December 2023 www.mepca-engineering.com
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2023
CONTENTS Editor Chris Callander chrisc@cimltd.co.uk Publication Manager James Davies jamesd@cimltd.co.uk 01795 509105 Account Manager Hannah Moody hannah@cimltd.co.uk 01795 509115 James Burke jb@cimltd.co.uk 01795 509115 Design & Production Grant Waters grant@cimltd.co.uk James Taylor james@cimltd.co.uk Administration Manager Natalie Murray admin@cimltd.co.uk 01795 509103 Credit Facilities Manager Gwen Lee creditcontrol@cimltd.co.uk 01795 509103 Marketing Manager Lucas Payne lucas@cimltd.co.uk Sales Director Tom Woollin tom@cimltd.co.uk Chief Executive John Denning © 2023 TGM Publishing Limited,1st Floor, Saphir House, 5 Jubilee Way, Faversham, Kent, ME13 8GD. No part of this magazine may be reproduced or stored in a retrieval system or transmitted in any form – electronic, mechanical or physical – without express prior permission and written consent of the publisher. Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and addressed envelope. Manuscripts should be typewritten. No responsibility can be taken for drawings, photographs or literary contributions during transmission or in the editor’s hands. In the absence of an agreement the copyright of all contributions, literary, photographic or artistic, belongs to TGM Publishing Limited. The publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed do not necessarily represent the views of the publisher. The publisher cannot accept liability for any loss arising from the late appearance or non-publication of any advertisement.
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December 2023
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ith all the hype currently surrounding large language models like ChatGPT, you would be forgiven for thinking that Artificial Intelligence (AI) and, in particular, its use in manufacturing, is a new thing. But its adoption dates back to the 1980s when advancements in computing power and the development of machine learning algorithms laid the groundwork for more sophisticated AI applications. In these early stages, AI in manufacturing primarily focused on robotics and automation. The introduction of robotic arms and automated machinery, controlled by increasingly intelligent software, revolutionised production lines. These technologies enabled more precise and efficient manufacturing processes, reducing human error and increasing productivity. Yes, it was relatively rudimentary by today’s standards, largely rule-based and lacking the advanced learning capabilities seen in current AI systems. But it was AI in a broad sense. Today, AI systems can process vast amounts of data much faster than humans. In manufacturing, this capability translates into more efficient production lines, where AI can optimise operations for speed and minimal waste. AI algorithms can predict machine failures before they happen and enhance quality control through advanced image recognition and machine learning. AI also enables a higher degree of customisation in manufacturing. AI-driven machines can quickly adapt to new specifications, allowing for smaller batches of customised products without the need for costly and time-consuming retooling. AI plays a crucial role in supply chain management, too, by forecasting demand, optimising inventory levels, and identifying the most efficient delivery routes. While AI can enhance worker safety by monitoring the manufacturing environment and identifying potential hazards. The value AI brings to manufacturing has grown significantly in the last 40 years. And it shows no signs of stopping any time soon. Enjoy the issue. Chris Callander, Editor
@Mepca-magazine To subscribe to MEPCA visit our website www.mepca-engineering.com or scan the QR code.
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CONTENTS Industry Partners:
FEATURES 16 OPINION AEMT
18 COVER STORY Southern Manufacturing & Electronics
20 ROBOTICS Mitsubishi, KUKA and Yaskawa
26 SENSORS & SENSING SYSTEMS Titan Enterprises and Kistler
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34 PACKAGING & INSPECTION Cobalt Systems
36 CALIBRATION Isotech
38 EVENT PREVIEW Tape & Functional Film Expo
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INDUSTRY NEWS
AI and machine learning set to boost industry’s automation push
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anufacturers are set to see a surge in the use of Artificial Intelligence (AI) and Machine Learning as they push for greater automation and improvements in productivity, efficiency and quality, according to a new survey published by Make UK and Infor. The survey, published to coincide with the recent Summit on AI held at Bletchley Park, shows that companies are increasing their investment in automation across a broad range of technologies and functions, from manufacturing processes to product design and development. These investments are set to accelerate in the next two years with greater automation leading to an increase in higher levels of skills and more than a quarter of companies (28%) saying they will have less need for lower skilled roles. However, despite this positive picture, the majority of manufacturers believe the UK is failing to keep up with competitors, while significant barriers to further automation remain in the shape of a lack of technical skills, data integration and workplace culture. In response, Make UK is urging the
government to roll out the successful Made Smarter scheme nationwide to help SMEs adopt digital technologies, as well as work with companies to address the continued shortfall of technical skills in the workforce and reform the Apprentice Levy. According to the survey, more than half of companies (55%) have already implemented or are planning to implement AI and Machine Learning to automate decision-making processes and improve operational efficiency. In addition, four-fifths of companies have already introduced or are planning to introduce Augmented Reality and Virtual Reality techniques in areas such as design and prototyping. This is part of a wider push by companies to invest in automation, with more than threequarters of companies (76%) having already done so, while almost six in ten companies (59%) plan to increase their expenditure compared to the previous twelve months. Furthermore, one in five companies plan to automate between a quarter and half of their processes in the next two years, while a
quarter plan to automate between 10% and a quarter of their processes. These investments are largely in improving manufacturing processes (65% of companies) and product design & development (49% of companies). And companies are seeing significant benefits as a result, in improving productivity (60%), improved labour efficiency (49%) and a similar number seeing improved quality. However, despite this positive picture and increased investment plans, significant barriers to the adoption of automation remain in the form of a lack of technical skills by almost half of companies (46%) and integration and data challenges (41%). More than a third of companies also cited high costs and workplace culture (38% and 36%, respectively) as barriers.
