax: +44 / 15 36 53 67 20 · Email: [email protected]
interroll.co.uk
34
complete motion control solution for
the MX500 reduced overall power
consumption and extended battery
life, and enabled the robotic dolly
system to consistently and efficiently
reach extreme performance metrics.
Extreme performance
Then, we realised that Elmo’s servo The Mega Trax MX 500 semi-
drives were the only ones that could autonomous robotic dolly system can
handle the power and motion control safely go from 0 to 62mph in 3-3.5
requirements that we needed to deliver seconds, and reach speeds of over
extreme action shots with our robotic 90mph. It can decelerate, switch
dolly system. Elmo helped us create a directions and again accelerate without
system that will give audiences the jaw- hesitation, thanks to perfect
dropping ‘wow factor’ of real, live-action synchronisation among four motors,
footage.” Each of Elmo’s four high- enabling the MX 500 to capture ultra-
voltage, lightweight, extreme power smooth camera shots at top speeds.
density Gold Drum HV servo drives can John McLaughlin, president for
handle up to 100A/800V and are North America at Elmo Motion Control,
capable of delivering more than 65kW says: “Mega Trax’s requisites for high
of continuous output power. power for acceleration and extreme
The compact Gold Drum HV’s power density outlined a unique and
extreme high voltage is vital to the complex configuration that could only
robotic dolly achieving high speeds and be achieved with a powerful, advanced
fast acceleration. The EASII software motion control solution. Through deep
tool’s flexible programming environment motion control expertise and extensive
makes it easy to quickly create and experience, Elmo helped Mega Trax
implement motion, and intuitively meet and exceed these
program and fully manage Elmo’s servo 10:ex4p1ectaPtiaognes.”35
drives and motion controllers. Elmo’s www.elmomc.com
Making the change from pneumatic cylinders to electric
actuators can simplify your design and deliver savings at the
same time. The new Thomson PC-Series electric actuators
are designed to deliver superior performance while saving
you time and money with easy product sizing and selection,
quick and reliable installation, and reduced maintenance.
> Higher power density
> More accuracy
> Longer stroke lengths up to 1200 mm
> Loads up to 6000 N
> Quieter operation
> Side load capability
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35
DRIVES, CONTROLS & POSITIONING Electrical Positioning
Easy to select, easy to
connect, easy to configure
Warren Harvard discusses the challenges facing machine builders and what can be done to
improve the easier selection, connection and configuration of electric drives solutions
For special purpose machine builders, being Electrical positioning systems movement re-
able to specify a solution quickly are a good example. They are quirements are not
and easily with total commonly used in almost any onerous, closed loop
confidence in the machine that needs to stepper motor technology
performance is key to winning position and move offers the same control capability
business in an efficient manner. objects. Typically and can manage similar loads to servo
For the replicating machine builder, consisting of a systems, at a lower cost.
the challenge is to find a way to positional controller, To address these issues, suppliers need to make it easy
build a standard solution that can be motor, gearbox and for machine builders to match components in order to
reconfigured easily and cost- mechanical axis, deliver the required performance: easy to select, easy to
effectively to meet customer cables and connec- connect, easy to configure. Manufacturers of electric drive
standards in terms of tions, their overall system components can play an important role by providing the
fieldbus and connectivity performance is a result of the combined tools and products to make it easier for designers and
protocols. In both cases it’s performance of the individual components. Machine machine builders to make the right choices. There needs
a highly competitive builders frequently source these different elements from to be more understanding of designers’ needs by the
environment. Cost is critical two, three or more suppliers; introducing questions around component manufacturer so that they can provide fast,
but it’s often the first to respond performance, compatibility and connectivity. Because of knowledgeable support through the specification, buying
with a quote that gains the advantage. this it is often easier, quicker and safer to stick to and machine-building process.
previously used solutions, rather than look for new ones. Festo offers a wide range of motion solutions, from
However, there is an inherent conflict between simple positioning to high-end servo electrics. The
reducing time and reducing cost. Shopping around The effort and risk involved in deviating from a known company’s overall approach is to focus on the needs of the
multiple suppliers can identify lower cost components; but solution is a real barrier to cost and performance machine builder. Festo wants to make it quick and easy for
the all-important final price often masks the associated optimisation. As a result, a machine builder may choose to designers to select the various components and
engineering sourcing, procurement, design and stick to a known servo electric system that provides top understand their combined performance and overall costs.
