IT_September_2017

www.industrialtechnology.co.uk September 2017

Industrial
Technology

FOR DESIGN ENGINEERS, MACHINE BUILDERS AND SYSTEMS INTEGRATORS

The next generation
of contrast sensors:

exploring the
advantages

Northern Manufacturing p10 Electric motors p24
Sensors & systems p26
Pumps & compressors p12 Machine building p34 IMnAdCuHs1tIrN6iaEplbBaTuUgeiIlecLdhDmiPnnINaagogcGlgoheugin3iyd4e’se
Industry 4.0 p52
Fasteners & adhesives p14 The sports pages p58

Batteries p18

Clutches & couplings p20

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COMMENT & ANALYSIS

www.industrialtechnology.co.uk EDITORIAL Defining the challenges

Editor for a low carbon future...

Mark Simms BSc Tel: 01732 773268 The Energy Institute has published its 2017 Energy Barometer, presenting the views of
UK energy professionals on the effectiveness of measures to reach emissions targets
[email protected] and transition energy supplies to sustainable sources. So what did the survey find?
Looking at what measures the government should prioritise to reach emissions
ADVERTISING targets, 64% of respondents said energy efficiency, 62% supported increased emphasis on
renewable energy and 60% supported emerging technology research and innovation. But there
Regional Director (Home Counties & South East) was less enthusiasm for decarbonising transport (38%) and nuclear energy (34%). Having said
that, when asked what effect UK energy policy had had on various areas, a majority of
Mark West Tel: 020 8467 3613 respondents thought that government support for nuclear energy had
had a positive effect.
[email protected]
Many measures to reach emissions targets will require investment
Regional Sales Manager (Midlands) from the private sector, but this is not helped when the government
chops and changes policies and backs away from particular
David Harman Tel: 01772 462596 technologies. So, for example, while carbon capture and storage
unarguably has potential, over a third of respondents thought it now
[email protected] carried a very high level of investment risk. Also thought to carry a
significant risk were investment in hydrogen power, marine power,
Regional Sales Manager (North of England, Scotland & Wales) nuclear power and low carbon transport, with over 50% of
respondents in each case feeling investment represented either a high risk or a very high risk.
Jan Anderson Tel: 01978 314730 Factors cited in particular as limiting low carbon investment included policy uncertainty in
respect of onshore wind, and technology readiness when it came to energy storage, hydrogen
[email protected] power and carbon capture.

Deutschland/Suisse/Österreich Tel: +49 228-2499860 Asked what one measure UK Government could implement to be more pro-innovation, 25% [email protected]
Eisenacher Medien [email protected] of respondents cited tax relief for R&D, while 24% thought an improvement in collaboration
between business and academia would have the greatest impact. Other factors cited included
Overseas Tel: + 44 161 374 5615 improved public procurement (13%), funding competitions (10%), enabling private funding
George Bennett MA [email protected] (9%), supporting competition (9%) and improving the digital infrastructure (4%).

MAILING ADDRESSES Respondents also ranked the biggest energy challenges in 2017, putting energy policy first,
Press Releases: [email protected] low carbon energy second, and security of supply third. Investment cost was cited as the
Advertising Copy: [email protected] fourth biggest challenge, an Brexit reared its head at fifth. Other challenges identified included
Head Office: Victoria House, 2 Mornington Road grid and infrastructure, international factors, public engagement, price volatility, and
Sale, Cheshire M33 2DA sustainability and climate change.
Email: [email protected]
Circulation Department: PO Box 85, Sale M33 2BB Mark Simms
Email: [email protected] Editor

GENERAL ENQUIRIES
Email: [email protected] Tel: 0161 374 5615

Industrial Technology ISSN 0967-5787 As a controlled circulation journal, Industrial Technology is sent
free of charge to individuals in the UK who meet the terms and
conditions of the publishers. To apply for free regular copies,
write to the Circulation Department. To those not meeting the
terms and conditions, the magazine is available on UK
subscription at a cost of £90 per year (10 issues). Single copies
are £9. Overseas subscriptions (airmail) are as follows: Rest of
Europe including Eire £140 (single copies £14); USA $220
(single $22); Rest of the World £170 (single copies £17).

Printing & production by Pensord Press, Blackwood, Wales

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3

Contents 16 Index to Advertisers

6 Industry news 48 Ace Fabreeka UK .................................... 3
Advanced Engineering Exhibition ............ 55
6 Industry makes hay while the sun shines 40 ATC Semitec ........................................ 19
8 Delivering the factory of the future British Encoder Products Co .................. 44
On the cover Centa Transmissions ............................. 20
12 Pumps and compressors EMS .................................................... 24
The next generation of Euro Bearings ....................................... 10
12 Connected compressors contrast sensors: exploring Fibet Rubber Bonding (UK) .................... 45
the advantages First Sensor .......................................... 27
14 Fasteners and adhesives See centre spread for details Gesipa Blind Riveting Systems ............... 14
Gold and Wassall .................................. 15
14 A track record of safety and success Also in this issue HT Servo ............................................. 25
16 Moving up a gear to solve a classic problem IDS Imaging Development Systems ......... 33
Industry news ..................... 6 Igus (UK) ............................................. 13
18 Batteries Northern Manufacturing .... 10 Igus (UK) ............................................. 37
PPMA Preview................... 48 Keller (UK) ............................................. 9
18 A designer’s guide to smart battery applications New products.................... 56 Kistler Instruments ................................ 29
Engineering Update ........... 59 KJN .................................................... 43
20 Power transmission KNF Neuberger .................................... 13
KTR Couplings ..................................... 23
20 A smooth path to drive coupling selection Mayr Transmissions .............................. 23
22 Coupling replaced without the need to dismantle the drive Mclennan Servo Supplies ...................... 25
24 Insulation damage at the heart of motor problems Mesago Messe Frankfurt ........................ 19
Minitec UK .......................................... 45
26 Sensors and systems Mitsubishi Electric ................................ 51
MK Profile Systems ............................... 41
26 Exhaust gas temperature sensors: the future’s digital Northern Manufacturing ........................ 53
28 IMUs deliver new levels of application flexibility OEM-Automatic .................................... 32
OEM-Automatic .................................... 41
34 Machine building and automation Optris .................................................. 27
Peli Products ........................................ 10
34 PLCs versus PACs Phoenix Mecano ................................... 39
36 The rise of the machines PPMA ................................................... 2
38 Two become one: hybrid bus cables tried and tested Reich Drive Systems ............................. 22
40 Perfecting power Rencol Components .............................. 42
42 New concept of assembly line Rotalink ................................................. 9
44 Simple, effective crosshole deburring of complex parts Rotor Clip ............................................ 17
46 Resist the urge to blame the robots Schaeffler (UK) ..................................... 47
Sensors UK .......................................... 28
49 Industry 4.0 SKF (UK) ............................................. 60
Spirol Industries ................................... 15
50 A modular computing platform for industrial networking Spirol Industries ................................... 17
52 Gigabit industrial Ethernet is key to Industry 4.0 goals Staubli Connectors Division .................. 35
54 Where and when will we actually see Industry 4.0? Tesa UK .............................................. 16
TFC ..................................................... 15
58 The sports pages TMC Technology ................................... 41
Turck Banner ........................................ 46
58 Subcontractor makes perfect Formula 1 parts with hypermill Wago .................................................. 11
Weidmuller .......................................... 39
Yaskawa UK ........................................... 5
Yaskawa UK ........................................... 7

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INDUSTRY NEWS www.industrialtechnology.co.uk

Industry makes hay while the
sun shines as exports grow

Britain’s manufacturers are enjoying buoyant conditions on the back
of export markets going from strength to strength according to a
major survey published today by EEF, the manufacturers’
organisation and accountancy and business advisory firm BDO LLP

According to the EEF/BDO Q3 Manufacturing significant capital and research investment required to [email protected]
Outlook survey manufacturers have taken the support continued growth.”
continued political upheaval and uncertainty at According to the CBI’s latest growth indicator, private
home in their stride, taking advantage of the According to the survey, both output and orders were sector growth held broadly steady in the three months to
upswing in the Eurozone in particular, as well as the in healthy territory with the output balance surging to August. The survey of 716 respondents across the
synchronised upswing in global +34% (+26% in Q2) with expectations that it will manufacturing, distribution and services sectors showed
trade. This boost in trade has the balance of firms reporting a rise in output was +14%
benefitted all sectors, with the boost remain in this area going into the final period of the year. in the three months to August, similar to the three
to confidence about individual firm Orders balances have seen further gains with total orders months to July (+16%). Economic activity was
performance translating into a reaching a historic high of +37% (+25% in Q2). supported by a strong performance from the
positive picture for both recruitment manufacturing sector and a pick up in volumes growth in
and investment intentions in the Whilst UK orders remained on the softer side, export business and professional services. Meanwhile, growth in
near term. The latter is being aided orders have continued to climb, reaching a balance of consumer services and the distribution sector eased after
by an improvement in profit margins. +33% (+28% in Q2). This tallies with the improvement a strong performance in the three months to July, but
in global trade across all markets, but the survey showed remained fairly respectable from a longer-term
In contrast to confidence about that EU prospects continue to stand out. Three fifths of perspective.
their company performance, companies reported positive demand conditions across
however, the same cannot be said the UK’s largest market, virtually unchanged from Q2, up Overall, the pace of growth in the private sector is
for their outlook for the UK economy from 47% a year ago and double the figure for Asia. expected to remain steady over the next three months
where confidence indicators have (+16%), with the exception of consumer services, where
dropped for the second quarter in succession in response More of the same to come growth is expected to pick up sharply.
to weak consumer spending and political uncertainty.
Moreover, inflationary pressures have not completely Looking forward EEF believes the third quarter could, Choppier conditions
subsided, with recent sterling depreciation likely to however, mark a peak with forward looking expectations
provide another ripple of price increases in the coming indicating that manufacturers are expecting more of the Rain Newton-Smith, CBI chief economist, said:
months. same rather than any further acceleration in the final “While it’s encouraging that growth in the economy as a
period of the year. whole remains steady, it’s also clear that firms in
Commenting, Ms Lee Hopley, chief economist at EEF, consumer-facing sectors are facing choppier conditions,
said: “Manufacturers appear to have taken the recent The positive picture for industry has translated into an as rising inflation squeezes household incomes. With
political upheaval in their stride and are taking advantage increase in recruitment and investment intentions. The continued uncertainty weighing on investment decisions
of growing world markets to make hay while the sun balance of companies taking on more employees rose for across the economy, businesses will be looking for
shines. This period is likely to be the peak, however, and the fourth consecutive quarter to +25% (+21% in Q2), positive signals from the UK-EU negotiations, chief
we are likely to see a more stable picture in the coming reaching a three year high in the process. Similarly among them agreeing transitional arrangements as
months rather than any further significant acceleration. investment prospects have had a strong quarter with quickly as possible.
capital expenditure plans more than doubling.
“There is little doubt that Brexit is likely to weigh on “Domestically we need to see urgent progress on
sentiment over the next twelve months with uncertainty Looking ahead, despite the buoyant picture the cloud productivity by powering ahead with a modern industrial
over the UK’s terms of exit. As such, it is vital the on the horizon remains the UK economy. While firms are strategy focused on ensuring growth reaches all parts
Government sends a signal to industry and investors in confident of their own performance, EEF’s indicator for of the UK.”
the UK and overseas that it is doing everything in its the UK economy has slipped for the second quarter
power to get growth of the UK economy back on the running in response to the continued political uncertainty
agenda. This must include a bold and ambitious cross - and squeeze on consumer spending. As a result EEF
government industrial strategy.” continues to expect tepid GDP growth of 1.6% this year
and 1.3% in 2018, with manufacturing growth of 1.0%
Tom Lawton, partner and head at BDO and 0.5% respectively.
Manufacturing, added: “Despite the economic and
political uncertainties, manufacturers’ continue to be a
force to be reckoned with, delivering a strong
performance as well as increasing both investment and
employment plans to make the most of the strengthening
export opportunities available to them.

“However, manufacturers’ confidence about the UK
economy has continued to fall for the second quarter
running. With growing opportunities around the world,
particularly the Eurozone, manufacturers’ need stability
and certainty in government policy (including Brexit) to
provide the right environment for them to commit to the

6 INDUSTRIAL TECHNOLOGY • September 2017

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COMMENT www.industrialtechnology.co.uk

Delivering the factory of the
future: the transition from
digitalisation to Industry 4.0

Steve Sands of automation specialist Festo explores the practicalities
involved in delivering the factory of the future, and shares some
first-hand experiences about the impacts of increased automation
on people and their roles