ABB and Imperial College extend carbon capture collaboration
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dedicated carbon capture pilot plant will continue to train the net-zero workforce and engineers and scientists of the future after ABB and Imperial College London signed a 10year contract to extend their successful partnership. The plant is the only one of its kind in an academic institution in the world. More than 4,500 students have had hands-on experience with ABB’s technology solutions at the plant since it opened in 2012 at Imperial College, which is one of the world’s top ten universities with a reputation for excellence in science and engineering. With the agreement, ABB aims to equip today’s students with the skills needed to run tomorrow’s industrial processes by
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demonstrating how the latest technology can help optimise plant performance and safely manage emergency situations in real-life applications. The collaboration between ABB and Imperial College gives the university access to some of the most advanced control and instrumentation technology available from any manufacturer. “Extending the partnership with Imperial College allows us to offer students practical training to prepare them for a career in industry,” said Simon Wynne, Head of Energy Industries, ABB UK & Ireland. “A report by EngineeringUK says that for the UK to meet emissions targets by 2050, there needs to be a workforce, with the right STEM backgrounds, ready to respond to the energy transition challenge.”
INDUSTRY NEWS
Europump chooses the UK for its 2024 gathering
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uropump (the European Pump Association) has announced that after a 10-year absence, its annual meeting and general assembly will be returning to the UK next year. This key event for the European pump sector was last staged in the British Isles back in 2014, when it was held in St Andrews, Scotland. Hosted by the British Pump Manufacturers Association (BPMA) and sponsored by WEG, this three-day event will take place at the De Vere Beaumont Estate near Windsor from May 22 to 24. In support of the current Europe-wide legislative agenda, as well as numerous broader topic areas of significant importance to the international pump sector, the BPMA, on behalf of Europump, will present a comprehensive business agenda of value to pump manufacturers. Commenting on the event, BPMA CEO Wayne Rose said: “A decade after the event held in St Andrew’s we are again delighted to be hosting the Annual Meeting at another world-famous location. Windsor provides a breathtaking backdrop to this important
W gathering for the European pump industry, and the impressive Beaumont Estate offers an unrivalled environment for both business and social interaction. As with previous annual meetings, there will be sessions dedicated to the activities of the various Europump working groups – Technical, Standards, Marketing and SME. However, a number of invited speakers will also share their thoughts and expertise on a range of topical issues, including Digitisation and AI, Sustainability, the post-Brexit political landscape and the world pump market.
Appointments herald a new era for Sprint Electric
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print Electric has announced several key appointments as part of a major expansion programme built around the launch of the groundbreaking Generis AC regeneration drive. Sprint has previously announced an investment of £2m from trusts managed by the Foresight Group private equity business, and from the Midlands Engine Investment Fund. The next stage of the development programme at the company is to bring in a new wave of experienced and knowledgeable professionals. Dorota Hayter joins as Supply Chain Manager, responsible for all aspects of commercial relationships with existing suppliers, developing new supplier relationships and negotiating supply contracts. Vivek Khistariya takes on the role of Senior test and Validation Engineer based
IPP Group announces the acquisition of Cupio
at the technology centre at the University of Nottingham, Hanae Abdala is coming into the position of Quality Manager with a primary objective to put in place a Quality Management System compliant with ISO9001. Meanwhile, Debra Hall is the organisation’s new Company Accountant, strengthening the accounts team with responsibility for the dayto-day running of the financial aspects of the business reporting. The addition of these key personnel will provide specialist expertise to Sprint Electric and support the ambitious growth programme following the Generis launch, which the company says represents a new leap for AC drive technology with cost-effective and highly reliable AC motor control combined with energy regeneration and low input current harmonics.
ith offices in Bromsgrove and Cork, IPP Group, the technical distributor of manufacturing equipment specifically to the electronics, pharmaceutical and medical devices sector, has come to an agreement with current Cupio Owner and Managing Director Andy Bonner, to wholly purchase Cupio, including associated brand Cupio Services. Basingstoke-based Cupio is a distributor of X-ray, acoustic, optical and electronic test and inspection equipment. Established in 2004, Cupio has grown to be one of the primary distributors and technical support functions in the UK. Cupio Services was added as an on-demand inspection and analysis service in 2018. IPP will welcome Cupio and Cupio Services, with them both becoming standalone brands within the IPP portfolio. Jack Daly, Managing Director at IPP, commented: “Cupio has an outstanding reputation in the industry; the technical team and products they offer will be a significant addition to the IPP business as we continue our ambitious growth trajectory. Andy and his team will add tremendous value and expertise, and we look forward to working closely with them. Particularly, the addition of X-ray and CT products and services will no doubt strengthen the overall IPP product offering.”
IPP Group’s Jack Daly (left) with Cupio MD Andy Bonner.