compatibility costs. Building a solution using multiple end performance even when the application doesn’t The company does this by supplying all the elements in
components from different suppliers is actually complex, require it – and when there are other, more cost-effective the control chain that are needed to make the solution
time consuming and risky. There is always the potential technologies that can be used. For example, if dynamic work, both mechanical and electrical. The result is an
that a mistake has been made – particularly when trying integrated and joined up solution – easy connectivity,
to ‘marry up’ different manufacturers’ data, which is guaranteed system performance and compatibility, plus
frequently presented in different formats, units, etc. The technical and customer support – all from one source. And
potential for issues to arise around compatibility and because Festo offers all the elements, machine builders
connectivity is high and, with multiple suppliers involved, and designers can take advantage of a free simulation tool
it is often unclear where ownership of that risk lies.
Time pressures and a desire to avoid risks can lead to
disadvantages for end users. It reduces the opportunities
for machine builders to consider all the options and add
real value at the design stage. Instead, the tendency is to
stay with a proven specification and often to adopt a ‘belt
and braces’ approach. This can mean that the
recommended solution is not optimised, may be over-
engineered to provide a safety factor, and is more
expensive than it needs to be.
As a result, the end user can get a less efficient, more
complex solution than necessary – creating potential
service, maintenance and life time cost issues.
BENEFITS OF THE FESTO OMS ELECTRIC DRIVE PACKAGE
G Speed to design, thanks to our free software selection tool
G Modularity in terms of connectivity options to fieldbus systems
G Fast to quote customers with different fieldbus options – no need to redesign whole electric drive system,
just change the fieldbus node
G Fast delivery – one week
G Performance guarantee of the system – proven in the software
G Cost effective technology (closed loop stepper appropriate for many applications)
G Simpler process - one supplier, one order, one purchase number, one delivery
36 INDUSTRIAL TECHNOLOGY • October 2017
Manufacturing systems connect
Festo has introduced its EMCA integrated FAULHABER Motion Control
positioning drive to offer designers and
engineers all the connectivity they need to Feel the
meet the demands of modern manufacturing Power
environments. The EMCA combines motor and drive in
a single piece of hardware and is designed for easy The EMCA consists of a maintenance-free and
integration into any machine or system where wear-resistant brushless DC motor with integrated
rotational movement is required. By using the EMCA in power and control electronics. The integrated drive
combination with other Festo automation products, system is compact, avoids long motor cables,
engineers can build a range of automation solutions: improves electromagnetic compatibility and reduces
from gear units to electro-mechanical axes and installation workload and space requirements, while
complete handing systems, including high speed built-in monitoring functions ensure safety and
robotics. reliability. The EMCA uses a 24 DC input and senses
absolute position using a single-turn encoder as
Applications include materials transport and standard, or optionally via a multi-turn displacement
conveying, printing, packaging and labelling, as well as encoder with buffering.
textiles and electronics manufacturing. Whatever the www.festo.co.uk
application, the EMCA will fit seamlessly into existing
manufacturing systems and has the connectivity to
support the factories of the future. Current models of
the EMCA positioning drive can already communicate
via an I/O -Interface, Canopen and Ethernet I/P.
Variants for ProfiNet, EtherCat and ModBusTCP are
scheduled for release in early 2018.