More and more companies are beginning to from the machine and its component parts, including (Above) Festo’s own experience indicates that Industry 4.0 will
appreciate and embrace the concept of instructions and detailed 3D models of the machine. deliver positive change to traditional roles, making people more
Industry 4.0 and the potential to improve They can even access detailed technical manuals or proactive, responsive and efficient. (Left) Near Field
production efficiencies, reduce costs, and be online help direct from equipment suppliers. Communications (NFC) means that equipment components can
more receptive to customer demands. Yet there is an exchange data directly with the Scharnhausen maintenance team
understandable concern about how full automation can Clearly, this level of automation has meant significant without passing through a central database
be achieved in practice, and how it might impact the changes for our people. First and foremost, they are now
workforce. able to take a fully proactive approach to maintenance. a business case can be made now for the added sensors,
The ability to analyse condition data and interrogate an intelligence and communications involved, the costs if
Digitalisation is a stage on the journey towards full alert from anywhere within the factory means they are implementing full automation will decrease rapidly due
Industry 4.0 adoption, and offers practical lessons for more mobile, more responsive and more efficient. The both to economies from the acceptance of standards and
what will be achievable as Industry 4.0 technology ability to access real-time information and analyse the the cross-over of ideas between the consumer, IoT and
becomes the norm. As a global manufacturer of industrial situation before making any intervention has led to better industrial “Industry 4.0” worlds. For example, a joint
control and automation components, Festo wanted to man management. Automatic ordering of tools and parts research project called ParsiFAL is already developing
maximise its own use of emerging technologies, has increased efficiency by eliminating journeys between better methods of data gathering: the prototype device has
experience the benefits at first-hand, and better the stockroom and the machines requiring attention. no standard battery or power source, but is looking at ways
understand the impact on people and processes. Our of harvesting energy from a magnet within a reciprocating
factory at Scharnhausen in Germany became a test-bed Shared experience pneumatic or hydraulic piston to charge the sensor that
for transitioning to an Industry 4.0 environment. measures and periodically wirelessly transmits data.
There is now a greater emphasis on understanding why a
The Scharnhausen Technology Plant is Festo’s main situation arose and how to solve it, capturing and sharing Augmented reality is another area under
production facility for valves, valve terminals and control this knowledge around the team. Regular, repeat tasks development. The concept of a Digital Twin – a CAD-
electronics, covering 66,000m2 of space arranged over therefore become easier because the engineer can benefit generated model that enables designers to simulate how
four levels and housing a workforce of around 1,400 from shared experience for faster fixes and improvement a machine will function – is already possible. Industry
people. It is at the forefront of automation for the future suggestions. To aid knowledge sharing, a training and 4.0 would see this model being taken much further, so
and is a constantly evolving environment for intuitive learning facility has been embedded right at the core of that it can emulate its physical counterpart in real time
human-machine interfaces, training and qualification, the factory. throughout its operational life. Information about smart
and innovative technologies. components will be held within the model and
While Scharnhausen is a compelling example of how continuously updated. The Digital Twin of the future will
To create the Industry 4.0 environment, intelligence the adoption of Industry 4.0 can deliver positive change, capture information about modifications as they are
has either been piggy-backed onto existing machines or, there are still major challenges ahead. One aspect that made, eliminating the need to revise technical manuals
where the opportunity arose, embedded in new should not be underestimated is the changing as variations to the original design are introduced by
equipment. For example, Scharnhausen uses Near Field relationships between humans and machines. Increased ensuring the latest information is always available.
Communications (NFC) for digital maintenance support. automation means that there is less human control
This means that equipment components can exchange required, but far more data available. This redefines the The role of data will drive business models in the
data directly with the maintenance team without passing role of the humans involved: from data gatherers to future, but there are still big questions being asked around
through a central database. interpreters and analysts. the ownership and interpretation of data, as well as access
and privacy issues to be addressed. Relationships
For the maintenance team, this presents new ways to Forthcoming Industry 4.0 developments will see between who generates, owns or uses data captured by
interact with the factory equipment and gather useful data. machine learning becoming more common, with Industry 4.0 enabled devices may well result in new
Their main tool is a tablet equipped with a custom- embedded intelligence allowing AI algorithms to detect industry sectors, with some companies specialising in
developed app which, together with a mobile depth sensor, data patterns indistinguishable to human minders and to buying and selling data while others focus solely on its
enables the user to access more information the closer they propose corrective measures. Whilst in some applications interpretation and application. The opportunities are very
are to the components requiring attention. At a high level, exciting, with OEM and End Users identifying the business
the tablet may show an overview graphic of the entire plant cases for Industry 4.0 investments as the pace of
layout, together with alerts that follow a simple grading development of the necessary standards, technologies
system to indicate their urgency. This makes the team far and products take shape.
more responsive because they can direct their resources to www.festo.co.uk
the highest priority notifications first.

Where intervention is necessary to resolve an issue,
co-ordination of people and parts is much slicker in the
automated factory. The team can check the availability of
components and tools so that everything necessary to
undertake a scheduled maintenance task is to hand
where and when it is needed. Using their tablets as an
interface, the engineers can access information directly

8 INDUSTRIAL TECHNOLOGY • September 2017

KELLER (UK) Ltd. pressure sensors

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E-Mail: [email protected]
Web: www.keller-pressure.co.uk www.keller-druck.com – User selectable display units:
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DIGITAL MANOMETER
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– Ei Version Intrinsically safe Ex ia IIC T4 Gb

9

EXHIBITION PREVIEW

FOAM ENGINEERING Northern
& PACKAGING SOLU T IONS Manufacturing

THINKING SPECIALISTS IN Northern Manufacturing celebrates its fifth
INSIDE anniversary this year. The industry and
THE BOX FOAM engineering spectacle returns to EventCity,
Manchester (27-28 September) to showcase
The UK’s leading custom CONVERSION some of the UK’s finest manufacturing,
foam service engineering, industrial products and services

Experienced design team The range and calibre of competitive edge, how lean and CE
with 3D scanning capability exhibitors makes Northern marking can be implemented, and how
Manufacturing & Electronics the new, emerging technologies, such as 3D
30,000 sq ft production most comprehensive collection printing can be optimised. There are also
facility of industrial technology, machinery, sessions looking at the new data
production and automation, electronics protection regulations which come into
ISO 9001:2008 certified and specialist engineering services in the force next year, which will affect nearly
north of the UK, including Scotland, all businesses. Although free-of-charge,
MPAS approved Northern Ireland and Wales. Exhibitors pre-reservation is highly recommended.
represent a range of industries and
PART OF THE PELI UK GROUP technologies from machinery and press Igus is returning to this year’s
brake technology to contract electronic Northern Manufacturing & Electronics
MSA FOAMS LTD 15 Cobham Road, Ferndown manufacturing, electronics, packaging exhibition, highlighting a wide range of
Industrial Estate, Wimborne, Dorset BH21 7PE and handling. Visitors can see live cost-effective, lightweight and
demonstrations on many of the stands, maintenance-free bearings and cable
t: 01202 850070 e: [email protected] w: msa.co.uk and many companies encourage visitors management systems for a variety of
to come with their plans and drawings to applications.
E U R O - B E A R I N G S LT D discuss projects with experts at the
exhibition. Predictive maintenance
TOLERANCE RINGS
To help the next generation of Predictive maintenance is the
Shaft and Housing Types engineers, SETA Training and Advisory cornerstone of Industry 4.0 and the
from Carbon Steel and Stainless Steel Services encourages young visitors to factory of tomorrow – Igus’ smart
visit its stand and discover more about plastics warn of potential failure in good
its technical training courses and time before unplanned and very costly
engineering apprenticeships. Another downtimes occur. At the event, Igus will
exhibitor, the Business Hub offers be showing new and improved smart
business support to companies, plastics products. These include, the
specialist programmes and funding. isense EC.RC, a new system for
monitoring e-chains, the optimised CF.Q
The show’s RoadRailAir feature module for the intelligent chainflex
highlights firms with particular expertise cables that customers are already using
in the aerospace, automotive or public today and the intelligent iglidur PRT
transportation manufacturing supply slewing ring bearings.
chain.
Injection-moulded, 3D-printed or
The drive to expand knowledge and machined from bar stock, Igus offers
skillsets goes beyond the exhibition floor, engineers a wide range of possibilities to
with a programme of free-to-attend obtain their self-lubricating parts, such
seminars on both days. Topics covered as gears or plain bearings quickly and
over the two-day programme include cost-effectively. During the show igus
manufacturing practices for a will introduce a new process for the
production of 3D printed injection mould
See the full range on our website tools that allows engineers to solve
difficult technical challenges quickly.
Email: [email protected] The entire range of 50 iglidur high-
Technical Sales: 01908 511733 performance plastics are available using
this new process, including specialists
www.euro-bearings.com/tol-rings for high load, food contact, underwater
or high temperature applications.
10 Depending on the iglidur material
chosen, the mould is either SLA or SLS

Supplying industrial and scientific SMALLER JUST
laser systems and accessories to many GOT STRONGER
of the UK’s leading companies, Laser
Lines offers expertise and experience to PFC100 Controller: High performance
help customers select the right laser packed into a smaller footprint
technology for their application, whether
printed and then used immediately in its laser marking, welding, cutting, • Extremely compact and
the injection-moulding machine. Thus, hardening, cladding or any other laser maintenance-free design saves
parts are ready for shipment within a related process. control panel space
few days. The material structure of the
printed injection mould ensures that it At Northern Manufacturing Laser • 600 MHz processing power allows
can withstand the high temperatures Lines will demonstrate high speed laser seamless automation of complex
during injection moulding, which means marking systems and laser welding, with industrial systems
that one mould can produce prototypes additional high speed dot peen marking
and small batches up to 500 pieces systems available for demonstrations r &RVWHƬHFWLYHFRQƮJXUDWLRQYLD
cost-effectively and quickly. also. The growth in the use of laser e!COCKPIT engineering software
technology around the world offers great
Lean energy chain advantages to modern industry and has • Scalable modular system ready for
seen great developments in the future challenges
Optimum use of installation space, light efficiency and speed that lasers can
weight and high stability – these are just offer. • Comprehensive on-board data
some of the benefits of the E4.1L lean security packages
energy chain from Igus. Compared to the Laser Lines can perform free trials for
E4.1, the application-oriented design of companies looking to investigate what • Two ETHERNET interfaces for
the E4.1 L could save so much mass laser processing can offer and with extensive compatibility
that the chain is about 30% lighter. This different laser systems and technologies
brings an additional advantage: a in their range including lower cost • Linux® operating system
considerable amount of drive power can systems as well as high speed high
be saved, making the application more power systems – Laser Lines has a • CODESYS 3 runtime system
energy efficient. The E4.1L can also solution to help both small and large
accommodate more hoses and cables in companies alike. Telephone 01788 568 008
a given space envelope. The E4.1L lean E-Mail [email protected]
energy chain is now available from stock Permabond manufactures high Internet www.wago.com
in numerous interior heights and widths. quality engineering adhesives for potting Search for “WAGO PFC100”
As for the open energy chain, Igus also and encapsulation of electrical
offers an ESD version and even a high- components, bonding heat sinks,
temperature option for the enclosed magnets/ferrites to rotors and housings
energy tube to protect against hot chips for electric motors, electrical
and debris. transformers components, sealing
transformer laminates, coating coils,
ESI Technology has been at the wire tacking and attaching electronic
heart of the pressure measurement dies. Permabond has recently developed
industry for almost 30 years. The most a range of thermally conductive
outstanding developments from ESI are adhesives including a toughened acrylic
the Silicon-on-Sapphire sensor adhesive for applications such as
technology and the new GD4200-USB bonding heat sink fins to transformers
digital pressure transducer will be on and a highly flexible epoxy hybrid.
display at Northern Manufacturing.
Silicon-on-Sapphire (SOS) sensor MSA Foams will be highlighting its
technology has redefined the expertise in the design and manufacture
performance capability of pressure of protective packaging solutions. Its
measurement instrumentation in the experience is such that is was recently
industry. This technology demonstrates given the opportunity to fit out the tool
excellent insulation properties, cabinets for the Bloodhound SSC
unbeatable performance with high support team. MSA incorporated the
overpressures and virtually no Bloodhound project colours by
hysteresis, superb repeatability and employing foam in the drawer inserts;
excellent chemical compatibility. this also highlights any missing tools.

The new GD4200-USB makes Designing foam inserts that are cut
pressure measurement simple and to size for individual collections of tools
portable, reducing the need for has been part of the MSA business for
expensive data loggers. It has all the over 20 years. MSA design tool inserts
advantages of SOS, sample rate of that organise tools efficiently and ensure
1000Hz and is available in ranges up to missing items are easily identified,
5000bar. The GD4200-USB software is eliminating the risk of foreign object
supplied and features the capability of damage. Durable custom foam inserts
measuring multiple inputs and also ensure tools are secured in position
customised test certificate generation. and fully protected in transit.
www.industrynorth.co.uk

11

PUMPS & COMPRESSORS

Connected compressors

What is the future for connected compressors?
We asked Stef Lievens of Atlas Copco

Anyone who has ever been stranded at the air users increase see performance metrics and other crucial data in real
roadside with a stationary car would have to maintenance and service time, keeping an eye on operations and communicating
reluctantly acknowledge that a proactive efficiency. Making smart via smart phone, tablet or laptop from any location.
maintenance plan is always better than a use of connectivity, data
reactive remedy. However, finding the time and resources monitoring and business The IoT changes data into actionable information. It
for regular servicing and health checks is not always intelligence, SmartLink enables a constant stream of performance data to provide
simple. For production managers in an industrial helps customers get a real-time insights on production processes. Big data
environment, the dilemma is particularly acute, since the better view of their provides an infrastructure for transparency in the
consequences of critical machinery failure not only maintenance needs, manufacturing industry and acts as the input into
include the time and cost associated with repairs but the maintain production predictive tools and preventive strategies, unravelling
grave prospect of production downtime. uptime and improve their uncertainties such as inconsistent component
operating costs, wherever performance and availability.
Could the burgeoning Internet of Things (IoT) provide possible, by minimising energy consumption. SmartLink
an answer? The IoT, which aims to add intelligence and works by monitoring indicators such as specific energy Predictive manufacturing, as an applicable approach
connectivity to almost any device or machine, is and compressed air pressure calculations so that toward near-zero downtime and transparency, requires
envisioned by many as a transformative force for change immediate improvements can be made when needed. The vast amounts of data and advanced prediction tools for a
in the manufacturing world, from the introduction of results can then be used for energy monitoring systematic process of data into useful information.
advanced robots in the workplace to smart components procedures.
that communicate their own assembly instructions to the A conceptual framework of predictive manufacturing
production line. This growing trend is reflected by the By combining the hardware monitoring unit with a begins with data acquisition that can be sourced via
latest findings of the EEF, which predicts that customisable data monitoring programme, data is remote monitoring devices.
manufacturing companies will invest more in internet gathered, compared, and analysed; and, when required,
connected capital equipment over the next five years. warnings are sent out in order to prevent downtime and to The culmination of these advances is fully embraced
allow local service providers to plan and prepare their in the concept of Industry 4.0. Originating as an initiative
The potential impact of IoT technology upon interventions. of the German government to enhance manufacturing
manufacturing in the future continues to be debated. efficiency and flexibility by computerising traditional
However, one of the most immediate applications of the Avoiding breakdown risks industries and processes, its ultimate goal and true
IoT is in the field of condition monitoring, where a potential is to transform factories from cost centres to
combination of hardware and software is capable of The SmartLink solution is divided into three options: profitable innovation centres, shifting from mass
conducting real-time diagnostics and transmitting findings Service, Uptime and Energy. SmartLink Service enables production to customised products.
to the relevant workshop or maintenance manager, either the user to easily schedule maintenance visits as they
as an immediate alert or a timeline of performance trends have an overview of machine data and the time left before Industry 4.0 is about fully integrated industry −
that may indicate longer-term changes. a service is due. The second option, SmartLink Uptime intelligent digital networking and integration of industrial
allows the end user to be informed by email or SMS systems and processes. The strategy focuses on creating
The objective of such smart monitoring is to identify message if there is a problem with the compressed air cyber-physical systems, the communication technologies,
and solve performance or efficiency issues before they production. Without this safeguard the user has to be alert software, sensors and processors that have the potential
evolve into a full-scale equipment failure. In addition to for warnings on the compressor system but even daily to communicate and interact with each other in an
supporting preventative maintenance, this stream of checkups do not offer 100% security. Based on the intelligent way to gain competitive edge. An essential
technology is helping plant managers optimise SmartLink information, the necessary actions can be component of this interactive process can be a remote
productivity and keep running costs down. Given such taken to avoid the risk of a breakdown − and it is possible monitoring programme such as that provided by
valuable benefits, it is little wonder that the onset of smart to visit the website at any time to see the actual SmartLink.
monitoring is reaching every corner of manufacturing warning/shutdown status of the machines as well as a
practice, and the compressor room is no exception. history of previous notifications. Finally, SmartLink Energy Looking to the future, there are greater opportunities
enables the continuous monitoring and analysis of the for the IoT to enhance best practice in compressed air
Remote monitoring of compressor and vacuum pump performance and energy efficiency of a compressor. operations. Remote monitoring, for example, as a
performance, with a system such as Atlas Copco’s component of the larger IoT trend, provides the gateway
SmartLink, enables functional problems to be identified in Remote condition monitoring is an example of to integrated industry – the concept that enables
real-time and resolved swiftly to avoid lost or reduced fledgling IoT technology that is already having an impact. machines to communicate with each other and ultimately
productivity, to remedy poor performance and to However, it is with the addition of control that the full allows entire production lines to reconfigure themselves
maximise energy efficiency. potential of the IoT can be realised in the future. One autonomously. As such, small-batch and one-off
definition of the IoT is that it ‘allows objects to be sensed production in large scale plants becomes commercially
The on-site servicing of compressor systems has and controlled remotely across existing network viable – achieving the goal of transforming the factory
traditionally followed two paths; the proactive route infrastructure, creating opportunities for more direct from cost centre to profit centre.
undertaken on a regulated basis, whereby users take out integration between the physical world and computer- www.atlascopco.com
service contracts to ensure regular planned visits from a based systems, and resulting in improved efficiency,
service technician, or alternatively taking appropriate accuracy and economic benefit’.
action only when an unforeseen problem requires an
immediate intervention. This latter scenario means the Vast volumes of data can be securely stored in the
plant operator has to keep a continuous eye on running Cloud and analysed for patterns and trends in order to
hours and performance parameters: if the call for service optimise future performance. The eventual goal is
is left too late there is an inherent risk of excessive energy progression towards full remote or automated control,
consumption and possible mechanical breakdown. based on the machine-acquired data – and with the IoT
evolving rapidly, that’s not too far off. As more devices
Offering an answer to this, SmartLink is a data become linked to the Internet, plant managers are able to
monitoring programme for compressors that intelligently
gathers, compares and analyses data to help compressed