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INDUSTRY NEWS
Five-point plan to grow engineering and technology apprenticeships
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ormer Labour and Conservative ministers Lord Knight and Lord Willetts, with support from charity EngineeringUK, have launched an ambitious new five-point plan for growing and sustaining engineering and technology apprenticeships for young people. Recognising the critical importance of engineering and technology for the UK and the sector’s growing workforce needs, the new report is the culmination of a comprehensive inquiry - seeking to find solutions to reverse the worrying decline in apprenticeship starts seen in the sector over recent years. Based on insights gathered from businesses, education providers and young people, the report contains five key policy recommendations for all political parties to consider. It calls on the government, along with employers and providers, to work together as a matter of urgency to rebalance and refocus apprenticeships to make them accessible for young people. The recommendations are: Rebalance education: Ensure that the
secondary school system is fit for the future, and there is genuine parity of esteem between technical and academic pathways. Recommendations cover curriculum, BTECs, English Baccalaureate (EBacc) and careers. Support young people: Provide better support for young people throughout their apprenticeship journey and take decisive action to break down barriers. Recommendations cover pre-apprenticeship support, benefits, transport and functional skills. Refocus funding: Ensure long-term funding and greater equity between vocational and academic routes. Recommendations include funding degree apprenticeships through the standard higher education fees and loans model and funding apprenticeships for 16- to 19-year-olds
through an increase in the Education and Skills Funding Agency budget. Enable businesses: Enable more SMEs to play an active role in apprenticeships. Work together with employers as well as providers to ensure that engineering and technology apprenticeship standards are given the strategic importance they merit and meet the skills needs of the sector. Recommendations also cover residential options. Employers taking action: Encourage employers to play their part in growing and sustaining apprenticeships for the future and to help widen opportunities for young people. ‘Fit for the future: A 5-point plan to grow and sustain engineering and technology apprenticeships for young people’ is available to download at bit.ly/EUKfftf
HANNOVER MESSE launches new AI conference for industry
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he new ‘AI in Industry’ conference has been announced for 24 January 2024, taking place at the Maindock Eventlocation in Frankfurt. For numerous industrial firms, AI spells new business models, new technologies, new processes and new applications. At the AI conference, experts appearing in three different sessions will employ use cases to illustrate how AI will be changing the face of industry and the steps required to remain competitive. According to the ifo Institute, one out of three industrial companies is already
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using or planning to use artificial intelligence (AI). This became clear at HANNOVER MESSE 2023, where the topic of AI, fuelled by the hype surrounding ChatGPT, was discussed both at exhibitor stands and at the supporting conferences for the event. But AI in industry is more than just a giant language model, presenting unique challenges of its own. Industry is curious about potential business ideas, how trained models are being deployed, and who is responsible for MLOps. “That’s where we come in with our AI conference to offer participants the
opportunity to discuss with the experts in small groups, ask questions and expand their own networks,” said Hubertus von Monschaw, Global Director of Trade Fair and Product Management for HANNOVER MESSE at Deutsche Messe. The conference is a one-day event featuring three sessions: Use Cases, Technology, and Business. The content partners and moderators are Peter Seeberg and Robert Weber from the Industrial AI Podcast.
VISOR® OBJECT AI HIGHLIGHTS • Easy setup without image processing knowledge • AI technology in a robust vision sensor, made for industrial automation • Train the detector with a few images on your PC • Reliable results with strong varying processes and products
Sensopart UK Ltd info@sensopart.co.uk - +44 1664 561539 Find out more at: www.sensopart.com/ai
SOLUTIONS FOCUS
New website for services relating to machine safety
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he Schmersal Group’s service division, tec.nicum, has announced that its new website has been launched. The new website features the new, overhauled corporate design of tec. nicum. The website is now characterised by a clearer and more user-friendly structure and can be reached as before at www.tecnicum.com. The website provides an overview of all services that tec.nicum provides in terms of machinery safety. tec.nicum’s range of services encompasses four pillars, which can be ordered as either individual modules or all-round packages: • tec.nicum academy – knowledge sharing • tec.nicum consulting – consulting services • tec.nicum engineering – conception of safety solutions • tec.nicum integration – practical implementation
The tec.nicum website includes current information on the comprehensive training and seminar programme of the tec.nicum academy, which also includes the new TÜV-certified qualification ‘Machinery CE Certified Expert’. The seminar calendar provides an at-aglance overview of all topics and dates, and events can be booked online through the website. The MRL News magazine, which offers a wealth of well-founded background information on the subject of machinery safety, can also be accessed free of charge via the tec.nicum website, either as an
e-paper or as a downloadable PDF. ‘Since its foundation seven years ago, tec. nicum has successfully evolved as a service provider. In the meantime, the organisation now operates domestically and at different locations internationally. “Our website ensures the best possible accessibility for our services,” explained Siegfried Wolf, Director of tec.nicum. www.tecnicum.com
Industry 4.0 on-premise data intelligence platform
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ICK has launched an Industry 4.0 on-premise data intelligence platform that empowers manufacturing and logistics organisations to optimise their operating performance. SICK Field Analytics can be quickly and easily set up to provide meaningful, applicationspecific condition monitoring and process insights, independently of an organisation’s existing machinery and systems. SICK Field Analytics is a vendor-agnostic digitalisation platform that collects and aggregates data from any source, including sensors, machine controllers and other IIoT devices. The software can be configured to display real-time data, provide timely alerts and alarms, and visualise historical trends through powerful dashboard graphics. Using the SICK Field Analytics software solution and a dedicated computer, users can aggregate data from disparate machines and automation systems or augment legacy
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automation systems to provide additional data insights. The solution is highly scalable, enabling users to adopt it on a project-by-project basis or at a wider Field Analytics’ compressed air monitoring dashboard. organisational level. The SICK Field Analytics software platform can be used Operators can set up and trend key in combination with data extracted from a performance indicators. Through realwide variety of existing sources, including time alerts, they can react more quickly to sensors from any vendor, PLCs, and smart production or process anomalies that might IIoT edge devices such as sensor integration otherwise lead to machine downtime. machines. Where necessary, SICK can Field Analytics can also track overall work with a customer to add smart operating effectiveness and trend sensors and edge devices to machinery other measurements important to an or automated systems as part of a organisation’s profitability and efficiency. For dedicated Field Analytics project. SICK Field example, it could monitor compressed air Analytics is compatible with most common usage or calculate and track the production communications protocols, including Rest costs of energy consumption. API, OPC UA and MQTT. www.sick.co.uk
FIELD ANALYTICS: COMPRESSED AIR MONITORING DASHBOARD.