that provides a range of technical solutions based on the feedback enables the system to operate in a cost effective FAULHABER Motion Controller
application requirements. The results provide guaranteed and full closed loop servo mode. Series MC 5004 / 5005 / 5010
performance, known costs and, critically, the opportunity
to make fast, optimised risk-free decisions. Providing support with specification and Perfectly optimised for the FAULHABER
commissioning, Festo has an online software tool called drive program – whether DC-micro-
A good example of Festo’s ability to offer performance Positioning Drives that is freely available and will help motors, brushless motors or Linear
oriented solutions is its Optimised Motion Series (OMS). OEMs and machine builders select the optimum electric DC-servomotors
Festo used its expertise to develop a total package that drive package for their application. The user just enters Modular kit concept with 3 performance
offers one cost-effective solution for many positioning the application details and the software comes up with a classes, peak currents of up to 30 A,
applications. Based on closed loop stepper motor range of technically matched solutions. The software’s comprehensive protective and diagnostic
technology, the Optimised Motion Series of electric drives inbuilt mechanical knowledge and understanding takes functions
has been developed to provide easy to use, multi-position into account the mechanical axis – whether piston rod, New connection concept via plugs,
control at a highly focused price point. So, OEMs and rodless gantry, cantilever-based linear drives or guided 4 interface variants – RS232, CANopen,
machine builders can order a complete electric drive rotary tables – and provides the optimum product choice EtherCAT and USB
system using one product code and get all the in terms of bearings, guidance and application demands
components they need – including the cables, connectors such as mass, centre of gravity, off-sets, velocity, etc. Easy commissioning with the
and gearbox – delivered in one box. Because you are Electrical compatibility is assured because once the new Motion Manager 6
dealing with one supplier for all the components, optimum mechanical drive is selected the motor and
compatibility is guaranteed. gearbox are matched to the performance requirement. NEW
The OMS Series uses Festo technology to facilitate The Positioning Drives software provides information WE CREATE MOTION
connection to various end user protocols. Machine about the safety margins offered by the proposed
builders can therefore design a standard electric drive solutions so the designer can make an informed decision Distributed exclusively in the UK by
system that, with a simple inexpensive change to the – making electric drive selection quick, simple and risk
connectivity node, can communicate directly with a wide free. There is also simple, free access to CAD drawings EMS
range of systems such as: in all standard native formats, electronic datasheets for
G I/O-link easy technical file compilation, performance assurance www.ems-limited.co.uk
G CANopen and a single complete system price, so all the
G DeviceNet information is available in one place.
G EtherCAT
G Profibus Once the machine builder has taken delivery, the
G Profinet chosen OMS package can be assembled out of the box
using one tool – a simple Allen key. Because all the
Even the programming is supported with simple, components come from one manufacturer the
modern, Web-config tools. All parameters are mechanical interfaces are designed to work together to
downloaded from the Festo web-server rather than provide secure, aligned axes; so there is no need for
having to be entered manually, significantly reducing additional, expensive brackets and adaptors. When
programming time and the potential for error. installation is complete, Festo’s free Web config tool
makes it fast and error free for the controls or
The Festo advanced CMMO stepper technology commissioning engineer to set-up and prove the
enables lower cost motor technology but with advanced solution.
control capability, including force and position control www.festo.co.uk
delivered in a smooth and optimised motion profile. Open
loop control is the lowest cost option; but where accuracy Warren Harvard is product manager for electric drives at Festo
and continuous monitoring is required then encoder
October 2017 • INDUSTRIAL TECHNOLOGY 37
FLUID POWER Hydraulics & Pneumatics
Can Formula One technology
benefit your own processes?
Behind Formula One motorsport is an industry steeped
in the ethos of overcoming challenges, finding better
solutions and embracing continual improvement, fully
supported by the technology and manufacturing
expertise to realise these goals. Transfer of this
approach to other sectors, especially in defence,
marine and aerospace, brings significant benefits
The synergies between motorsport and the secure method of disconnecting and re-connecting materials; its advanced use in aerodynamic and structural
defence sector may not be immediately apparent, essential liquid and gas lines. No draining or refilling is components has been the norm for over two decades.
but dig deeper and opportunities arise for necessary enabling faster maintenance without the need This expertise is increasingly in demand in the aerospace
transferring some of the thought processes and for specialist tools, equipment or training. sector where composites are replacing metals and
techniques. Take, for example, military vehicles; providing operational advantages in many applications.
minimising time out of commission is the equivalent of a Aerospace technology transfer
lengthy pit stop in motorsport. The F1 approach would be Parallels between motorsport and marine industries
to engineer a quicker solution capable of getting the car Vehicle air-conditioning circuits used for personnel cooling are also numerous, not least because both sectors are
back on track as soon as possible. The military answer is are critical in the hot arid climates of operation and involved in sporting activities which serve as a proving
often to discard the troublesome vehicle and use another, cannot be compromised. Using Stӓubli’s refrigerant ground for innovative new technologies. Offshore
effecting repairs at a later date probably back at base, couplings, high integrity leak free connection points powerboating is one, more obvious, example of marine
resulting in the vehicle being out of action for some time. provided a simple solution for breaking cooling lines, motorsport technologies. As in a single-seat racing car,
Could some of the techniques used to keep F1 cars racing ensuring reliable operation and maintenance without boats competing in the Powerboat P1 World
be used to advantage in this aspect of the military arena, spillage of ozone depleting gasses, or inclusion of dirt into Championship use carbon fibre hulls as their main
increasing effective utilisation and the time available for the system. Applications for this innovative connection structural part. Similarly, aerodynamic and hydrodynamic
the vehicle to be fully operational? technology are now also being found in the aerospace and performance is optimised using motorsport-developed
electronics markets. Computational Fluid Dynamics (CFD).