12 INDUSTRIAL TECHNOLOGY • September 2017

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13

FASTENING, JOINING & ADHESIVES Bonding Systems

A track record of safety

and success

We asked the experts at Henkel to explain the benefits
that adhesives can offer in different bonding applications

The use of bonding systems is gaining increasing production rates and machine availability mean thereby preventing micro-movement. As transversal
popularity among machine builders as more and that industrial machine builders are under huge forces are prevented, load transfer capability is
more come to recognise the potential advantages pressure to build faster equipment without actually enhanced without any design modifications
on offer. For instance, bonding systems enable compromising attributes such as reliability and and with no need for surface finishing improvements.
manufacturers to incorporate new materials into their productivity. To fulfill this task, machinery
designs, combining their properties to best effect. Indeed, manufacturers must safeguard all mechanical Cylindrical joints can also be retained using
taking a design approach that embraces adhesives and components by guaranteeing that part dimensions and anaerobics. In this case, stress distribution is more
sealants means that imagination becomes the only movements are not compromised. even, preventing all typical fatigue-related failures
restriction in creating a new generation of class-leading that occur when keyways and other mechanical
machines. Anaerobics have evolved dramatically since they were systems are used. Compared with welding, the metal
discovered in the 1950s. Modern properties include high properties are not modified by high temperatures and
Compared with welding, structural adhesives that cure temperature resistance of around 200ºC in many grades, no residual stresses are generated.
at room temperature – the preferred assembly system and compatibility with oily surfaces and low surface
today – do not alter material properties, nor do they create sensitivity, which means that most grades cure even on In one example, rollers can now be manufactured
residual stresses, which in turn leads to more durable, inactive surfaces such as stainless or passivated metals. using this cheaper and more sustainable system. In
fatigue-resistant joints. In addition, bonding processes simple terms, anaerobic retainers make transportation
consume less energy, the equipment used is less costly Loctite threadlockers are well known by machinery rollers more reliable and easier to manufacture. The
and fewer safety precautions are required in the factory. manufacturers, although their use is still associated with bondline evenly transfers the dynamic loads expected
heavily loaded bolts. In terms of cost, threadlockers are as during roller operation to reduce fatigue-related
A further benefit is that lightweight materials such as cheap as washers and significantly cheaper than other failures. In addition, rollers of all sizes and functions,
plastics and composites can be incorporated and joined mechanical solutions such as high quality bolts or tab including conveyors, lamination systems, wrapping
with other materials, while flanged joints in casting parts washers. They are also more efficient in ensuring bolt and thermoforming rollers, converting equipment and
can be sealed and reinforced using anaerobic liquid clamping force. Vibration is not only a source of bolt calendering machines, can be manufactured using
gaskets, which enhances their load transfer capability. loosening, it also causes issues such as temperature this system.
These materials prevent fretting corrosion between mating change, pressure load and part surface settling.
flanges, thus guaranteeing long term machine reliability. Not long after anaerobics were introduced, another
Fretting corrosion is another major problem that can be adhesive technology was added to the Loctite range:
Manufacturing machinery is evolving continuously in prevented using anaerobics. Flanges sealed with liquid cyanoacrylates, or superglues. These adhesives were
response to new industry demands. Trends such as gaskets not only prevent leakages and the ingress of fluids, soon adopted by machinery manufacturers to bond
energy efficiency and the requirement for increased but also reinforce the joint against any local shear stresses, materials such as plastics and rubbers used in door
seals, tags and other parts. Today, cyanoacrylates are
unrivalled in terms of performance and manufacturing
speed, as the latest developments have increased
temperature resistance by 50%, up to 120ºC.
Moreover, fixture speed is just a few seconds in most
working conditions, an attribute that no other
commercial grade is able to equal.

Temperature resistance is not only noticeable at
close to the upper limit of 120ºC, but these adhesives
exhibit higher strength than competitor products even
at temperatures of around 50-60ºC, where the
resistance of most grades falls dramatically. Several
food compliant grades are available in addition to
medically approved grades that have been used for
decades to manufacture disposable medical devices.

In short, bonding systems such as Loctite
anaerobics and cyanoacrylates from Henkel have a
huge role to play in making life easier for machine
builders – the benefits are high and the costs are low,
as more and more are discovering to their
competitive advantage.
www.loctite.co.uk

14

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Call the experts [email protected]

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15

FASTENING, JOINING & ADHESIVES Retaining Rings

Moving up a gear to solve

a classic problem

The origins of British Motor Sport began in the himself as an independent racing gearbox designer “However, the build of the gearbox was held for
final year of the 19th century with a number of having spent many years working in the technical weeks as the correct retaining ring for a motion shaft
events described as ‘hill-climbs’, but a key event departments of Ferrari and Maserati. His company went could not be located – that is until TFC facilitated the
was to be a dash along a public road and up a on to successfully develop gearboxes for many leading supply of a Smalley retaining ring perfect for the job. It
gentle hill at Bexhill-on-Sea, East Sussex in 1902. This race teams of the time including the legendary Lotus, wouldn’t be possible to keep historic race cars racing if
event neatly combined the essence of it wasn’t for the support of companies such as TFC.”
what was to become sprinting and Alfa Romeo, Lancia, Minardi and,
speed hill-climbing, and in 1905 the the iconic Ferrari. As the leading European supplier of Smalley
world’s first permanent hill-climb took products, TFC offers thousands of retaining rings to fit
place at what has now become the Martin said: “Racing historic any application requirement. Smalley retaining rings are
iconic Shelsley Walsh in Worcestershire. classic cars brings its joys, but available off the shelf in carbon steel, 302 stainless
also major headaches when it steel and 316 stainless steel.
When Martin Rutter, an avid hill- comes to sourcing components. www.tfc.eu.com
climber, contacted TFC for help, the This is where TFC came to the
company was were keen to assist as the rescue for my Fiat X1/9 that I
heritage of the competition venue was campaign in national speed hill-
matched by the application. Martin was climb championships. An urgent
looking to solve a problem with the race and much required upgrade was a
developed Colotti gearbox used in his Colotti race gearbox originally
specially adapted Fiat X1/9. developed many decades ago by
Valerio Colotti, the famous
Colotti Transmissions began in Italy designer of many F1 and Ferrari
in 1958 when Valerio Colotti established transmission systems.

16

Blind rivets for body
in white applications

Advances in materials and the or as a secondary operation after the
"Industry 4.0" are challenging base material has been coated or
the joining technology of the treated. With high load bearing
automotive industry. Requirements are capacity they provide guaranteed and
the control of the setting processes and secure joint creating high-class threads
the fully automation and integration of in thin and soft materials.
the technology in the OEM operations.
The purpose is to ensure high quality GESIPA developed an aluminum
of all joints as well as fast and blind rivet stud as a repair solution in
economic processes. the aluminum body, because the
welding of aluminum in downstream
With the focus on new materials in processes is very difficult. The
body-in-white applications and the aluminum blind rivet studs offer a fast,
light weighting advantages of using easy and safe process for creating a
different materials together, Gesipa fixing point in a thin material.
blind riveting technology provides www.gesipa.co.uk
many solutions for joining different
materials, such as a mix of high-
strength steel, light metal as well as
carbon fibre materials.

The rivet nut and rivet nut stud
technology offers easier, neater and
quicker installation process by one-way
access to the riveting position. They
can be fitted at any stage of the build

17

ELECTRICAL EQUIPMENT & DESIGN Batteries

A designer’s guide to

smart battery applications

When integrating a rechargeable battery into a professional, simultaneously, which is no mean feat. Another important
perhaps mission critical application, the first things that come to factor to consider, and one that applies to the integration
mind are reliability and safety. However, there are many other of all sub-assembled components, is the availability of
factors designers need to consider. Michele Windsor guides parts and their potential obsolescence. For this reason,
design engineers through the process of embedding batteries in engineers should avoid designing-in off the shelf consumer
medical, military or automation applications batteries. Our experience has shown that these are poorly
supported technically and very likely to become obsolete
Many design engineers believe that, as its cells that are suitable to these conditions. In these quickly. Simply choosing a customised industrial or
power source, the battery is the very heart of instances, the electronics need to be programmed professional battery, designed with your application in
the product. However, I would go even differently to cope with the various environments, whilst mind, guarantees you a lifetime of support.
deeper into the core of the battery and argue the physical characteristics of the battery need to be
that it is the cell that is the nucleus of the battery, robust enough for the given extremes. Once a battery prototype has been developed, the final
determining the performance, lifecycle and durability of stage is to certify that product for use, from both safety
the application. Intelligent cell selection can also help ensure the future and performance perspectives. Accutronics normally
availability of the battery, which means the cell can be manages the entire approval process on behalf of its
There is no such thing as a typical battery design replaced if a superior version becomes available. This customers. Each battery design undergoes the appropriate
project. This is partly because bespoke power sources are guarantees a longer life-cycle for your battery and helps safety testing from, for example, the IEC (International
used everywhere from hospitals to manufacturing plants alleviate obsolescence related issues. Electrotechnical Commission), the UL (Underwriters
and military operations. Some customers might be looking Laboratories), as well as the IATA (International Air
for high energy capacity, whilst others might need low Physical characteristics Transportation Authority) and military standards testing
temperature performance, high availability, a longer cycle from MIL (the US Department of Defence Test Method
life or a specific battery size. In other words, finding out The physical characteristics of a battery, such as its size, Standard for Environmental Engineering Considerations
exactly what you want the battery to do for your piece of durability and weight, also play a crucial part in its design. and Laboratory Tests), if relevant.
equipment is crucial to the success of the design. Similarly, performance characteristics such as efficiency,
reliability and availability are also essential. For instance, It is clear why the battery is the very heart of many
One fundamental guideline is to decide whether the portable medical devices might require a high tolerance to military, medical and industrial electronic devices. We
battery has to withstand extreme conditions such as vibration, so that they can be used while transporting might also argue that it is the quality of the design process
freezing temperatures, scorching heats, humidity or dirt. patients by helicopter. Achieving this is a matter of which ensures the heart will continue to beat during
In order to guarantee efficiency, we select only the type of managing the physical and performance characteristics the lifespan of the OEM’s device.
www.accutronics.co.uk

Michele Windsor is direct sales and marketing manager
at Accutronics

18 INDUSTRIAL TECHNOLOGY • September 2017

28. International Exhibition
for Electric Automation
Systems and Components
Nuremberg, Germany, 28 – 30 November 2017
sps-exhibition.com

Answers for automation Ysopus-refxrheeibeitniotrny.ctoicmk/ettickets

Electric Automation and Digital Transformation

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mixture of lively comment, informed debate, educational articles and military, and industrial applications to
technology updates. everyday uses in portable technology.

Register today to receive your free copy by visiting the ‘become a reader’ These require thermal components which have
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design thinking and engineering news in areas such as mechanical overcurrent and long term reliability.
components, power transmission, machine building, electrical
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motors and controls, and linear motion technology. in thermal components which support the
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19

POWER TRANSMISSION Couplings

A smooth path to drive
coupling selection

David Proud explains how to navigate through what can sometimes
be seen as a technical minefield for designers and engineers

Engineers and designers working on power size and/or weight, which will have to be taken into rise to the attention of maintenance engineers in the form
transmission applications can often face a account. The prime mover, diesel or gas engine, hydraulic of a catastrophic failure of the coupling and hours of
daunting task when it comes to specifying the or electric motor will also be influential in the specification unplanned downtime. Other less visible effects will be
most appropriate drive coupling for the task in and selection of the drive coupling. undue wear on bearings, shafts and gears, which will
hand. Detailed consideration must be given to both sides ultimately impact motors or gearboxes.
of the drive equation, input and output, with regard to Get it right, and the coupling will provide years of
torque, shock loads, starting frequency, temperature and uninterrupted service, requiring little or no Before making a final decision on selecting the drive
environmental conditions, but where to begin. coupling the specifier must fully evaluate and
maintenance in its own right, whilst ensuring that understand the forces and loads that will be applied to
Drive couplings vary greatly in their design and mating components are protected from undue the coupling in use. Making an “educated guess” at these
capabilities, so for any given application engineers must stresses and keeping downtime to a minimum. values is not an option and could result in either a
ensure that they specify the drive coupling correctly to coupling being specified which is not fully up to the job,
ensure reliable efficient, and in the more challenging Common mistakes can be costly or design overkill, which would result in an unnecessarily
applications, safe operation. larger and more expensive solution to the application.
There are a number of commonly made
A detailed review of what the coupling will be mistakes, which result in the wrong The specific application will dictate whether the
subjected to in use is an essential starting point. Factors coupling being specified. This can have coupling required is a disc coupling, shaft to shaft
such as torque transmission, speed ranges, running serious consequences both for the coupling coupling, auxiliary coupling or other variant, however it is
starts and stops, and potential shock loadings are just and the other elements in the drive train. essential that consideration is given to factors such as the
some of the key elements in the selection of the coupling. Often, it does not take long before these issues torque rating and torsional stiffness required for the task.
However, we must also consider alignment between the Generally, couplings with a higher torque rating will be
various components, the environmental operating larger and less flexible. In addition, the degree of axial,
conditions that could include high temperatures or radial or angular misalignment that the coupling will be
moisture, etc, and any maintenance requirements or required to compensate for will influence choice, and it is
essential that the coupling to be used, is able to meet
restrictions. There may also these criteria, but have the capacity to accommodate a
be potential limitations level of unexpected deflection whilst in service without
on available space, failing.