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SOLUTIONS FOCUS
Beckhoff wins the Industrie 4.0 Innovation Award for its MX-System
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ith the MX-System, Beckhoff offers a flexible, spaceoptimised, intelligent system solution that completely eliminates conventional control cabinets and can thus revolutionise the world of automation. This innovation has now been recognised with the Industrie 4.0 Innovation Award, representing an award for control cabinet-free automation. In the MX-System, Beckhoff has combined over four decades of automation expertise into a modular system that performs all of the tasks and exhibits the properties of a classic control cabinet. The system assembly, consisting of the baseplate and modules, is waterproof and dustproof and can be mounted directly on the machine without any additional protective housing. This innovative system won over the expert jury for the VDE Verlag’s
Industrie 4.0 Innovation Award, along with the readership of etz elektrotechnik & automation and openautomation. Every year, they award prizes to the three best products
that make an enriching contribution to Industry 4.0. The MX-System won first place this year. www.beckhoff.com/en-gb
New class of edge AI industrial cameras allows AI overlays in live video streams
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DS NXT malibu marks a new class of intelligent industrial cameras that act as edge devices and generate AI overlays in live video streams. For the new camera series, IDS Imaging Development Systems has collaborated with Ambarella, a leading developer of visual AI products, making consumer technology available for demanding applications in industrial quality. It features Ambarella’s CVflow AI vision system on chip (SoC) and takes full advantage of the SoC’s advanced image processing and on-camera AI capabilities. Consequently, image analysis can be performed at high speed (>25fps) and displayed as live overlays in compressed video streams via the RTSP protocol for end devices. Thanks to the SoC’s integrated image signal processor (ISP), the information captured by the light-sensitive onsemi AR0521 image sensor is processed directly on the camera and accelerated by its
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integrated hardware. The camera also offers helpful automatic features, such as brightness, noise and colour correction, which significantly improve image quality. “With IDS NXT malibu, we have developed an industrial camera that can analyse images in real time and incorporate results directly into video streams,” explained Kai Hartmann, Product Innovation Manager at IDS. “The combination of on-camera AI with compression and streaming is a novelty in the industrial setting, opening up new application scenarios for intelligent image processing.” IDS NXT malibu has entered series production. The camera is part of the
IDS NXT all-in-one AI system. Optimally coordinated components – from the camera to the AI vision studio – accompany the entire workflow. This includes the acquisition of images and their labelling, through to the training of a neural network and its execution on the IDS NXT series of cameras. www.ids-imaging.com
PUMP SOLUTIONS FOR ALL APPLICATIONS
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SOLUTIONS FOCUS
Optical sensors improve performance for a cheese factory.
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large dairy which produces numerous types of white cheese has improved its ultrafiltration systems using Satron’s optical sensors. The innovative VOD sensor measures the purity of the permeate, (the liquid that has passed through a filter or filtrate) and thus the effectiveness of the filtration. The Satron VOD optical sensor measures the absorption of light by the liquid as it passes the sensor. The absorption is measured with light of different wavelengths depending on the desired application. Its ability to detect remnants of fat, protein or lactose in a liquid, means that it can monitor if there are milk residues in water. Therefore, Satron is trusted to protect quality and productivity by providing 24/7 monitoring and immediate detection of the non-optimal operation of either the ultrafiltration or reverse osmosis processes. A
process operator will be alerted to resolve any problems that arise to quickly optimise the membrane filtration, and resume full capacity. The sensors protect against product loss and also have environmental benefits, helping to ensure more sustainable production. A continuous improvement engineer at the plant explained: “An o-ring seal may fail in the ultrafiltration system, causing a leak, so that the efficiency of the whole system decreases. This is detected by the sensor immediately and gives an alarm to the process operator who can get the o-ring changed, and then the membrane filtration system can get back to full production again. “The sensor measures the purity in the permeate, then registers it immediately if the permeate contains fat or protein – and that’s just fat and protein collected in the retentate. Without the sensor, the valuable fat and
protein would run into the permeate and be lost, thereby the yield of membrane filtration would be significantly reduced” Four Satron VOD optical sensors are installed on the various membrane systems. As the membranes gradually become worn, their capacity decreases until it is time to change the membranes. When the membranes are worn, small amounts of fat, protein or lactose enter the permeate, which the Satron sensor detects. With the information from the sensors and analysis of the permeate, the dairy can change the membranes at an optimal time. plusautomation.co.uk
Leading manufacturer and charitable trust support local foodbank to fight food poverty
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inn & Coales International Ltd. (W.C.I.) and the F.B. Coales No.4 (Family) Trust were delighted to support the Norwood & Brixton Foodbank with a £25,000 donation in 2022. The donation has now funded the hire of an electric delivery vehicle and driver for a 12-month period, increasing food parcel deliveries across the borough. The foodbank, part of the Trussell Trust’s UK foodbank network, is a lifeline for the local community, providing emergency food parcels, advice, and support in times of crisis. Operating since 2011, the foodbank serves all of Lambeth and north Croydon, with a team of dedicated volunteers working to provide much-needed items to families in need. “The sheer scale of the foodbank’s operations is astounding, matched only by the professionalism and kindness of
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the volunteers working there,” said Sarah Hashmi, an F.B. Coales Trustee. “We’re overjoyed to support the foodbank’s great work to reach more families facing food poverty in Lambeth.” W.C.I. is a leading manufacturer W.C.I.’s Sarah Hashmi (far right) joins volunteers from Norwood & and supplier Brixton Foodbank at the unveiling of their new delivery van at St. of corrosion Margaret the Queen’s Church, Streatham. prevention and sealing technologies based in West Norwood, Coales, and today has three trustees and is London. The F.B. Coales No.4 (Family) Trust a registered charity (no. 1179856). www.denso.net was set up by company co-founder Frank
OPINION
Don’t ignore pump maintenance Regular pump system maintenance is essential to prevent significant cost and reputational issues. Thomas Marks, General Manager at the Association for Electrical and Mechanical Trades (AEMT) looks at several issues that poor pump maintenance can lead to and outlines some of the key steps that can be taken to minimise the chance of them emerging.