This is a real example where transfer of connection
technology developed by Stӓubli in the motorsport arena Back at the racetrack what other considerations The Motorsport Industry Association (MIA) has a
has been used to advantage in another sector. Panther commonplace to F1 engineers could be adopted by other central role in this transfer of skills, expertise and style of
reconnaissance vehicles were increasingly suffering sectors? Motorsport embraces the continual need to approach. It has established initiatives bringing together
mechanical damage due to being used in the hot, stony improve, gain competitive advantage and perform reliably companies in the defence, marine, aerospace and
hostile environment of the Middle East, significantly under some of the most severe operating conditions. automotive sectors with those operating in motorsport
restricting the availability of these vehicles in the field. To These are all considerations that should also be in the using products and techniques that potentially could have
provide an effective and easy to implement solution, quick minds of those operating in other market sectors. The applications in these other sectors.
release connectors were fitted to the air conditioning and initial design of the product at the OEM stage is the
radiator assemblies. These non-spill clean break starting point; can the design be adapted to improve Nick Wills appointed Defence Development Director
connectors made it possible for the complete condenser performance and reliability, make maintenance and for the MIA in 2014 after a successful career in the Army
and radiator sub assembly to be quickly removed from the servicing easier, faster, and even unnecessary? commented: “Maintaining complex equipment at war is a
vehicle and replaced without any need to de-pressurise, significant challenge faced by all three services, be that in
purge and recharge the refrigerant in the system. An Perhaps the synergies between motorsport and the the land, air or sea environments. Equipment failures can
operation that would normally take 2½ hours and often aerospace sector are more readily apparent. After all, lose battles and ultimately lives, and so the transfer of
require a return to base was reduced to just 30 minutes aerodynamically a race car operates as an aeroplane in technology from a cutting edge sector such as motorsport
and could be performed in the field. reverse, creating an incredible amount of downforce. in order to increase the battlefield serviceability and
There are manufacturing similarities between aerospace availability of warfighting platforms is highly attractive to
The use of quick release connectors, like those used and motorsport; top-end motorsport uses aerospace- defence sector companies.
on F1 cars, on military vehicles has provided a safe and grade metals and advanced metrological inspection. Over
80% of an F1 car’s volume is made from composite “The capability that the connectors from Stäubli
provide will ensure that, if fitted, the equipment is the
favoured choice of the defence maintenance and
engineering communities. To have motorsport-proven
technology that reduces the need for strict engineering
hygiene, speeds up the procedures, and saves resources
through no loss of fluids or gas, is a game changer for
those at war. I am convinced that Stäubli connectors are
facing a considerable market opportunity in the
defence sector.”
www.staubli.com/en/connectors
38 INDUSTRIAL TECHNOLOGY • October 2017
Connect all in one and boost
your productivity
Stäubli MCS (Multi Connect System) solutions increase your process performance and equipment
safety and productivity. By choosing these tailored solutions, you can simultaneously connect your
vCarious energy sources.
Manual or automated multi-connection solutions, in just one move: Reliable. E cient. Safe.
Stäubli.