Another contributing factor, which will influence
success, is how the coupling is mounted. In applications
where there are minimal shock or reversing loads,

CENTAFLEX-A

01274 531 034 • WWW.CENTA-UK.CO.UK/TECHNOLOGY

Couplings POWER TRANSMISSION

Servo couplings for high
torque applications

keyways and taper bushes KTR has developed a steel lamina 340Nm with a maximum speed of 14,000rpm. The
will be a reliable solution. coupling for servo drives in the higher servo coupling is maintenance-free and can be used
For applications where power range. The backlash-free and with temperatures up to 200°C and under aggressive
there may be high shock torsionally rigid RADEX-NC High ambient temperatures. Application ranges are
loads it may be preferable to Torque (pictured below) covers speeds up to machine tools as well as measuring and test bench
avoid a keyway solution and instead 27,500rpm while transmitting torques up to technology, but also automation technology and servo
opt for a taper bush fixing, or couplings with shrunk discs, 2,000Nm. Main application ranges are machine gears.
which will also provide backlash free operation. tools as well as measuring and test bench
technology. Also new from KTR is a new shaft coupling for
Maintenance requirements drives with severely high speeds. The backlash-free
Compared to the standard series of the same and flexible ROTEX GS HP (pictured above) achieves
From a maintenance perspective, the time required to remove name, the connections between laminas and hubs peripheral speeds up to 175m/sec and is available in
or replace a coupling or any change parts, is a major have been made non-positively and with positive three sizes. The main fields of application are
consideration. Therefore, the selection of a coupling which not locking with the new RADEX-NC High Torque which machine tools as well as measurement and test
only meets all of the technical and application requirements, allows for the use in servo drives in the higher power bench technology.
but is either maintenance free, or has the ability to have range. Its torsionally rigid and flexible laminas are
change parts replaced in-situ will bring significant benefits to made of stainless steel while the hubs are made of The ROTEX GS HP has a circular and closed
uptimes and efficiency. high-strength aluminium. The coupling is light- design. In this way the radial deformation of the hub
weight, with compact dimensions and has a low geometry is reduced. In addition KTR dispenses with
If there is any doubt on the part of the individual mass moment of inertia. It is available as a single- the need for a spider with this coupling generation.
responsible for specifying and selecting the coupling, seeking cardanic and double-cardanic type. Individual elastomers are embedded between the
expert advice from the manufacturer will both eliminate risks cams instead. They are kept in their position and
and ensure longevity and reliability in operation. With a history KTR provides two backlash-free versions for the shape by the closed design of the coupling, even with
spanning over 70 years, Reich Kupplungen has built up shaft-hub-connection: on the one hand is a version peripheral speeds up to 175 metres per second.
unrivalled expertise in the design and manufacture of drive with a clamping ring hub for the non-positive
couplings for use across a wide range of industries and connection. This hub has a torsionally symmetric The large number of elastomer segments
applications. The company also embraces a D2C (design to structure and is suitable for high torques. It is transmitting the torque reduces the surface pressure
customer) principle, which allows the creation of customised mounted as a block which facilitates the installation on every single elastomer. This allows for transmitting
high-quality and long-lasting power transmission products in of the coupling. On the other hand there is a version high torques with a small outside diameter of the
collaboration with the customer and their specific with a clamping hub, optionally available with a coupling. As an example, size 38 has an outside
requirements. positive- locking or non-positive connection. diameter of 80mm transmitting torques up to
www.reich-uk.com 400Nm with a speed of 40,000rpm.
The new RADEX-NC High Torque is available in www.ktr.com
David Proud is general manager of Reich Drive Systems UK seven sizes covering torques from 35 to 2,000Nm
and speeds from 6,500 to 27,500rpm. As an
example, the average size 36 has an outside
diameter of 84mm transmitting torques up to

MISALIGNMENT | VIBRATION | NOISE | MAINTENANCE COSTS

T: +44 (0) 1274 531034 DISCOVER HOW CENTA CAN SOLVE YOUR TRANSMISSION
E: [email protected] PROBLEMS AND SAVE YOU MONEY - CALL US TODAY:
01274 531 034 OR VISIT: WWW.CENTA-UK.CO.UK/TECHNOLOGY
@CentaUK

POWER TRANSMISSION Couplings

Coupling replaced without the

need to dismantle the drive

Quick and easy replacement solution saves time and money steel, composite, and super-lightweight
carbon fibre shafts, now has a new
What do you do when one of the most loss of operational performance. Centa says connection option that means the flexible
versatile and reliable flexible couplings CENTAFLEX-A is one of the most versatile coupling and shaft can be installed in two
reaches the end of its working life and you flexible couplings available and is installed in parts, rather than as a single unit. This
need to fit a replacement, quickly? As part countless applications in many different means that the problems caused by small
of the CENTAFLEX-A range, the CENTAFLEX-AR from industries. Not only does it overcome four-
Centa is designed for use on ‘O’ type couplings size 25 way misalignment, it is available in a bulkhead apertures and a lack of space
to 600, enabling engineers to replace that worn out CF- wide range of model types and SAE are now a thing of the past.
A coupling quickly and easily. Most importantly, you can sizes, and copes with a wide range On this new version of the
do it without the need to strip the drive. of nominal torques. coupling, the centre shaft
section and the flanges are
Whilst the CENTAFLEX-AR is a single-piece coupling It is used in a plethora of connected using a Hirth face
with exactly the same vibration and noise eliminating applications in the plant, rail, spline. This means that the
attributes as the conventional CF-A, there is one critical marine and wind power main tube can be fed
difference. The CF-AR is split at one point; this means industries, connecting the through any structures in
that it can be installed around the drive, without the gearbox, electric motor, the drive line, before having
need to dismantle it. All that needs to be done is to cut compressor, PTO drive, the larger diameter flanges
the old coupling away and then slot the replacement CF- generator, pump, driveshaft or attached. Smaller openings
AR around the shaft. You then simply bolt the ends of the water jet to the diesel engine or in structures, such as
new coupling together, using the two washers provided hydraulic drive. bulkheads, are no longer a
and the installation is complete within minutes. problem.
A recently introduced product www.centa-uk.co.uk
This means that operational downtime is minimised from Centa, the Centadisc-C
and precious time and money can be saved, without any coupling, which can be used with

22

www.mayr.com Safety 4.0

ROBA®-topstop® — the certified
braking system for vertical axes
with brake monitoring

your reliable partner

Quality brakes... full stop. KTR-STOP® TB

KTR manufacture hydraulic and electromechanical floating caliper disc www.ktr.com
brakes in compact designs with clamping forces up to 1400 kN! KTR-STOP®
and EMB-STOP® offer active and failsafe designs which ensure maximum www.ktr.com
protection for operation in hazardous environments such as mining, marine
and other industrial applications. KTR also offer a new range of thruster disc and
drum brakes for braking torques up to 15,200Nm.

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Industrial Technology is the essential magazine for engineering designers, machine engineers, Industrial Technology provides a mixture of lively comment, informed debate,

builders and systems integrators across all sectors of industry. Written by engineers for educational articles and technology updates. Register today to receive your free copy.

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23

POWER TRANSMISSION Electric Motors

FAULHABER Motion Control

Feel the
Power

FAULHABER Motion Controller Insulation damage at the
Series MC 5004 / 5005 / 5010 heart of motor problems

Perfectly optimised for the FAULHABER Partial discharge testing completes the picture for motor reliability
drive program – whether DC-micro-
motors, brushless motors or Linear Most electrical problems in motors and as the winding experiences high voltage transients.
DC-servomotors generators start with insulation problems. Conventional test equipment doesn’t sample rapidly
Modular kit concept with 3 performance Insulation damage that begins with small enough to capture these short, transient effects.
classes, peak currents of up to 30 A, manufacturing defects, contamination,
comprehensive protective and diagnostic excess heat or wear can rapidly develop into major issues SKF’s latest generation of motor analysers, like the
functions that shut down critical machinery. That’s why static Baker DX range, however, are equipped with new, ultra-
New connection concept via plugs, electrical testing is widely used as part of the modern high speed analogue to digital convertor technology that
4 interface variants – RS232, CANopen, condition-based approach to motor maintenance. can capture the high frequency component of the signal
EtherCAT and USB generated during the surge test. Smart software
There’s one category of problem that is particularly algorithms then separate the high frequency component
Easy commissioning with the difficult to identify using conventional testing methods, from the low frequency impulse waveform, allowing the
new Motion Manager 6 however. A partial discharge (PD) is a small electrical presence of PD events to be measured and their
discharge caused by the ionization of oxygen in the magnitude calculated.
NEW presence of a high voltage electrical field. In motors,
partial discharge can occur when bubbles or other Trending test results on the same equipment over
WE CREATE MOTION manufacturing imperfections create an air gap between a time gives users a clear and straightforward indication of
winding conductor and its surrounding insulation. The how the PD inception and extinction voltages are
Distributed exclusively in the UK by resulting ozone is corrosive to many common insulation decreasing. When these voltage levels fall into the range
materials and, over time, PD effects can lead to complete of the normal voltage transients seen by the motor, the
EMS breakdown of the insulation and failure of the motor. weakening of the insulation will accelerate. For
manufacturers and service providers, that provides
www.ems-limited.co.uk Partial discharge was once mainly a concern to greater assurance that equipment will perform reliably in
manufacturers and users of high voltage equipment, but service. For operators, an earlier warning of potential
24 the widespread use of variable speed drives to improve problems improves maintenance planning, reducing
the performance and efficiency of low voltage motors costly downtime or unscheduled loss of production.
means these systems are often exposed to many more of
the transient high voltage peaks that can lead to PD SKF’s desktop software package, Surveyor DX, has
events, and eventually to motor failure. been updated to store, display and trend the partial
discharge results, as well as the other standard tests
The challenge during testing is that the discharge offered by the DX analysers.
happens very quickly, usually in just a few nanoseconds, www.skf.co.uk

25

SENSORS & SYSTEMS Emissions Sensors

Exhaust gas temperature

sensors: the future’s digital

Patrice Flot considers the current approach to sensing exhaust
gas temperature (EGT) on high horsepower engine platforms
and the capabilities provided by new digital technology

An EGT sensor measures the temperature of the repetitive from day-to-day when engine load, performance but nevertheless, they can hit the cable when
engine exhaust gas to prevent damage to critical speed and conditions are the same. close to the flanges. How much the cable can meet the
components such as the after treatment system, requirements of any excessive or abnormal engine
turbines and cylinder head exhaust valves. It can The most common use for this information servicing, typically when heat insulation is incorrectly
also be used inside the combustion chambers where hot has been, and continues to be, EGT monitoring refitted around the pipes following maintenance, is also an
gases are generated. Exhaust gas temperature does not devices, which survey individual and average values, issue to be considered.
provide an accurate measurement but gives a good as well as temperature gradients: they deliver pre-alarm
indication of heat in the cylinder during combustion, and and alarm status by comparing each individual value to The tendency to add more and more sensors to
is most commonly measured close to the head. Since all the average value. By monitoring individual gradients, the engines has added a new challenge to the complete wiring
metals melt, deform, or undergo transformation under devices can also detect if any cylinder showing an system, affecting both reliability and component costs. For
excessive temperatures, too high a temperature can cause abnormally fast or slow EGT value change. instance, larger connectors on ECUs can be vulnerable
damage to engine components and therefore it is critical during routine maintenance programmes: a single contact
to have a sensor in place to assess the combustion inside For a turbine gas outlet, the pulse effect is dampened damaged inside the connector can be costly, resulting in
the engine, either across the whole unit or cylinder by by the blades and therefore temperature variations are the whole unit being rendered unfit for purpose.
cylinder. within ±1°C. The measurement provided is used to
This together with improvements in materials, design,
Operating at peak levels, EGT can optimise engine The tendency to add more and more technical applications and CAN protocol has driven
performance and deliver significant fuel and maintenance sensors to engines has added a new increasing numbers of engine manufacturers to look at the
cost savings. Any abnormal change in the combustion capabilities offered by a new generation of digital
cycle due to the fuel supply system, air supply system or challenge to the complete wiring technology, which heralds significant competitive
combustion chamber configuration can obviously be system, affecting both reliability and advantages over the very first sensors.
problematic so having sensors currently located on an
engine is vitally important. component costs Today, it is possible to equip engines with an array of
sensors fully digitised to comply with the CAN bus
Exhaust gas is a mix of fuel components characterised accurately evaluate the amount of energy produced in the protocol. (The protocol usually refers to the data link layer
by temperature, pressure and mass flow; which are all exhaust while also being used to calculate the gas protocol defined by ISO 11898-1 and the physical layer
constantly changing in the exhaust pipe during every temperature at turbine inlet. This not only provides an defined by ISO 11898-2 and can be summarised as: The
combustion cycle. At the exhaust outlet of the cylinder indication about the thermodynamic behaviour of the physical layer uses differential transmission on a twisted
head, gas temperature can range from around 800°C engine but the real status when compared to the pair wire. A non-destructive bit-wise arbitration is used to
during exhaust valve opening to 40°C during exhaust and theoretical values of mathematical modelling. control access to the bus.) The speed and position
inlet valves opening overlap. Considering a medium/high sensors, and ON/OFF switches can also be digitized, thus
speed engine running at 1200rpm, this can see extreme EGT sensors, sited on the hot areas of the engines, reducing the wiring system to a single cable CAN loop on
changes in temperature up to 10 times per second. During pose some significant challenges for cable, which might the engine.
each cycle, the temperature sensor located at the cylinder have to withstand surrounding temperatures that can
head will be exposed to the heat and cold exhaust flow. reach as high as 600°C depending on where they are Purely digital engines lie in the future but the first steps
located. Here, Mineral Insulated Cable (MIC) is used for are now being taken by far-sighted manufacturers, who
The intermediate temperature observed depends on the hot spots before being connected to flexible cable
the location of the sensor on the exhaust pipe outlet, the running across cooler parts of the engine. are starting to adopt digital sensors to sit
length of the sensor plunger (in comparison with the alongside traditional ones on their engines. In
diameter of the exhaust pipe), the materials of the sensor The electronics cable must also be resistant to part, this is being driven by the restrictive number of
– and the corresponding thermal coefficients – and the problems caused by water or humidity ingress, and analogue input ports available on ECUs. Now, digital
design of the sensor itself. And typically, when electronic carefully routed to minimise damage caused by gas technologies are offering an advantage: any additional
sensors were introduced, many engines retained double leakage at the flanges of the exhaust pipes - leakages number and combination of CAN exhaust-after-treatment,
measurements: thermo-mechanical to provide a local might be slight, not even detectable through engine turbine inlet/outlets, cylinder head outlet, combustion
reading and an electronic one to produce a remote output chamber temperature and liner wall temperature sensors
– providing two different yet acceptable reading can be connected to the existing ECU.
references. The EGT measurement at These sensors can incorporate unique series numbers
the cylinder head outlet is not embedded in their software and delivered with temporary
an absolute value, providing addresses, or with pre-set ones. And when plugged into
an indicative value that
is highly

26

Any issues surrounding digital We are there State-of-the-art. Also interested in really fast, rugged, light, accurate, customised
complexities can be overcome as most when innovation and inexpensive infrared thermometers and cameras for
leads to an edge. non-contact measurements between –50 °C to +3000 °C?
engine end-users are industrial Visit ZZZRSWULVFRXN
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address. Software tools enable the engine builder to create the ±
address in the factory via a PC and a simple CAN interface, www.first-sensor.com Birmingham, UK
address that is uniquely allocated to given and unique function on Hall 4 / F1
the engine.
Innovative Infrared
The superior ‘intelligence’ digital sensors offer is set to herald Technology
a whole new world of possibility when it comes to new
functionalities. For example, it will be possible to have the various
sensors communicating with each other, sharing their respective
values. This will enable them to calculate an average value and
deliver pre-alarm and alarm when an individual value starts to
stray too far from the mean.