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ailing to adequately maintain industrial pumps can lead to various issues that can compromise the safety, efficiency, and longevity of the equipment and the wider systems the pumps are part of. One of the most immediate risks is the failure of the pump itself. Worn-out parts, clogged systems, or misalignments can cause a pump to break down, leading to potentially costly unplanned downtime. In addition, further unnecessary costs can be incurred when a poorly maintained pump consumes more energy to deliver the same output. Inadequate maintenance can also accelerate the wear and tear of pump components, leading to more frequent parts replacement and higher maintenance costs. And pumps that are not adequately maintained tend to have a shorter operational lifespan, leading to more frequent pump replacements. Frequent breakdowns, reduced efficiency, and the need for replacement parts can significantly increase operational costs. Worn-out seals or corroded parts can lead to leakages, resulting in the loss of valuable fluids, environmental contamination, and safety hazards. Without proper lubrication or cooling, pumps can overheat, damaging internal components and reducing their lifespan. Other issues, such as misalignment or imbalance, can cause excessive vibrations, damaging the pump and its supporting infrastructure. While cavitation, which can be a symptom of poor maintenance, can damage a pump’s impeller and other components as vapour bubbles in the pumped liquid collapse, causing destructive shock waves. Of course, without regular cleaning, contaminants can enter the pump, affecting the quality of the fluid being pumped and potentially damaging the pump. Leakages, overheating, and equipment failures can pose safety risks to personnel working around the pumps. This can lead
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to accidents, injuries, or even fatalities. While leaks or spills due to poor maintenance can also lead to environmental contamination, which can result in regulatory penalties and damage to a company’s reputation. And for companies that rely on pumps for critical operations, frequent breakdowns or safety incidents can also damage their reputation and customer trust. Indeed, in some industries, ensuring that equipment like pumps are adequately maintained is a regulatory requirement. Failure to comply can lead to financial penalties or legal actions. Regularly inspecting pumps for signs of wear, damage, or corrosion is essential. This helps in identifying potential issues before they escalate. Proper lubrication is also vital for the smooth operation of pumps. It’s essential to use the correct type of lubricant and to ensure it is applied at the correct intervals. Regularly checking and replacing worn-out seals is crucial, as is ensuring that cooling systems are working efficiently to prevent overheating. Vibration can indicate misalignment, imbalance, or other mechanical issues. Regularly monitoring and analysing vibrations can help with the early detection of problems. Ensuring that the pump and its motor are properly aligned is also essential to prevent wear and tear and to ensure efficient operation. As part of condition monitoring solutions, vibration sensors can now continuously monitor a pumping system to identify vibration-related issues as they emerge, and other types of sensors can track a pump’s performance and help to identify problems like reduced flow or increased energy consumption. Systems such as these
can also monitor the state of bearings to enable them to be replaced as soon as any performance issues are indicated. Ensuring the maintenance team is well-trained and updated with the latest maintenance practices is crucial. This ensures that they can identify and address issues promptly and are fully up to date with and following necessary safety protocols during maintenance activities to prevent accidents and injuries. Keeping detailed records of maintenance activities, parts replacements, and performance metrics can help plan future maintenance and identify recurring issues. While having a well-stocked inventory of essential spare parts, which can be informed by historical requirements, can reduce downtime in case of failures. And understanding the expected lifecycle of a pump and planning for eventual replacement or upgrades can help in budgeting and ensuring continuous operations. Industrial pump maintenance is a comprehensive process that involves a combination of regular checks, timely interventions, and proactive measures to ensure the longevity and efficient operation of the pumps. But it is essential if the risks that can lead to wide-ranging consequences, from increased operational costs to safety hazards and environmental damage, are to be avoided and the smooth operation of industrial pumping systems is to be ensured.
Contact: YASKAWA.
Tel: 0330 678 1990
www.Yaskawa.co.uk
COVER STORY
Southern Manufacturing & Electronics becomes truly international In early February, the Southern Manufacturing & Electronics show will return with an even greater international flavour, following a remarkable upturn in interest from overseas companies and strong repeat stand bookings by previous exhibitors.