Connect to our solutions at www.staubli.com
Stäubli (UK) Ltd - Phone: +44 1952 671918 - Mail: [email protected]
FLUID POWER Hydraulics & Pneumatics
Hydraulics will run and
run with proper servicing
Over the last 30 years, the performance, sophistication and
operational demands of hydraulic equipment have increased
significantly. So planned maintenance and servicing are vital for
maximising working life and minimising costs. David Atkinson
runs through the basics of looking after a hydraulic system
Modern cars are fantastically reliable, but only Regular (often monthly) checks should be made of and experience and their advice will be invaluable. An
if they are well serviced and maintained. copper, silicon and water content, the ISO particulate effective, proactive maintenance program requires time,
Similarly, well designed and built hydraulic count, viscosity, additives and oxidation concentration. effort and some expense to implement. However, it is cost-
machines will run for many years, but only if Minute amounts of metal debris, or dirt ingress, can, over effective, with the investment quickly recovered through
servicing extends beyond the occasional fluid level check. time, damage seats, seals, pistons, bearings and other savings as a result of improved machine performance,
Servicing can be reactive or proactive, but either way it components. At the time same checks should be made for increased component life, longer fluid life, reduced
needs to be of a high quality to ensure optimised excessive heat and vibration – simple but effective
performance. In fact it is a simple truism that hydraulic indicators of system health.
system failures are very often down to lack of maintenance
– the main cause being lack of fluid cleanliness. Thus the Some hydraulic users undertake these checks
first key to hydraulic performance is maintaining the fluid. themselves, but it is often better to have a hydraulic
specialist visit site, as they have considerable expertise
Miniature High Flow Latching Solenoid Valve
G Low Power Consumption
G Magnetically Latched
G Light Weight: - less than 4.5 grams
G Ultra Compact Size
G Plug-In, Face Mount and Ported Styles
G Operating Pressure Range: Vac – 45 psig (15 psid)
The Lee Company’s ultra-miniature 3-port magnetically
latched solenoid valve is now available in a Lo Lohm design
for higher flow rates. Optimized for applications that
demand ultra-low power, low heat and small size, this
design is ideal for compact, battery powered instruments.
For more information visit www.leeproducts.co.uk Innovation in Miniature
Tel: 01753 886664 Fax: 01753 889588 email: [email protected]
Lee Products Limited, 3 High Street, Chalfont St Peter, Gerrards Cross, Bucks. SL9 9QE
40
An effective, proactive
maintenance program requires
time, effort and some expense to
implement. However, it is cost-
effective, with the investment
quickly recovered through savings
downtime and fewer repairs. Well made hydraulic Oilgear commissioning engineers in a vehicle fully
components have a long life expectancy (which in some equipped with state-of-the-art flow and pressure
cases can be measured in decades) and first-rate monitoring equipment and accumulator charging
hydraulic companies offer full lifecycle support for their equipment so that re-installation can be carried out
products. For example, there are Oilgear pumps that quickly and efficiently.
have been running for over 50 years, while axial piston
assemblies tested in-house to 100,000 hours running Changing times
can show zero wear.
Hydraulics service providers understand that site
Repair, refurbish, replace requirements may change over time, often driven by
environmental requirements and legislation, and should
Related to servicing, premium hydraulics manufacturers work with users to meet these. For instance press
will also offer a repair service for parts that have been operators increasingly want to develop energy efficient
damaged. This will include disassembly, inspection, ‘power on demand’ capabilities, while other users are
quotation, refurbishment with approved parts, and looking for water based solutions to reduce fire risks.
complete testing. Ultimately there will be a ‘good as new’
guarantee. Oilgear has developed on-demand systems using
inverters, softstarts and other complementary
If and when a failure happens, users need support to technologies and has recently added a new multi-fluid
quickly arrange repairs or fit replacement parts. A good test rig to its suite of testing stations, so can simulate
hydraulics company will carry an extensive inventory of virtually any working system.
spares for equipment dating back over 20 years or more,
so should be able to supply a replacement part (and A hydraulic system’s longevity can depend on good
expertise) promptly. installation and commissioning by experienced
engineers. Oilgear can provide such staff, or alternatively
Larger items are often returned to their manufacturer run training courses, which can be tailored to suit the
for repair or refurbishment, where they will be stripped individual user’s requirements.
down, inspected and an assessment report prepared.