The EGT sensors can also record the number of low frequency
cycles (start/stop of the engine; start/stop of voltage supply to
sensor) and the high frequency combustion cycle. It can then
perform residual lifetime estimation and provide the expected ‘date
for change’ information, which delivers improved condition-based
maintenance and longer term cost savings. Eventually, considering
that similar intelligence will be embedded in every sensor, this
approach will see the possibility of splitting the software of the
ECU into sub-programs that, if one sensor fails, will re-route to
another one, delivering improved reliability and all round system
performance.

The ‘Internet of Things’ sensor

There’s no question that EGT sensors are becoming a ‘must have’
technology to assess the health of the valve actuators for fuel
injection, whether liquid or gas, and the health of the after-
treatment systems on industrial engines. Any issues surrounding
digital complexities can be overcome as most engine end-users are
industrial organisations, who have requisite experience in dealing
with automated systems and digital device management. Indeed,
we are seeing confident users, who know that sensor
manufacturers such as CMR Group will provide them with easy-to-
use maintenance and management tools.

Engine builders are also recognising the benefits of digital
technology that facilitates rapid implementation of additional
sensors, without any physical change in input/output ports of the
ECU. This is allowing almost unlimited additional reserves of
sensors compared to original design capabilities - the complexity
of harness design is reduced as any additional sensors only require
an additional harness connector, without an increase in size or
additional wiring.

Finally, digitisation is pushing back the spares’ business from
third parties to OEMs who are managing the whole engine control
software. This is providing greater safety for the end-user thanks
to the availability of original parts, while reducing instances of
engine damage caused by incorrectly sourced instrumentation and
component parts.

Current technologies have minimum and easy-to-use
functionalities but no doubt the future will offer much more: the
capability to release the ECU from its high load and support CBM
systems while offering an ‘Internet of Things’ sensor that can
deliver clever data to remote parts of the world, regardless of
time zones.
www.cmr-group.com

Patrice Flot is chief technical officer at CMR Group

27

SENSORS & SYSTEMS Inertial Measurement

IMUs deliver new levels of

application flexibility

Tri-axis inertial measurement sensors are widely used in car and
vehicle applications from driver monitoring to fully autonomous
vehicles. Here, Jon Bentley of Mclennan explores some other
interesting uses that this technology is being be applied to

As a well proven six degree of to 0.2% F.S. More sophisticated products These IMUs can materials cut by machine tools is often
freedom sensor for vehicle motion meet the needs of measurement of attitude be equipped with extended accompanied by rotational motion. As
measurement, tri-axis inertial and three-dimensional motion for vehicles functions including a Bluetooth abnormal vibration is often a first
measure-ment units (IMUs) are and mobile machines. Available as a low communication board, a GPS receiver indication of machine failure, this could
available in various packaging and feature cost PCB or as a housed IMU, they are board and a battery pack. Units are improve the availability of the machine
styles that include low cost pitch, yaw and equipped with vehicular standard MEMS supplied with data logging software. through enhanced preventive
roll measurement sensors which might be gyro sensors and feature outputs for tri- Other versions can include completely maintenance which is a requisite of
used from fleet driver evaluation to axial angular velocity, acceleration, and packaged IMUs in waterproof and Industry 4.0.
sophisticated IMUs with integral GPS that angles and is supported by stable thermal dustproof cases as well as software,
can be as part of complete dead reckoning behaviour and reproducibility. With I/O evaluation units and a full complement Overhead traveling cranes: In crane
systems for autonomous vehicles. interfacing for CAN, RS232C, and USB it of accessories. safety, an IMU fitted to the crane hook
incorporates digital input command to be can provide superior X-Y axis deflection
For single axis vibration measurement composite with external information such As IMUs include both gyro and sensing than camera systems by directly
over a typical ±60 to 720 degree/sec as vehicle speed. accelerometer sensors they can provide detecting angular velocity and
range, MEMS gyro sensors provide linearity certain advantages and may be used acceleration. In other types of crane
effectively for industrial and other application such as marine loading
LOW COST CAPACITIVE SENSORS application areas where complete cranes the IMU could be used to
orientation feedback and movement can compensate for heave.
Inclination Acceleration be used to enhance performance,
improve productivity, increase safety and Measurement of inclination of
s ±1° to 360° s DC to ±1000g even aid recovery in medical construction and agricultural mach-
s 0.001° resolution s Easy Calibration rehabilitation. So let’s look at some inery: The IMU is capable of accurately
s Integrated electronics s High long term stability potential uses: measuring the inclination of a heavy
s Analogue or Digital Outputs s Low power consumption mobile machine even under extreme
Robot arm control: In this example vibration conditions, because the
SENSORS UK LTD For more information an IMU is used to detect the amount of inclination is measured by both
135A HATFIELD ROAD, ST ALBANS AL1 4JX please visit: deflection in terms of position and accelerometer and gyro sensors. The
www.sensorsuk.com velocity for a robot end effector. This IMU is also suitable for attitude
UNITED KINGDOM information may be used to optimise the measurement of up to 0.1 degrees for
TEL: + 44 (0)1727 85 93 73 dynamic performance of an assembly heavy construction vehicles as well as
EMAIL: sales[at]sensorsuk.com robot during set-up or in-situ by MEMS-based dead reckoning systems for
automatically adjusting some or all of the autonomous guiding of agricultural
axes. As the position element is vehicles.
essentially in all six degrees of freedom,
the precision of the adjustment is Monitoring of movement for
potentially higher than just relying on rehabilitation: IMUs can bring several
torque demand from servo feedback. The benefits to rehabilitation with precise
IMU is this case can help improve measurement of movement available for
quality control and even speed tracking a patient’s progress. With six
throughput on the assembly line. degrees of freedom measurement
available, complete data including
Positioning tool for a torque wrench: acceleration, angular velocity and
In this example the torque wrench is attitude angles forms a fundamental part
fitted with an IMU and set up to sense its of a rehabilitation when used with
exact position in space. The control appropriate software.
system then adjusts the torque output for www.mclennan.co.uk
each individual location so that large
machine assembly might be carried with Jon Bentley is managing director at
increased safety and speed. Mclennan, the UK distributor for the
Tamagawa range of tri-axis IMUs
Detection of abnormal vibration of
machine tools: In this example on a
stamping machine the IMU’s gyro can
detect abnormal micro-vibration more
effectively than individual acceler-
ometers because the vibration of

28



Taking the register

Until recently, SICK’s registration any printed pack is likely to have them. Accuracy of surrounding machinery can fool an inferior sensor into
sensor portfolio has been led by the registration is critical for FMCG manufacturers to giving false signals.
SICK KT5 sensor – probably the eliminate wasted product and materials. Registration
most commonly-used and sensors are being constantly tested to cope with higher The consistency in the light signal returned to the
depended-upon contrast sensor in industry machine speeds, greater product batch changes and sensor could be affected by several factors, for example,
worldwide. Now, a new breakthrough in packaging design trends such as subtle colour differences, an uneven, dirty or wet substrate material, minimal
registration performance, the KTS/KTX family reflective foils and the use of transparent materials. contrast differences between colours, when converted into
is being officially launched in the UK at the gray scales by the sensor, matt black colours that absorb
PPMA Show in September 2017. David A bottle of shampoo could be transparent and/or most of the light or highly-reflective finishes that divert
Hannaby, SICK’s UK Product Manager for reflective, making registration marks more difficult for a the light away from the receiver.
Presence Detection, takes the opportunity to photo-electric sensor to detect. In automated electronics
review registration sensing – a technology manufacture such as wafer cutting, or placing Registration sensing options
whose challenges and solutions should components on a printed circuit board for soldering, the
resonate with anyone using photo-electric consequences of inaccuracy could lead to product failure The principal technology employed is contrast sensing,
devices in high-speed production today. in use and even costly recalls. developed originally to detect the difference between
black and white. Higher resolutions means that smaller
Next time you accept a sachet of sugar from a barista Overcoming production challenges marks can be detected, and improved algorithms and
to sweeten your mocha, munch on your morning more intense light allow ever more subtle differences in
cornflakes, or reach for your bottle of shampoo, stop and Photo-electric registration sensing is based on the gray scale tone to be distinguished.
take a closer look at the packaging. It may be cleverly detection of differences in the amount of light returned to
hiding the tell-tale signs of decades of engineering the sensor when a projected spot moves across a surface Colour sensing detects a difference from a background
development in a vital photo-electric technology. such as a package or a bottle. Technology development colour to determine position for registration, for example,
has seen the size of the spot decrease for improved the blocks of colour incorporated into a logo. To achieve
Look closely, and you may see the tiny printed marks resolution, the colour of the sender LEDs change for more this, the sensor emitter/scanner set-up has to be tuned to
that are vital, precision-manufacturing instructions for reliable detection of marks and the intensity of light particular colour frequencies and may use filters of
labelling, printing or cutting machinery. In fact, almost increased for better tone differentiation and greater speed specific colours to enhance the colour selected. Print and
of response to match production speeds. packaging are typical applications, but paint and wood
finishes and even automotive components and textiles
Registration sensors need to be a class act to achieve can benefit.
consistently accurate detection rates, time after time – no
matter what the challenges presented by the surface or Luminescence sensors detect non-visible marks
added with materials which can be made to fluoresce
substrate to be detected, or from under UV light, for example adhesive. The marks can be
the surrounding industrial placed on a label, pack or product without clashing with
environment. the ‘design aesthetic’ of the branding. Luminescence
sensing can be particularly useful where transparency and
With higher speed also clarity are a prerequisite of the package or substrate, such
comes the more exaggerated as see-through blister packs used for medical instruments
flutter of the materials being or cosmetics.
passed by the sensor, such as
reel to reel material, or bottles on Any photo-electric device is potentially susceptible to
a filling line, so the substrate for error from unwanted glare or reflections whether from the
the registration marks moves background environment, such as metal machinery
unpredictably. surfaces, or even a white conveyor belt, glass screening or
foil and reflective varnished print surfaces on a pack.
The manufacturing Glare sensors can be used to overcome challenges and
conditions may be wet or dusty using careful set-up and advanced algorithms, the control
so that the sensor’s lens needs to system can be taught to disregarded incorrect messages
compensate as it becomes from glare.
coated and opaque, and
background reflections from With advanced sensors that use SICK Delta-S
technology, the glare problem is transformed into a
solution by defining the boundary between reflection and
non-reflection as a registration point. For example, in a

30

pack design, an area of reflective varnished colour might previously available. Through the combination of sensor and controlled switching is consistently achieved. As a
border a matt white block where the sell by date and self-monitoring and the ability to notify the control result the KTS/KTX sensors have a significantly larger
batch number are over-printed. system precisely which sensor needs replacing, depth of field, as well as a sensing distance tolerance of
production teams have much greater flexibility in ±5mm, as-yet unique in contrast sensors of this type.
Industry 4.0-ready monitoring their processes.
The KTS and KTX PRIME options enable fine contrast
The SICK KTS and KTX family of contrast sensors set a By standardising on key product families such as the and colour differences to be detected using one device
new benchmark in detection accuracy and switching KTS/KTX, SICK is also ensuring wide applicability across with a high degree of process reliability, while also
frequency speed. SICK’s KT5 contrast sensors have long different production process demands to reduce the need blanking interfering colour gradients and imprints on the
been an industry standard for detection of registration for large spares inventories. surface, or ‘noise’ from the detection background.
marks and customers now have the option of upgrading
to the more compact KTS, for a space-saving solution, or The SICK KTS/KTX sensor SICK – breaking new ground
to the KTX, which incorporates the new technology
benefits into the same housing size as the KT5. The SICK KTS/KTX family incorporates key features to The SICK KTS/KTX range of sensors is just one example
meet the need of high-speed sheet and reel-fed of sensors breaking new ground in smarter sensing
The KTS sensor reflects the trend towards production. With up to 70kHz switching frequency and technology. Many of the production and detection
miniaturisation common to photo-electric sensor down to 3µsec jitter rate, the KTS and KTX are easily challenges described are common to photo-electric
development. Smaller and more compact sensors pack capable of coping with up to 250 packs per minute and solutions. By referring to a manufacturer like SICK, you
greater processing power into the confined spaces compensating for high-speed flutter on reel-to-reel can be confident of products developed with close
demanded by automated machine designs. material edges. customer collaboration that are ready to meet the needs
of Industry 4.0.
As Industry 4.0-ready sensors, the KTS and KTX also Twin Eye Technology
demonstrate the benefits of incorporating IO-Link To find out more about SICK registration sensor
connectivity. A key advantage of IO-Link enables quick SICK’s pioneering Twin-Eye Technology improves solutions and the new SICK KTS/KTX sensors, visit the
and easy sensor teach-in and commissioning. When contrast detection with better depth of field and a wider SICK stand A26 at the PPMA show or visit the SICK
sensors need to be replaced, parameter settings can be sensing distance tolerance. The greater grey-scale website.
easily downloaded from a PLC to a new sensor for rapid sensitivity means even better sensing of monochrome or www.sick.co.uk
replacement and commissioning. colour registration marks, even on high gloss packaging.