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ll exhibitors at the Southern Manufacturing & Electronics show will be keen to show their latest products and services to thousands of visitors from the UK, Ireland, continental Europe, and beyond. It is undoubtedly the premier domestic annual trade show serving the engineering sector, with a roughly equal split between mechanical engineering and electrical/electronic. The show has come a long way since its inception in 1997, evolving from a regional gathering of local companies into a globally significant show, a process that accelerated once it moved to the Farnborough International Exhibition & Conference Centre in 2008. It is an essential venue for professionals who are involved in design, development, production, or procurement to visit. It offers a comprehensive platform to explore the latest in machine tools and tooling, workholding, metrology equipment for both tactile and non-contact measurement and quality control, finishing machines, laser cutting and marking equipment, 3D printers and consumables, and industrial hardware.
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On display also will be a vast array of high technology mechanical, electrical, electronic, optoelectronic, electromechanical, hydraulic and pneumatic components and assemblies, as well as PCBs, connectors and sensors, control systems, drives, rotary encoders, linear scales, fasteners, pressings, wireforms, springs, mouldings, gaskets and more. Industry 4.0 solutions will be in evidence alongside controls, displays, HMIs, data acquisition systems, augmented and virtual reality, and robot/cobot machine tending. Automation solutions on both the mechanical engineering and electronics sides will be prominent this year, as they help to alleviate the increasing shortage of skilled
labour in Britain and across Europe. The event also presents a useful opportunity to source subcontract services. Skilled practitioners will present components they have machined from a wide variety of materials, including aluminium billets, iron castings, exotic alloys, sheet metal and engineering plastics. Traditional subtractive machining companies will be joined by others specialising in additive manufacturing, and all will be available to discuss the work they can undertake. Further subcontract engineering services include electronics assembly, finishing, test and inspection, while providers of business consultancy services will similarly be able to outline how
COVER STORY they can help industrial companies to thrive. The Southern show organisers operate an inclusive approach when it comes to stand bookings, ensuring that smaller vendors have a significant presence and are not overshadowed by the major manufacturers. It creates a vibrant atmosphere that fosters a welcoming and collaborative environment, distinguishing it from most other events in the trade show calendar. Although the industries and technologies represented are diverse, there is no separation between the areas, allowing cross-over between the different disciplines. Visitors often comment that it is a facet of the show that is particularly useful, as it encourages a wide-ranging itinerary through the exhibition hall, leading to the discovery of firms specialising in related technologies that would otherwise probably be missed. Technology Trails grouping exhibitors with similar expertise in particular areas help to guide visitors around the event. There will be a strong line-up of machine tool companies taking stands, with Ajax, Bruderer, Chester, Colchester, Hurco, Matsuura, Mazak, Mills, XYZ and YMT already confirmed attendees. Additive-X, Creat3D and Matsuura will be among those promoting 3D printing, 1st MTA, Bison and Thame are three of the firms offering workholding, and Aberlink, Keyence, LK, Mitutoyo, Optimax, Vision Engineering and Zeiss will be there to promote inspection and measurement. Visitors will see the latest developments in power supplies and display technology, with Relec Electronics launching groundbreaking additions to its range. Its classic line-up remains an integral part of the company’s activities, offering versatile AC-DC power supplies and DC-DC converters along with many display options like TFT, HDMI, IPS and Panel PCs. Customisable screen enhancements set the firm apart, making it a clear choice for applications in sectors like rail, instrumentation, medical, marine, military and telecoms. New power products from Vox Power set new standards in efficiency and reliability to address demanding applications. The exhibition will also feature Mactron’s rugged tablets and panel PCs, built to withstand harsh conditions while delivering top performance. Cembre is at the forefront of electrical compression connectors and tooling, cabling accessories and marking systems. The Markingenius MG4 represents the company’s newest solution for identification and labelling requirements.
It is designed to offer high-quality and longlasting printing capabilities for text, logos, electrical symbols, QR codes and various vector images. Jauch Quartz specialises in battery power supplies for mobile devices, offering primary (non-rechargeable) lithium batteries – including the energy-dense lithium thionyl chloride range. The company’s expertise extends to frequency control products, including crystals designed for RF applications and AEC-Q200-qualified crystals for automotive use. Electrolytic, polymer and film capacitors, as well as inductors, transformers and wireless charging solutions, will also be presented. An important part of the show is the extensive technical seminar program. Presentations will provide valuable learning opportunities, with topics spanning advice
for small manufacturers looking to improve their relationship with customers, how to enhance a sales team’s performance, CE and UKCA marking compliance, sustainable practices in manufacturing, management skills coaching, including how to address the challenges of hybrid working, and digital process management. Southern Manufacturing & Electronics 2024 co-locates with AutoAero, a specialised theme within the exhibition focusing on aerospace and automotive engineering. The venue is easily accessible by road and public transport, and there is a complimentary bus service between Farnborough’s Main and North Camp railway stations and the showground. Parking is free, and so is entry to the show. www.industrysouth.co.uk
www.mepca-engineering.com
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ROBOTICS
ESD certification for industrial robot portfolio Mitsubishi Electric has become one of a select few manufacturers to achieve third-party certification for the protection against electrostatic discharge (ESD) across its MELFA family of industrial robots.