From this a full technical quotation for remedial work can In conclusion, modern hydraulic systems are
be provided and if an item is beyond economical repair, expected to have long, productive working lives and this
the company should be able to manufacture an ‘as new’ can be achieved by using high quality components and a
part. When it comes to breakdowns, Oilgear will work strong co-operative relationship with the manufacturer.
around the clock if required – combining a manufacturing By working closely together, it is possible to deliver a
department’s quality with a service department’s proactive maintenance routine with the necessary
response. Repaired or replacement parts are assembled technical expertise to minimise any downtime,
and fully tested in-house and may be delivered to site by thereby improving productivity.”
www.oilgear.com
David Atkinson is service centre manager
at Oilgear
41
The Sports Pages
Cycling Wind tunnel key to performance improvements
Cutting-edge aerodynamic
insights for performance sports
Anew joint venture, Sports Aero Solutions (SASL), performance. Although hugely expensive, improvements we’ve seen it. In fact, as air resistance accounts for the
has launched a range wind tunnels for specific were enormous. Because of this experience, Boardman vast majority of an athlete’s energy expenditure, it is the
performance sports such as cycling and winter and Lewis wanted to make aerodynamics exploration single most important thing to understand.
sports. It brings together the skills and available to the wider sporting world. In 2015, they
experience of Olympic gold medal cyclist Chris Boardman, teamed up with high performance engineering solutions “Wind tunnels are by far the most accurate way to
aerodynamic and computational fluid dynamic (CFD) provider KWSP to form a new company, Sports Aero measure the impact of drag on performance. The high-
expert TotalSim and high performance engineering Solutions. The purpose of the partnership was to design fidelity instrumentation of SASL’s wind tunnel solutions
solutions provider, KWSP. The SASL wind tunnels will and manufacture accessible, highly accurate, sport- and its ability to recreate any wind condition that an
overcome the prohibitive costs of using wind tunnels specific wind tunnels, with a goal of providing cutting- athlete will encounter, make it the best tool to measure the
designed for automotive and motorsport. edge knowledge for everyone, from sports enthusiasts, to implication of tiny changes which would not be detected
elite athletes and coaches. in any other way.
Cyclists and triathletes – in fact athletes in general –
routinely measure speed to the fraction of kph, record Making aero exploration available “The SASL wind tunnel can run tests at every wind
heart rate to the beat and power to the watt. They are speed and angle athletes are likely to encounter. Our
obsessed with numbers – so it is ludicrous that knowledge Chris Boardman said of the venture: “It’s not an proprietary, highly-sensitive balance measures all the
of air resistance, the force they spend up to 90% of their exaggeration to say the knowledge I gained from using a forces acting on the athlete and the output can be fed
energies overcoming, is minimal. wind tunnel in the early 90s enabled me to win an back to the user, real-time, in a format familiar to them:
Olympic Gold. Nearly 20 years later, I spent a decade watts, speed, grams or newtons of force, or time saved
A tiny fraction of the very best athletes in the world get helping other GB athletes access that same advantage. over a given distance and speed.”
to spend a few precious hours in a wind tunnel (usually The few tunnels available to us were geared up for motor
designed primarily for the needs of the motor industry). sport, they were very expensive to use, had to be modified Kieron Salter, MD of KWSP added: “SASL brings
For the vast majority of sports people, this all important for our use and were hard to gain access to. Without together a set of complementary skills, all focused on
knowledge is gleaned from articles in magazines and Lottery funding, we would not have been able to make the creating cost effective wind tunnels honed to the specific
hearsay. This is because the only ways to accurately advances we made. needs of the sport in question. As a high-performance
measure the effect of positional changes and equipment engineering business KWSP will use our team of engineers
choices on performance, are both prohibitively expensive “We set up SASL to remove this barrier – to make aero to design and manufacture wind tunnel solutions for our
and hard to access. SASL will change this paradigm by exploration available to enthusiastic cyclists, runners, customers based on their specifications, TotalSim’s
delivering wind tunnel time at a fraction of the cost of the winter sports, in fact any athlete who is limited by aero aerodynamic requirements and Boardman’s
traditional solution. drag and wants to do something about it.” understanding of the needs of performance athletes."
For more than a decade, aerodynamicist and CFD Rob Lewis of TotalSim explains the benefits of using a The partnership is based in the south Midlands, with
expert Rob Lewis of TotalSim and Olympic gold medalist wind tunnel: “Small efficiency improvements in KWSP’s and TotalSim’s facilities both located in Brackley,
Chris Boardman worked with some of the best athletes in aerodynamics, be they equipment, clothing or position Northamptonshire, an area well known for its pre-
the world to explore the effect of aerodynamics on their have an enormous impact on race outcome; we know, eminence in motorsport engineering.
www.kwspecialprojects.com
42 INDUSTRIAL TECHNOLOGY • October 2017
ENGINEERING UPDATE
How is IIoT transforming our world?