With new levels of detection accuracy and switching Conventional contrast sensors can struggle to perform
frequency speed, the KTS/KTX sensors offer flexibility in reliably when faced with jittering webs, products with
batch manufacturing, so product changes can be high-gloss surfaces, or where there is not much
identified and new parameter settings automatically difference in contrast between a mark and its
triggered with little or no interruption. More rapid and background. SICK has overcome these challenges by
frequent production changeovers help manufacturers introducing a second receiving channel – a first for any
meet customer demands for product diversity, local or contrast sensor – achieving better process stability and
custom orders. reducing the risk of machine downtime.

In Industry 4.0, the control system is fully connected SICK’s Twin Eye Technology analyses the optically-
to locate and “see” the sensor, so processes are given split remission signal from the material surface and
access to a full range of diagnostic capabilities not compensates for any noise pulses it contains, so stable

31

SENSORS & SYSTEMS Machine Vision

Smart camera offers a vision of the future

With the wide variety of good quality vision products, packaging, or other objects that are in the shape Models are available in 2MP (1600 x 1200 pixels),
systems available today, machine builders of a circle or arc, or contain a circle or arc. This makes it 1.3MP (1280 x 1024 pixels) and WVGA (752 x 480
and end-users are spoilt for choice when it easy to find imperfections as well as measure or determine pixels), all with powerful inspection capabilities. Higher
comes to selecting the best system for a circumference, diameter or the bend radius of a target. resolution models (2MP) are used where larger areas of
given application. There is no shortage of vision systems inspection are required or where a high degree of accuracy
that can offer complex inspection capabilities at incredible The software includes runtime editing capability that or resolution is required. However, the higher the
speed but their performance often falls short in harsher reduces costly downtime and the software emulator allows resolution the larger the image file and the more
industrial environments. for offline building and troubleshooting of applications. processing power is required, therefore the slower the
The Inspection Analysis feature allows users to review past response time. For speed or basic applications the lower
This problem has been overcome by Banner resolution cameras are used.
Engineering with the VE series of smart inspection results, view system logs and
camera, deigned to offer high performance in quickly configure inputs and outputs. FTP The VE Series seamlessly interfaces with the factory
the toughest applications. The VE Series Image Export capability enables the floor using EtherNet/IP, Modbus/TCP, PROFINET, and
utilises robust metal housings and with the automatic export of inspection images as Serial RS-232 communication protocols.
addition of a range of optional lens covers well as the creation of custom file names for www.turckbanner.co.uk
achieves an IP67 rating for use in each exported image. This facilitates the
environments where heat, vibration or recording, tracking, and analysis of
moisture are a concern. inspections and builds on Vision Manager’s

Banner’s free and easy-to-use capability to export images over
Vision Manager software provides a TCP/IP.
number of tools and capabilities Test Summary provides an at-
that enable VE Series smart a-glance display of current test
cameras to solve a wide range of result values, along with
vision applications, such as minimum and maximum
item detection, part positioning, allowed values for each tool
feature measurement and flaw being used. This feature gives
analysis. Included in the range powerful insight to the current
of tools is the Circle Detect tool state of an inspection and is
that can be used to inspect parts, available in normal and full
screen mode.

Universal sensors from Datalogic

SM MINI MIDI M18 MAXI

OEM Automatic is Datalogic’s UK distributor for sensors and safety products.

Datalogic has more than 40 years experience in as automated material handling systems related
the development and manufacture of universal to manufacturing industries such as automotive,
photoelectric sensors. Today, they are one of electronics, pharmaceutical, food & beverage,
the largest manufacturers of sensor products paper and printing, woodworking, ceramics, glass,
worldwide. textiles etc.

Datalogic’s sensor portfolio solves customer Ranging from the very small ‘SM’ sensors, to M18
applications in factory automation, specialising barrel sensors, through to the MINI, MIDI and
in processing and packaging machinery as well MAXI sensors, Datalogic has all bases covered.

www.oem.co.uk [email protected] 0116 284 9900

32

CUSTOMAXI-
MIZED!

Sensor? Housing? Lens holder? Plug orientation?
It´s your choice! The uEye LE USB 3.1 Gen 1

BOARDLEVEL SINGLE-BOARD OPTION: PLUG USB POWER 1 SOFTWARE OPTION: WIDE RANGE
ORIENTATION MIC OPTION USB TYPE-C
VERSIONS CAMERA DELIVERY FOR ALL LENS HOLDER OF SENSORS

Learn more about the possibilities with the uEye LE camera: www.ids-imaging.com/usb3.1

It´s so easy! www.ids-imaging.com

MACHINE BUILDING & AUTOMATION Machine Control

PLCs versus PACs

What is the difference between PLCs and PACs, and which is the complexities of the operation. PLCs are ideal for both
right choice for a given application? Zach Arnold offers guidance simple and high speed machine control. PLCs are a
more cost-efficient option for standard automation
Programmable Logic Controllers (PLCs) and PACs have an open architecture and incorporate control. A capable PLC will help many automation
Programmable Automation Controllers (PACs) modular design. This helps multiple devices, networks projects perform to the best of their abilities. PLCs
are industrial computers constructed and and systems communicate and operate with each other. operate a large variety of machines such as: automated
adapted for manufacturing environments. These PACs are used to communicate, monitor and control spray equipment, dispensing systems, motion control
computers are the brains of a manufacturing operation as equipment across multiple networks and devices. This is and assembly equipment.
they control automation equipment with high reliability. possible because they utilize standard protocols and
network technologies such as Ethernet, OLE for Process It’s the unique, large scale automation projects with
PLCs and PACs are very similar to each other as they Control (OPC) and Structured Query Language (SQL). intricate complexities that require a PAC. That’s why PACs
both perform the same essential functions, and with are great for complex automation system architectures
modern technology, their differences are becoming more By utilising modular design, PACs simplify system composed of several PC-based software applications.
blurred. All automated systems are built with a PLC or expansion processes. Adding or removing components is Combine the previously mentioned systems into a single
PAC to control individual machines or stations. easier to execute. PACs have the ability to monitor and automated process and a PAC will control all of them.
Additionally, the computers can also be programmed to control thousands of I/O points in addition to offering tag-
control a grouping of machines or stations. based programming. With tag-based programming, a As technology progresses, PACs and high-level PLCs
single tag-name database is used for development and are incorporating internet connections to send and receive
So if PLCs and PACs perform the same function, what these tags can be assigned to a variety of functions before data. Adding these Internet of Things (IoT) devices to
makes them different? The most notable difference being tied to a specific I/O. manufacturing operations increases the real-time
between PLCs and PACs is their programming interface. information gathered and shared to interested parties
PACs are more intricate, using C or C++. PLCs on the Increased flexibility anywhere in the world. Their connection to the internet
other hand, are most often programmed using ladder also enables users to remotely control the PLC or PAC and
logic, a programming language that uses symbols PACs provide more flexibility in programming, larger change its functions to control automation equipment in a
representing an electrical schematic of relays. These memory capacity and better scalability for future different manner, from something as simple as increasing
programming differences create distinctions in the expansion. They are particularly useful for systems with a or decreasing speed to a change in motion and position
architecture and capability between the two computers. high percentage of analogue I/O. They are often used in parameters. This level of customisation enables
systems with extensive network interface requirements businesses to adapt manufacturing operations with less
PLCs have simple program execution scans but with and in systems with direct user interaction requirements. downtime.
limited memory and discrete I/O. Modern PLCs are
capable of high-speed I/O, sequencing and proportional- Based on their differences, it appears PACs are the PLCs and PACs both control machines in an
integral derivative control in addition to digital and logical choice for any automated system, but that is automated process. Final determination for which one to
analogue I/O. Many PLCs have built in networking simply not the case. It all comes down to what is needed use comes down to the process’ complexities and
capability enabling the communication between multiple currently and in the future. There is no need to use a scalability for the future. Working with an automation
PLCs, the distribution of I/O and communication between sledge hammer to simply drive a nail for hanging a expert can help determine the extent of your needs for
HMIs and SCADA systems. PLCs are particularly useful photo frame. Similarly, there is no need to invest in a now and the future.
for simpler processes and smaller automation projects high-powered PAC to run machinery that requires www.arnoldmachine.com
without the need for rapid scalability. simple programming. It all comes down to the
Zach Arnold is the founder of Arnold Machine

34 INDUSTRIAL TECHNOLOGY • September 2017

Robot tool change
systems from Stäubli

Tool change systems from Stäubli extend the range of applications of all robots and
turn them into a highly flexible production system for a diverse range of tasks in all
assembly and handling processes.
0VSSPCPUUPPMDIBOHFSTPGGFSPVSDVTUPNFST:

functionality & efficiency
safety & reliability
flexibility & precision
long service life due to high number of mating cycles

www.staubli.com

Stäubli (UK) Ltd. mail: [email protected] - phone: +44 1952 671918

MACHINE BUILDING & AUTOMATION

The rise of the machines

According to industry commentators, machine building is one of and waste reduction deliverables, there’s nothing quite as
convincing as hard facts. A recent report from PwC
the hot topics within UK manufacturing right now. Kieron Salter highlights a number of tangible benefits already enjoyed
by 2,000 responding digital manufacturers. While the
explains why this sector of the industry is experiencing a period of vast majority of companies agreed that embracing digital
manufacturing had enabled shorter operational lead
dynamic change that looks set to continue over the next decade times, higher asset utilisation and improved product
quality; on average companies reported annual increases
First defined by industrial academics Tseng and G Efficiencies and cost reduction in digital incomes of 2.9% and cost reductions of 3.6%.
Jiao back in 2001, the concept of mass G Horizonal innovation
customisation is finally making serious in-roads Horizontal innovation is the final trend that is
into consumer markets such as fashion, FMCG, Control of data has always been one of the Achilles’ accelerating the nascent digital machine building trend.
automotive and sportswear. From bicycles to personalised Heels of digital manufacturing. The data was always Our adoption of many of the technologies, principles and
spectacle frames, the ability to manufacture products there, but it was a question of collecting, storing and then materials pioneered in motorsport have informed our
designed specifically for an individual at low cost is now (crucially) harnessing that data to inform process journey into digital machine building. The identification of
a reality. decisions. Thanks mainly to the shift from big PLC control technologies and solutions across industrial sectors is a
systems to PC-based tools, (provided by micro-control key theme that has been adopted by the IET. Moreover,
This development was previously held back due to two specialists such as Beckhoff), there is now much more the Institution believes that UK PLC could benefit
key constraints; the cost of production and the availability flexibility and choice within the machine control significantly from a more joined up approach to the
of useable technology – both of which have now been environment. This fundamental shift in data management sharing of knowledge across sectors.
largely overcome. The movement of global players such has enabled us to be much more dynamic and creative
as Siemens, Bosch, Statasys, IBM and Dell into the when it comes to developing digital manufacturing KWSP’s active support of this strategy has led to us
Internet of Things (IoT) arena has meant that the cost of systems. Using PC-based controls, we are currently solving data control issues on a cycle wind tunnel project
implementing Industry 4.0 solutions is falling as new involved in the development of a game-changing digital for Boardman Bikes, as well as reducing weight on
products become available. And with the huge increase in Braille printer, that could transform the life of millions of numerous machine build projects. While not a central
data processing power (Moore’s Law), we have now blind and partially sighted people across the world when ingredient of change in the digital manufacturing sphere,
reached the stage where large amounts of information can it enters volume production. the adoption of Horizontal Innovation principles is
now be stored and interpreted into usable data. certainly a significant catalyst for change.
Materials development is another industry trend that
Despite the inevitable hype and widespread is driving the new era in machine building. Indeed, the Granted, while there are potential constraints to
misunderstanding around IoT, Industry 4.0, 4IR or M2M advancement of new, lighter composites with even better anticipated growth – such as availability of skills, Brexit
(all different terms for what is essentially the same trend weight bearing properties, is opening up a new chapter in and the state of the global economy – the digital machine
in manufacturing), the future facing UK and European machine development. Last year, we designed and building market presents a significant opportunity for UK
manufacturers is exciting. As designers and builders of developed a digital printer for the textile sector, which engineering to become a global innovator in this area.
systems, we now have the skills, technologies and enables mass customisation of wallpapers and other Perhaps our biggest constraint to growth is product
systems to create a new era of intelligent machines to materials. This was only made possible by the use of manufacturers’ relatively poor understanding of the
deliver the digital manufacturing dream. lightweight composites to reduce the original weight by potential that digitization can offer. Then again, maybe
approximately 30%. it’s our job to spread the message.
I believe there are four main drivers to this digital www.kwspecialprojects.com
revolution: Efficiencies and costs savings are other obvious drivers
G Control systems of the digital manufacturing revolution. While it’s all very Kieron Salter is managing director of KWSP
G Materials development well predicting Industry 4.0’s potential productivity gains

36 INDUSTRIAL TECHNOLOGY • September 2017



MACHINE BUILDING & AUTOMATION Cables

Two become one: hybrid
bus cables tried and tested

Modern servodrives use a single-cable connection, or hybrid bus cables fulfil the demands of many moving applications,
cable, for the power and encoder signalling. The lack of a especially for the use in machining centres and machine
dedicated feedback cable not only reduces the connection costs, tools. Such features are also important for conveyor
but also the cable variance. These hybrid cables were first technology as well as in low temperature applications.
introduced by Igus for moving applications in 2013; Justin
Leonard reviews their performance four years on For medium duty applications, the chainflex
CF220.UL.H hybrid bus cable is suitable for travels up to
Igus first added into its development programme a integrated into the servo cable. For this reason the 10m. It has a PVC outer jacket, which is oil resistant
single-cable solution for servo motors four years ago, element shield, as well as the entire shield of the hybrid according to DIN EN 50363-4-1 and flame retardant, as
which integrates a hyperface bus element. With it, cable, is made of a particularly bending-resistant shield well as being silicon free. Typical indoor applications
the company took up the emerging trend of the made of tinned copper wires with an optical covering of include wood/stone processing, packaging industry,
single-cable technology for servo motors. The first hybrid 80 percent. The high-quality shields ensure the supply systems and handling/adjusting equipment. It is
servo cable introduced was based on the chainflex cable electromagnetic compatibility (EMC) of the cable. also suitable for use in ISO Class 2 cleanroom
series CF270.UL.D. applications. Igus also offers its hybrid bus cables fully-
Durability in tough applications assembled according to Beckhoff standard.
Up until then, the servo motor and converter were
generally connected with two cables – one servo cable for Beyond that the hybrid bus cables developed by Igus are All these cables have been rigorously tested at Igus’
the energy supply of the motor and an encoder cable to designed for use in energy chains and have a minimum Cologne headquarters, home to the world’s largest facility
give data about rotation speed and position of the motor bending radius of 10x cable diameter. The basis of the for testing moving cables. As part of its commitment to
back to the control. The principle on the single-cable hybrid cables is the technically high-level chainflex family customer success, igus has operated an extensive test lab
solution is simple: to couple the energy supply and data CF270.UL.D that has been tried and tested in the market for more than 20 years. This state-of-the-art 2750m²
feedback in one cable. In this case complex measuring for many years. Their durability in tough applications and facility carries out more than two billion test cycles per
system cables, which are usually used for the encoder environments is good, this is the result of the specific Igus year. Conducting more than 700 tests simultaneously,
function, are replaced by bus technology. design. four test robots put chainflex cables through their paces in
a series of demanding material tests, including torsion
The main advantage over standard servo cables are The core pairs, wound with optimal pitch length, testing and -40°C cold chamber test stations.
their space-saving function, a very important aspect for satisfy the high mechanic demands of constantly moving
the use in energy chains. Apart from that, the number of applications. A low-adhesion PUR outer jacked covers the More than 5000 measurement locations are
plugs and therefore the costs for additional material and cable. It is customised to the specific demands in energy monitored continuously, taking 1.4 million electrical
installation is reduced. chains and provides a long lifetime of the cable due to the measurements per year. As well as rigorous and
proven Igus materials. comprehensive testing to Igus standards, customer-
A good and durable shield is especially important for specific application testing is also undertaken. All tests
servo cables to prevent possible electromagnetic Moreover these hybrid bus cables meet relevant are systematically documented; this exacting process is
interference from neighbouring cables within the energy standards such as UL, CSA and NFPA79.2012 and are part of how igus is able to offer customers a 36-month
chain. This is even more important in the case of hybrid oil resistant. Due to their Desina conforming orange outer guarantee on its cables and carriers, giving them the
cables, because the sensitive bus signals are directly jacket, which is flame retardant and halogen-free, these reassurance that their system will deliver a reliable
long life.
www.igus.co.uk

Justin Leonard is a director at Igus

38 INDUSTRIAL TECHNOLOGY • September 2017

Safe power supply to equipment in the panel with Klippon® Connect and
maxGUARD for integrated load monitoring and control voltage distribution
Let’s connect.