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he certification for the The models offer high speed with excellent All models are also compatible with the protection against electrostatic repeatability and are easy to use with clear MELFA Smart Plus card, which can offer discharge (ESD) covers a range visual programming. Key attributes include a variety of intelligent functions such as of MELFA FR horizontal and highly accurate 2D/3D vision and force predictive and preventative maintenance, vertical industrial robots with sensors, in-house motors, highly rigid arms calibration assistance and enhanced a maximum payload of 20kg, as well as the and original drive control technology for vision and force sense control provided RV-5AS-D-ESD industrial collaborative robot. high-torque output at high rotation speeds. by MELFA Safe Plus that enables the safe It has been achieved through interaction of people and the use of a specialist paint industrial robots. on non-loadbearing plastic Barry Weller, Product components, which enables Manager – Mechatronics the entirety of the robot arm at Mitsubishi Electric to be earthed and prevents Automation Systems UK, ESD build-up. commented: “The presence All units have been tested of electrostatic discharge in accordance with EC could spell disaster during 61340-5-1:2016 and ANSI/ the handling and assembly ESD S20.20:2014, which of delicate electrical includes static and dynamic components. Ensuring testing and measurement of your automation equipment triboelectric charges. is working with you, not The certification approves against you, is critical, the MELFA ESD range for especially in high-volume use in a variety of complex production. production environments “Becoming one where the presence of ESD of a select few robot could cause significant manufacturers to secure damage to the components third-party certification for being assembled. Potential protection against ESD applications include is a big step forward for printed circuit board (PCB), Mitsubishi Electric in the semiconductor and silicon UK. Our MELFA FR range chip wafer assembly, as well of vertical and horizontal as the handling of electronic industrial robots has built components throughout the up a strong reputation for automotive, electrical and repeatability and reliability; medical device market. now manufacturers are able The MELFA ESD models to confidently deploy them in incorporate all the core very sensitive environments, functionality of the RVknowing they can be trusted FR and RV-RH range of to perform in a safe and industrial robots, and offer sustainable way.” Mitsubishi Electric has achieved third-party certification for the easy systems integration protection against ESD across its MELFA family of industrial robots. with PLCs, servos and HMIs. bit.ly/MitsBot
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THE WORLD’S SMALLEST ELECTRONIC SOLENOID INTERLOCK SCHMERSAL | Enigma Business Park Malvern, Worcestershire, WR14 1GL
With dimensions of just 119.5 x 40 x 20 mm, the AZM40 by Schmersal is the smallest electronic solenoid interlock in the world. This makes it especially suitable for small safety doors and flaps. Despite its compact size it has an amazing 2000 Newton interlocking force and 25 Newton latching force. Thanks to the 180° angle flexibility of the actuator, it can approach the AZM40 on a stepless basis, making the interlock also suitable for flaps which do not close at 90° or those that open upwards to a 45° angle. This means the angle flexibility helps the interlock easily fit into compact spaces and difficult to access areas. In the event of a power cut, the AZM40 retains the current position. This ensures safe operation, whatever the status of the machine. Even if there are hazardous run-on movements, the safety door remains locked in the event of a power failure. Another advantage of the bistable principle is the consistently low energy consumption, as the interlock only requires power when the door is to be locked or unlocked.
www.schmersal.co.uk uksupport@schmersal.com
ROBOTICS
Cobots are on the move Mobile cobots are gaining popularity in industrial settings. They offer a great mix of flexibility, safety, and efficiency, designed to work alongside humans and boost productivity. KUKA explains what sets them apart from your typical, static robot and how they are revolutionising efficiency and productivity in supply chain management applications.
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obile cobots offer exceptional mobility, effortlessly adapting to evolving tasks and seamlessly transitioning between various locations within industrial facilities. Their rapid reprogramming and redeployment capabilities make them a cost-effective and incredibly versatile solution. By harnessing sensor technology and artificial intelligence, they can navigate dynamic environments, overcome obstacles, and collaborate seamlessly with their human counterparts. This adaptability and proficiency in handling monotonous, laborious, or perilous tasks position mobile cobots as the ideal choice for industries seeking to streamline and optimise their operations, such as logistics, warehousing, and supply chain management. Intralogistics, which entails the management and movement of materials and goods within facilities like warehouses, distribution centres, and manufacturing plants, is increasingly turning to mobile robots for internal material handling and movement. This technology is leading to significant increases in productivity. The logistics industry plays a vital role in the UK economy, contributing approximately £124 billion annually. However, the industry faces a significant shortage of skilled workers, with an anticipated shortfall of 59,000 workers by the end of 2023. This shortage presents significant challenges for businesses in the industry, but those recognising the benefits of automation are successfully overcoming these obstacles and remaining competitive. Traditionally, the logistics industry has heavily relied on manual processes that involve tasks requiring manual handling, lifting, and extensive internal material movements performed by human operatives. These activities contribute limited value to the business, particularly when considering the associated labour costs. Why not delegate these repetitive and monotonous
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tasks to automation, freeing up skilled workers to focus on more intricate and high-value responsibilities, such as inventory management, order processing, and packing? As cutting-edge technologies, like robotics, reshape the future of the supply chain, optimising process flows for an industry pressured by increased demand and fluctuating markets, businesses considering the adoption of automation can enhance their existing processes by utilising mobile cobots. One such solution is the KMR iisy from KUKA. Designed for flexibility and reliability in demanding production facilities and warehouse settings, KMR iisy is an excellent choice for Industry 4.0 applications, as a smart logistics partner. The KMR mobile cobot can move quickly and safely in various workspaces. Its versatility means it can be used at assembly workstations, in intralogistics, and as a robot service system. Consisting of the LBR iisy with a load capacity of either 11 or 15kg and a mobile platform that can carry an additional 200kg, the KMR iisy sets the bar high for logistics 4.0. They use differential