Igus has published a white paper WHITE PAPER and plant builders of problems before they
entitled: ‘How the Industrial Internet of occur. The tracking of patterns to indicate
Things has led to the development of devices being used to create integrated failure would be an enabler to condition
next-generation smart plastics with systems across all levels of automation,” based modelling, unleashing the true
sensing capabilities built in.’ Set to grow at says Matthew Aldridge, managing director potential of predicative maintenance. “This
a CAGR of 8 percent from now until 2020, at Igus. “Such data transparency opens up predicative approach takes the black art out
when IIoT will reach a value of over new business models for machine and of maintenance, and turns it into a
$150bn, the paper assesses the plant builders across a wide range of science,” adds Aldridge.
advantages and benefits it brings. industrial sectors.”
The white paper can be downloaded
“There is now a discernible trend IIoT is helping manufacturers capture from the Igus website at:
towards communication-capable, intelligent and analyse this data, warning machine www.igus.co.uk/smartplastics
Structural bonding – the ROTAFLOW FV Ltd
next generation
Rotec House, Bingswood Trading Estate
Why does a new brochure on Loctite universal structural Whaley Bridge, High Peak SK23 7LY
bonders have an image of a freight train on its front email: [email protected] www.rotaflow.com
cover? Because it depicts an application that sums up tel: +44 (0)1663 735003 fax: +44 (0)1663 735006
what makes this new technology such an important
development. The coupler that connects the engine with Robust and Durable Swivel
the freight wagons, allowing it to pull a load of 208 tons, Joints
is an assembly bonded with just 3g of Henkel’s new Loctite hybrid adhesive that
cured in one hour. This powerful example demonstrates the cure speed, strength Rotaflow FV Limited manufacture a range of robust and
and durability of the new range. These attributes are achieved through the durable Swivel Joints which provide 360° movement
combination of several adhesive technologies, opening-up endless possibilities in through a clear bore to transfer fluid under pressure
the way products are designed and made. without leakage from a static position to a moving point –
ideal for loading arms or removing the twist in hoses.
www.loctite.co.uk/limitless
Single-flow, and multiport swivel joints available in carbon steel and 316 SS. Sizes 1⁄4” to
40” nominal bore, with a choice of seals for maximum compatibility.
www.rotaflow.com
Plastic energy chain, bearings and flexible cables
Improve technology and reduce costs with igus’ lubricant free e-chain
cable management systems, cables and bearings and linear slides.
igus is the largest producer of injection moulded
polymer bearings and reinforced plastic cable
carriers in the world. Product lines include
industry-leading E-Chain cable carriers,
Chainflex continuous-flex cables, iglidur plastic
plain bearings, igubal spherical bearings,
DryLin linear bearings and guide systems.
www.igus.co.uk
TorqSense and LoadSense range of sensors Maximum performance for any automation task Electro Mechanical Systems Limited
Sensor Technology offers solutions for customers’ torque and load Perfection in Automation – complete EMS offers a wide range of small to medium sized DC motors utilising a
measurement requirements, developing its own unique technologies for automation solutions from a single source. range of technologies. Brushed and
the instrumentation, test and brushless DC motors from just 2mm
OEM markets worldwide. The Products include industrial PCs, visualisation diameter offering the highest power
TorqSense and LoadSense range and operation, control systems, I/O systems, to weight density and high dynamic
of sensors offer accurate, safety technology, motion control, performance. Skew wound ironless
affordable, market leading networks and fieldbus modules, rotor and rare earth magnet
products across the whole range software, process control, power technology maximise efficiency
of industrial applications. supplies and accessories. making them ideal for portable
battery powered devices.
www.sensors.co.uk/indtech www.br-automation.com
www.ems-limited.co.uk
ADVANCED
ENGINEERING2017
1 & 2 November 2017, NEC, Birmingham
The UK’s largest annual gathering of advanced
engineering professionals
Advanced Engineering is
the industry event where
high-technology manufacturing
sectors converge under one
roof to meet and do business.
Join us where the familiar and
the unfamiliar collide to provide
new opportunities across the
engineering supply chain.
Register to attend today!
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Register for FREE entry today mm
www.advancedengineeringuk.com
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