Potential distribution and electronic load monitoring in one complete solution: with maxGUARD,
you save up to 50 percent of space and 20 percent of time compared to existing wiring solutions.
For separate protection, use our tailor-made Klippon® Connect voltage distribution terminal blocks.
Sales: 0845 094 2006 Tech: 0845 094 2007
Email: [email protected]
www.klippon-connect.com

39

MACHINE BUILDING & AUTOMATION Power Supplies

Perfecting power

When you need a 24V DC power source for an industrial control
system, it’s easy to think that almost any standard power supply
will do the job. And it might, at least for a while. But if reliability
and convenience are priorities, it pays to give a little more
attention not only to the power supply itself, but also to other key
components of the power system. Peter Croucher explains

The traditional approach to providing 24V DC if the overload on the PSU valuable space in the control panel and, because of the
power for control systems is to use a single continues for longer than this, forward voltage drop in the diodes, they increase losses
power supply unit (PSU) mounted within the automatic current limit operates and heat generation.
control panel. For some applications, this to protect the PSU itself and the
may well be all that’s needed, provided that the circuits fed from it. A better solution is offered by PSUs with integrated
power supply is a high-quality unit and has an MOSFET ORing. These PSUs can simply be connected in
adequate power rating. However, even in these So much for simple applications, but what parallel to form redundant combinations – no diode
straightforward applications there are some important of critical systems where an even higher level of power modules are needed, as they are intrinsically protected
points to consider. supply reliability is needed? In these cases, redundancy is against power back feeds under fault conditions. This
the solution and is typically implemented by using two saves panel space and wiring. In addition, the losses
The first is efficiency. The best PSUs now achieve PSUs, each capable of supplying all the essential loads if associated with MOSFET ORing are up to ten times
efficiencies in excess of 95%, which will trim a small but the other fails. lower than with conventional diode circuitry.
useful amount from the running costs of the control
system. Possibly even more important, it will reduce the As well as the power supplies themselves, one or more Having chosen the right PSU (or PSUs) for a control
amount of heat generated within the control panel. With diode modules is usually needed so that, in the event a system, the next step is to think about how the power will
today’s very compact panels that are densely packed with fault, power does not feed back into the failed PSU. These be distributed. Typically, a fuse or MCB is provided to
components, this is often an important factor. modules necessitate additional wiring, they take up protect the output of the PSU and then the power goes to
a row or two of standard feed-through terminals.
Another point to consider, and one which is often However, this arrangement provides only limited circuit
overlooked, is peak power capability. It is often beneficial protection, and it is wasteful of panel space.
for a PSU to be able to supply currents well in excess of
its nominal rating for short periods. This ensures correct A better approach is to use application-specific
functioning when switching devices like solenoids and products for power distribution. Terminals are now
motors, which have high inrush currents. High short time available that incorporate multiple connection points.
peak power capability is also essential in systems where These save space and make it easy to create compact and
the loads are protected by miniature circuit breakers clearly structured 24V DC distribution systems. Further,
(MCBs) as, in the event of a fault, the PSU must be able these new terminals also support comprehensive colour
to supply sufficient current for a long enough period to coding which helps to avoid wiring mistakes and
ensure that the MCB trips reliably. simplifies maintenance. These distribution terminals are
available in fused versions, allowing protection to be
To meet the requirement for reliable MCB operation, provided conveniently for individual circuits.
the latest PSUs can supply up to 600% of their nominal
output current for 20 milliseconds. As would be expected, An even more versatile approach to circuit and load
protection is provided by terminals with integrated
electronic load monitors (ELMs). Compared with fuses,
ELMs have many advantages, not the least of which is
that they can be remotely reset. They can also provide a
pre-trip warning when a circuit reaches 90% capacity,
allowing problems to be rectified before they result in a
shutdown. In addition, ELMs trip instantly when the rated
load is reached, thereby providing better protection than
a simple fuse.

Almost every modern control system needs a source of
24V DC power. Many options are available but they are
by no means equal, especially in terms of reliability and
convenience. Following the guidance given in this short
article will, however, allow a power system to be
developed that’s compact, convenient, cost-effective
and dependable.
www.weidmuller.co.uk

Peter Croucher is product manager at Weidmuller

40 INDUSTRIAL TECHNOLOGY • September 2017

Indexing Chain Conveyor System Next Gen IPC for Automation

Interlink machining stations cost efficiently Compact industrial system for automation – with
Sturdy system, total load capacity of up to 700 kg the latest 6th / 7th generation Intel Processors
Flexible modular designs, variable lengths
& widths possible

AMS301 – with
FieldBus Support

The AMS300 systems maintain impressive performance even in
such a compact design. All systems are built to perform reliably
in harsh environments making them ideal for smart factories.

• High performance:

– 6th/7th gen Intel® CoreTM i7/i5/i3 processors VISIT
– Built-in 8GB dual-channel system memory US AT THE
– 4 x USB 3.0 and 2 x USB 2.0

• High availability and data security:

– Front bay for HDD/SSD drive (RAID 0/1) STAND A61
– Optional 2MB MRAM data storage

• Remote access via Intel iAMT

• Energy saving with iSMART scheduled start-up / shutdown

• Supports Fieldbus interfaces with 3 ports

For more information, please call us on: 01438 846 090

www.mkprofiles.co.uk mk Profile Systems Limited See our industrial computing on:
a company of the www.ibase-europe.com
[email protected]
mk Technology Group

Turning cables
inside out

KDSClick is a new cable entry system that minimises
the time required for connecting preformed cables in to
cabinets and enclosures.

The unique system comprises of only three basic
components, frames, inlays and sealing inserts.
Unlike other systems that have a split frame that
needs to be assembled with the cables before
mounting.

Conta-Clip’s new solution is based on a single
unit frame that requires no pre-assembly.

IP66
Simple modular design
84 different sealing inserts
Fits in to industry standard cut outs

www.oem.co.uk [email protected] 0116 214 5264

41

MACHINE BUILDING & AUTOMATION Aluminium Frameworks

New concept of assembly line
for one piece flow manufacturing

With an increasing trend towards to address issues of safe and ergonomic working
customisation of finished products, conditions and quick start up/changeover times, even
combined with small batch sizes, a UK when dealing with multi product manufacturing and
manufacturer needed to increase its assembly.
flexibility without compromising quality and efficiency.
To meet these requirements, it turned to Minitec for a The Minitec profile-based solution met all of the
new assembly line concept – a one piece production flow requirements of the manufacturer. Electronic interfaces
line built around Minitec’s aluminium profile system.

The new concept lines are perfect for multi-shift
operation and the frequently changing teams operating
the lines. The design from Minitec also needed to be able

link the manufacturing process to the operator’s ERP and details the variants required. Minitec’s software
systems and ensure that the correct documentation, controls the line and adjustments to the assembly
work instructions, etc, are available for each order being process can be made with minimal software
produced on the line. modification. By deploying new generation wireless
power tools torque settings and speed can be adjusted
Before the job starts the operator scans the order in according to the requirement of the job in hand.
and his screen will pull up which item is to be produced
The flow line manufacturing concept is an essential
part of reducing waste on the line and neatly fits in with
the Industry 4.0 push towards automation of hitherto
manually processed activities.
www.minitec.co.uk

42

QUALITY EXPERTISE PRICE

KJN BR & ITM profile systems offer an extensive range of quality profiles and
components for all your production requirements.

Our Product knowledge and expertise allows us to offer the best to our customers.
KJN will always offer their most competitive prices.

KJN ALUMINIUM PROFILES AND ACCESSORIES

KJN Aluminium Profiles and Accessories range is available ✓ Available to order
to order easily via our online shop online cut to length

@ ✓ High volumes of stock
of BR & ITM profiles
www.aluminium-profile.co.uk
✓ Compatible accessories
KJN can provide a complete solution ✓ Competitive prices
from DESIGN & ASSEMBLY or simply as ✓ No minimum order
✓ Flat packed or
a FLAT-PACKED KIT for self assembly
G Test Enclosures G Robot Cells assembled
G Guarding G Workstations
G Benches G Machine Bases ✓ In-house design
services
G Conveyors G Racking G Test Rigs
G Trollies G Clean Rooms

Buy online: www.aluminium-profile.co.uk

Sales: 01455 823304

MACHINE BUILDING & AUTOMATION Machining

Simple, effective crosshole

deburring of complex parts

By integrating flexible hones in the machining process, complex
parts with cross-drilled holes and other difficult to access features
can be deburred in house, at high quality and at less cost

In automated machining, removal of burrs and sharp up the manufacturing process and ensure uniform quality knives and cycling components for BMX, road and
edges in cross-drilled holes and other difficult-to- for precision parts. According to Scott, flexible hones are mountain bikes. He also continues to perform contract
access areas such as undercuts, grooves, slots, or ideal because it is a cost-effective solution to smooth manufacturing work.
internal holes can be tedious and time consuming. edges and produce a blended radius for crosshole
One particular challenge is deburring the intersection of deburring. “It is really about accessibility, because there Spaulding particularly appreciates how the flexible
cross-drilled holes frequently found in engine and aren’t really any other tools that can do what a Flex-Hone hone’s abrasive globules each have independent
transmission components. can,” he says. “Whether it is internal grooves or multiple suspension that is self-centering, self-aligning to the bore,
cross-holes, there is really no way to reach those areas and self-compensating for wear, all of which facilitate
Despite the challenges, the removal of burrs from the with any sort of other tool.” close-tolerance finishing work. “The hone conforms to
production process is an absolute must for high quality, whatever you are working with, even if it’s irregular,” he
precision parts. In many applications, cross-drilled holes Unique appearance says. “For example if the back side of the part is not flat
act as conduits for fluids, lubricants and gases. Failing to or not on consistent level plane in z, the tool is flexible
remove burrs can cause blockage of these critical For engineers in the automotive, aerospace, enough to still remove any burrs.”
passages or create turbulence in the flow. Burrs can also manufacturing and machining industries, the ball-style
lead to part misalignments, affect dimensional tolerances, hone is a highly specialised abrasive tool that is instantly Symmetrical deburring pattern
and limit the overall efficiency of machined components. recognisable by its unique appearance. Characterised by
the small, abrasive globules that are permanently For best results, the deburring tool is typically rotated into
“Getting rid of burrs is really important because if mounted to flexible filaments, the product is a flexible, the main bore into which the crossholes break. After a few
there is any loose material that gets dislodged when the low cost tool utilised for sophisticated surfacing, clockwise strokes, the tool is removed and the spindle
product is in use, it can cause major problems,” says deburring and edge-blending. reversed to rotate and stroke the flexible hone in a
Anthony Scott, lead machinist at Orange Vise Company, a counterclockwise direction for a few more strokes. The
manufacturer of machine vises and quick change fixturing Available in sizes ranging from very small diameter forward and reverse rotation creates a symmetrical
components. hones (4mm) to those up to 36 inches or more in deburring pattern. Coolant should be used to keep metal
diameter (a size appropriate for large engine cylinder cuttings and deburred metal in suspension.
Although there are many techniques for deburring bores), these deburring tools can be custom designed to
internal passages at cross-holes, the majority require the size, shape and abrasive grit to fit any application’s
sending out parts or investing in equipment to complete needs. “I used the Flex-Hone quite a bit when I was
the work in-house that can cost tens of thousands of working in aerospace,” explains Ken Spaulding of Zodiac
dollars. These options, which include thermal, abrasive Engineering, a contract manufacturer in California. “We
flow, electrochemical, and high-pressure water, effectively did a lot of parts that involved tubes with multiple
remove excess material but they also build time into the crossholes and slots. Getting inside there to reach the
manufacturing process and add to costs. burrs, particularly if the walls were thick, is extremely
difficult.”
The more ideal option, however, for many machining
operations is to integrate deburring into the automated With a background in aerospace parts as well as mold
process with a simple, effective crosshole deburring tool making, Spaulding is currently focused on creating
such as the Flex-Hone from Brush Research products of his own design, such as high end pocket
Manufacturing (BRM). By doing so, operators can speed

44

(Left and above) Before and According to Orange
after pictures of the Flex- Vise’s Scott, although the
Hone crosshole deburring
process, meeting the needs Flex-Hone is often
of companies in areas such used with automated
as the automotive, production equip-
aerospace, manufacturing ment it can also
and machining industries. be used for
The hone conforms to secondary de-
whatever you are working burring options
with, even if it’s irregular. offline as need-
ed. “The tool
can be used in
CNC machines
and also with a

cordless drill,” he
says. “So, if you manage
to deburr 90% of the holes
in a machine, but have a few
left you can’t access easily, you can
use it with a handheld drill and maintain the uniformity
in surface finish and process.”
Additional customisation from BRM in a variety of
shapes is also possible to meet the requirements of
non-traditional applications. This includes spherical-
end configurations, stepped or multi-diameter
configurations for double diameters and counter-bores,
tapered or cone shapes, segmented shapes, or
combining Flex-Hone globules with other filament
materials.
www.brushresearch.com

Manufacturer of High Quality

Anti Vibration Products

Email: sales@fibet.co.uk
Visit: www.fibet.co.uk | Tel: 01282 878200

45

MACHINE BUILDING & AUTOMATION Packaging

Resist the urge to

blame the robots

Production and packing lines will stop working for a number of reasons,
yet the default assumption and human impulse will often be that a
robotic malfunction is to blame. Paul Wilkinson shares five reasons
whey the buck does not always rest with automated intelligence

Sometimes, when there is an Even with the most well programmed downtime can help to prevent serious
element of complexity or variety robot, needs change after installation. failures.
in an operation, say on a Usually this will be driven by new
packaging line, there’s an customer production requirements. Yet, A good grasp on end effectors: As
assumption that robotics is simply not it’s surprising how often technology is with programming, a robot is only as
up to the job. But let’s look at some of good as its end effectors. Where a single
the issues around robotics that can Utilise the knowledge robot is performing multiple actions and
impact on line efficiency. of line operators to handling a range of pack types and
pre-empt daily challenges sizes, changeovers may involve
A robot is only as good as its substituting an end effector. Robust
programming: It is essential that robots mothballed when it can easily be training and knowledge of processes will
and other automated sections of your reprogrammed to accommodate new ensure the correct tool is selected for the
line are programmed to recognise and production requirements. job. To increase the longevity of different
handle every stock-keeping unit, end effectors store them appropriately.
including all variants at the primary and Good Housekeeping is more than a For example, compressing a grippers
secondary packaging stage. This means magazine: Unless systems offer highly foam pads when not in use can impact
investing an equal amount of time sophisticated self-diagnostics, routine their ability to handle product effectively.
understanding the full project scope as actions like checking accumulation of
selecting and specifying equipment. product residues or dust can help avoid Overall, worker ‘buy-in’ at all levels is
Always check that the appropriate vital sensors being blocked or conveyor critical to seamless automated
programming is available, compatible belts jamming which could trigger an production success. A robotic
and easily accessible. overload. malfunction is likely to be just part of the
story and in most instances robots can’t
With product handling and case Likewise, for smooth, uninterrupted be blamed for a production blip. In fact,
loading, problems may occur when operation, monitor wear and tear on key well-programmed and maintained robots
integrators don’t fully consider the parts. Regular checks during scheduled can liberate your workforce from
movement of the robotic arm from pick mundane, labour intensive tasks,
point to place point, the timings on the enabling everyone to use their time more
line, etc. To ensure all current and future productively and pursue more satisfying
expectations are considered, involve all and professionally challenging career
personnel, from operator level up to paths.
directors, in discussions. www.pacepacker-services.co.uk

Keep your workforce on-side: Rather
than being wary about the impact of
automation, turn your workforce into
champions of the technology. For
operational reasons you may reassign
them to more skilled or technical duties,
however be mindful that in doing so you
could be removing an essential layer of
visual monitoring and inspection.

Instead of relying on short-term
troubleshooting, encourage all
operatives to stay vigilant and take
responsibility for thinking through and
resolving issues that might cause
potential bottlenecks. Give clear,
comprehensive training to those
responsible for line changeovers.

Even the best teams need sound on-
going technical support: The most
clued-up your workforce can benefit
from partnering with integrators that
offer strong, on-going technical support.

INDUSTRIAL TECHNOLOGY • September 2017

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

EXHIBITION PREVIEW

PPMA Show 2017

The PPMA Show, the UK’s unmissable, free-to-attend, processing
and packaging machinery exhibition, returns to the NEC from
26-28 September to provide manufacturers with insights into the
latest machinery products, technologies and materials

The PPMA Show is organised by the Processing to Control Techniques’ achievable elsewhere. Furthermore, the Quattro is also
and Packaging Machinery Association (PPMA) the only Delta robot which is USDA certified and
which comprises the PPMA, British Automation approach to interoperability constructed with materials that are safe for primary food
& Robot Association (BARA) and the UK handling, making it more hygienically-advanced than
Industrial Vision Association (UKIVA). Serving between different existing robots on the market.
manufacturers within the food and beverage,
pharmaceutical, personal care and FMCG industries to communications protocols. Automation specialist RARUK Automation will be
contract packers and more, the show will offer visitors a showing the full extent of its products and systems for the
chance to see new machinery in action, find inspiration, All Control Techniques processing and packaging sectors at PPMA 2017 but
new ideas and solutions, gain access to potential new several areas of its stand have already been earmarked for
suppliers and evaluate and purchase the latest technology drives are designed to new introductions. Among the first to be confirmed is a
as well as talk face-to-face with the industry’s leading new Robotiq gripper system that enhances the
technical experts. overcome the issues productivity of the company’s Universal Robot six-axis,
collaborative robotic arms and a new autonomous mobile
Interesting products on display inherent with using equipment from different suppliers, robot, designed to change the way businesses move
include the AMS300 series materials inside their facilities.
expandable modular box PC from offering users the ability to incorporate Control
iBase. The AMS300 is a compact, For RARUK Automation, Universal Robots and
yet expandable fanless system Techniques’ advanced motor control technologies into an Robotiq grippers and sensors provide the perfect
designed for industrial control combination for off-the-shelf, customised automation
and measurement processes in existing factory with the minimum of hassle. solutions. Widening the scope of this partnership is the
smart factory automation applications. It is powered by new Robotiq Dual Gripper, designed specifically for
7th/6th Gen Intel Core i7/i5/i3 processors and comes HepcoMotion will be showcasing a selection of its machine tending applications, to speed productivity and
integrated with 8GB memory as well as 64GB of relieve employees of repetitive tasks. Indeed, it’s even
industrial-grade SSD storage. An optional 2MB MRAM industry leading range of linear motion technology. Key possible to fit two, Dual Grippers on the same robot to
expansion module is available to store data even without boost output even further.
power. The AMS300 is built with two module products on the stand include the highly-regarded GFX
compartments for PCI-E/PCI cards and Fieldbus modules, With the aid of a ProSeal GT0 automatic in-line tray
giving flexibility to customers to configure the various I/O Hepco Guidance System for Beckhoff XTS (eXtended sealing system on its stand at the PPMA Show, Mitsubishi
required. The unit also features high vibration and shock Electric is demonstrating how the most advanced high-
resistance crucial for deployment in harsh conditions and Transport System). This solution utilises Hepco’s PRT2 speed heat sealing technology and robots are becoming
all interfaces situated on one side for easy assembly and far easier to deploy. The advanced functionality, simple
expansion. and 1-Trak guidance systems to work with Beckhoff’s XTS integration and ease of programming of its automation
technologies are being shown to deliver tangible benefits
Control Techniques will be demonstrating its circuit linear system to meet the needs of higher duty XTS – both for machine builders looking to gain a competitive
advanced servo technologies designed for packaging and edge and for end users looking to increase productivity
processing machinery builders’ industries at the PPMA applications where motion profiles and long-term and flexibility.
exhibition. Among the products being exhibited will be
Control Techniques’ new range of control systems, which durability requirements are particularly demanding. The Discovering how smart sensor technologies help to
offer users the flexibility to choose between distributed or deliver manufacturing flexibility and predictive
centralised control structures. Users can now choose combination of technologies from market leaders Beckhoff maintenance in Industry 4.0-enabled manufacturing and
between using the on-board PLC integrated into the logistics environments will be the focus for Sick UK’s
Unidrive M300, M400 and M600; the complete drive- and Hepco provides users with a robust, high production stand at the PPMA Show. Sick will be unveiling the latest
based machine control solution in the flagship Unidrive Smart Sensors in its rapidly-expanding portfolio of
M700; or the new standalone machine controllers, the and flexible solution that will revolutionise production intelligent solutions for real-time data sharing and IO-Link
MCz600 and MCz200. This flexibility is carried through connectivity. Sick sensors are breaking new ground for
processes in many manufacturing applications. This better productivity and machine availability through
benefits such as more rapid product changeovers,
system is ideally suited to a range of applications, such as transparent track and trace and improved diagnostics.

a variable speed lane divider to sort randomly positioned Interroll will display the world’s most powerful,
stainless steel synchronous drum motor for belt conveyor
items into separate lanes, or a double-sided system for a systems, with a proven output of up to 1.1kW, a high
torque up to 100Nm and high belt tension. With this
compact application that requires multiple motion profiles. drive solution the food and pharmaceutical industries
have an ultra-hygienic and energy-saving option.
As the trend of Industry 4.0 takes the world by storm, www.ppmashow.co.uk

collaborative robots and smart factories are becoming the

latest hot topic. At this year’s PPMA show, HMK will

demonstrate the world’s first collaborative robot with

built-in vision recognition from Techman Robot. The new

TM5 Cobot from HMK merges systems that usually

function separately in conventional robots, the Cobot is

the only collaborative robot to incorporate simple

programming, a fully integrated vision system and the

latest safety standards in a single unit.

Another innovative robot will be on display on the

Omron stand. With a pick rate of 300 per minute, Omron

will debut what it claims is the world’s fastest and most

flexible Delta pick and place robot. The only Delta on the

market with four arms, the Omron Quattro also offers a

larger working envelope and a degree of manipulation not

48 INDUSTRIAL TECHNOLOGY • September 2017

KEY TRENDS: WHEN AND WHERE WILL WE ACTUALLY SEE INDUSTRY 4.0

Industry 4.0
Supplement

September 2017

Introducing a modular
computing platform for
industrial networking

Industry 4.0 Industrial networks

A modular computing
platform for networking

We take a look at Harting’s
MICA computing platform,
which can form the basis for
industrial networking

AMICA (Modular Industrial Computing many of Harting’s customers and partners have completed both the network and the ERP. With the MICA, this data
Architecture) is a modular computing platform projects that exchange data over existing Ethernet and USB stream can be buffered directly on the machine and edited
made from open hardware and software interfaces. With the new Industrial Ethernet variants, it is down to just the business-critical information using proven
components. Unlike single-board computers possible to directly integrate MICA into production networks. tools from the IT world. This cuts costs and radically
such as the Raspberry Pi, the MICA circuit board is simplifies the overall solution.
divided into three parts, one of which can be customised. Many industrial companies have installed their own
The form factor and degree of protection remain complex automation solutions using real-time networks such The introduction of terms like EtherCAT, PROFINET,
unchanged after hardware adjustments. as EtherCAT, Profinet or Ethernet/IP. In Industry 4.0 it is MQTT and OPC UA shows that anyone who wants to
necessary to capture more and more relevant data from converse in the language of the fourth industrial revolution
Software applications run in virtual, Linux-based these systems and pass the data on to the business level via must be fluent in IoT (Internet of Things) terminology. The
containers (virtual machines) which contain all the necessary an ERP system or the Cloud, for example. Both for reasons Node-RED function on the MICA now enables the simple
libraries and drivers for the respective application. This of cost and to maintain the reliability of the automation visual “wiring” of communication networks and the
means that there are no more problems with package network, in virtually all cases it is not possible to build this integration processes of sensors and controls to back-end
dependencies and incompatibilities. concept into the real-time network via additional PLCs. systems and the Cloud.

MICA’s open source approach permits the user to choose MICA offers a cost effective and minimally invasive Industry 4.0 embodies the increasingly comprehensive
the programming language and development environment. option to collect data “on the fly”, as well as to extract networking of the production environment, from individual
Its architecture makes it possible to temporarily save, business-critical data. In such applications, it is connected to sensors all the way to the Cloud. When it comes to the
evaluate and process data in the immediate vicinity of an existing network as a client via standard bus systems and integration of digital components, the use of a large variety
machinery and equipment. The modular open platform cables (for example, D-coded M12 for EtherCAT). New of heterogeneous data models and communication protocols
means that the system can be customised with custom variants of MICA are equipped with built-in EtherCAT, poses a major challenge.
hardware, software and interfaces – to suit users’ individual Profinet and Ethernet/IP function boards. The software
requirements for Integrated Industry applications. environment, developed in collaboration with HMS Industrial In order to realise cross-level system integration, software
Networks, allows these MICA units to be integrated with tools are needed which permit the orchestration of relevant
With dimensions of 13×8×3.5cm, MICA is extremely standard PLC programming environments such as Beckhoff components of the integration process which can be flexibly
compact and fits on the DIN rail in the electrical cabinet. It TwinCAT. enhanced to meet new requirements.
can also be installed discreetly and directly at the machine
or facility. To optimise network connectivity, the front bezel On the MICA side, the data are available in a container Using Node-RED, IBM has developed an open source
can be customised with the proper connectors to fit the and can be processed with all the tools present on the MICA. software tool suitable for the design and integration of
user’s application. The system is designed for harsh For example, the data could be picked up from the EtherCAT modern IoT architectures. Node-RED permits digital
industrial and railway environments. It has no fan and is container using JSON and then sent via MQTT or OPC-UA to components to be “wired” by creating workflows in the visual
maintenance-free. It can be used in metallic environments a Microsoft Azure or SAP Hana Cloud. Alternatively, it is editor, whereby the programming effort when developing
and is resistant to dust, moisture (to IP67) and temperature possible to store data in a MySQL database container on the integration processes can be enormously reduced. Node-
fluctuations. Remote servicing can be performed with a web MICA and then process it with the R statistical language on RED is based on the Node.js programming language, which
browser. the MICA itself (both MySQL and R for MICA are available enjoys great popularity in IoT projects in particular thanks to
free from Harting). There is even the possibility of more than 250,000 available packages and the active open
MICA features a powerful 1GHz ARM processor, 1Gbyte programming the workflow on the MICA graphically using source community.
of RAM and 4Gbyte of eMMC flash memory (expandable up Node-RED.
to 32Gbyte on a micro-SD card). Harting’s virtual industry On the MICA equipped with Node-RED and other
computing technology enables multiple programs to run in The option to pre-process data on the MICA is available packages, new opportunities arise for the flexible
parallel within virtual containers. The containers run in particularly significant: even simple manufacturing facilities and efficient development of integration solutions for data
individual “sandboxes”, thereby isolating and securing the can generate multiple gigabytes of data in the course of a acquisition and pre-processing of sensor and control data
different components and applications from one another. The day, and relaying this directly to the ERP risks overwhelming in back-end systems and in the Cloud.
touch-optimised interface for end users and administrators is www.harting.co.uk
implemented entirely in HTML5 and JavaScript. It can be
customised by developers without any special tools.

The one-time investment for MICA is significantly lower
than for complete industrial PCs. There are no licensing or
leasing fees. The open development environment allows
inexpensive prototyping and development, even for multiple
projects. The power consumption for the base version is less
than 5W. Since the market launch of the MICA in 2016,

50 INDUSTRIAL TECHNOLOGY • September 2017