drive for manoeuvrability and can adapt autonomously to their designated routes for efficient navigation around your production facility, even charging themselves at a charging station or during workflows. Imagine a scenario. In a busy e-commerce warehouse, the decision was made to improve the order fulfilment process. A KMR iisy could be introduced to help move and pick items instead of relying on manual workers, navigating the warehouse, and delivering items to human workers for packing. Mistakes could be mitigated, and order accuracy improved. As a result, business efficiency and output could improve while also making the work environment more comfortable for employees, who can focus on high-value tasks like quality control and customer service. The introduction of mobile cobots in intralogistics holds the potential to revolutionise the efficiency and productivity of businesses, clearing the path for a future devoid of bottlenecks and offering a competitive edge. www.kuka.com
Customisable and intelligent sensing The perfect solution for environments where acids, alkaline, solvents and other aggressive liquids or fumes are present and where accurate level or wrong material detection is required. • M18 and M30 in AISI316L stainless steel or PTFE • Programmable sensing distance and hysteresis • Configurable output/input • Sensing modes: single point, two point and windows • Logic, Timer and Logging functions • Alarm outputs • Quality of Run (QoR) and Quality of Teach (QoT)
CA18/CA30..IO Series: 4th generation of TRIPLESHIELD™ capacitive proximity sensors with integrated IO-Link in AISI316L or PTFE housings
SAFETY FOR PERSONNEL AND MACHINE
Carlo Gavazzi UK Ltd. - 4.4 Frimley Business Park, Frimley, Camberley, Surrey GU16 7SG Tel: 01 276 854 110 - www.gavazziautomation.com
More than simply safeguarding Multifunctional Gate Box MGB2 Modular u u
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Safety system with guard locking device Modular layout for maximum flexibility during operation Bus module with PROFINET/ PROFISAFE/ EtherCAT with FSoE
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Expansion module MCM for even more functions
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Category 4 / PL e according to EN ISO 13849-1
www.euchner.co.uk
AZ 178x124 CTM, MGB2 Modular, EKS_UK.indd 3
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ROBOTICS
Robot solution for automated paint centre Robotic specialist YASKAWA is involved in a collaboration that supports customers’ requirements for automated painting solutions, as MEPCA discovered.
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ASKAWA’s expansion into new manufacturing applications is demonstrated by its involvement in a stateof-the-art automated robotic painting technical centre in Derby. The centre represents a highly advanced automated painting solution as a result of collaboration between the centre’s owners, engineering solutions specialist Peak Contracts Ltd, Yaskawa and paint supplier Graco. The centre offers the flexibility of a full turnkey solution for those requiring either a new automated facility or the ability to upgrade to a current manual or automatic installation, enabling customers to apply both solvent and water-based paints using Yaskawa Motoman’s painting robot and the Graco ProBell. An important focus of the technical centre is its support for all aspects of a full turnkey approach. This includes painting robots, electrostatics, rotary atomisers, air guns, up to 3k auto mix, paint mix and supply, complete booths, conveyor systems, 3D programming, safety planning and ATEX compliance. It can also be used to provide customer training in all aspects of automated painting, from mixing and paint supply to robot programming and maintenance. The engineers at Peak Contracts will work with 3D offline programming to understand the Yaskawa Motoman robot requirements in terms of reach and available cycle time. The 3D models, which can be imported into Yaskawa MotoSim, support rapid reach studies and robot programming. This enables customers to choose from the wide range of Yaskawa robots to ensure the most suitable and cost-effective solution for each application. The in-house design team is then able to establish a booth design to house the required robots and equipment, together with the controls department to size and
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design any conveyor system of handling equipment required for the turnkey solution. Peak Contracts offers full paint trials in the new centre, and working together with paint supply companies and customers, a full set of painting parameters can be tested, helping to establish film builds, appearance and laydowns of desired coatings. The Yaskawa robot’s various settings, such as path speed, tool centre point and atomiser settings, can be calculated and approved together with all stakeholders in a project. Commenting on the collaboration with Peak Contracts, Yaskawa’s UK Sales & Marketing Manager Jonny Grey said: “Yaskawa Motoman offers manufacturers a wide range of robotic solutions for today’s automated paint finishing applications, as demonstrated by this successful collaboration with Peak Contracts and its paint delivery partner Graco.” www.yaskawa.co.uk
SENSORS & SENSING SYSTEMS
Flowmeters meet the beverage sector’s demand for growth With consistent growth in the beverage sector forecast for the coming years, Titan Enterprises explains how its certified flowmeter solutions are helping producers rise to the challenges they are facing.
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itan Enterprises maintains certification for its beverage flow meters and 800 Series turbine flowmeters under NSF/ANSI 169 as equipment for food products. This accreditation is especially important for food and drink manufacturers, food production and handling machinery, and processing and dispensing, as these flow meters can be installed securely in the knowledge that they meet NSF standards. These NSF-Approved flowmeters, constructed from food-safe PVDF, are also used in the pharmaceutical and medical industries where end products are consumed. Titan’s beverage flowmeters are widely used to monitor the accurate delivery of beer, cider and spirits in distilleries, to automated batching and dispense systems, bar taps in mobile bars and your local pub. Collaborating with OEMs in today’s modern food and beverage industry, Titan is enhancing production processes such as fast batching, and developing technology capable of differentiating between liquids in the production line, e.g. beer and cleaning solutions. Having been in production for 26 years, Titan’s liquid flow beverage meter is a lowcost measurement sensor used for multiple applications in the food and drink sector. It is an exceptionally effective, economical and reliable method for direct beverage dispensing – beer, coffee, spirits – and dosing additives and colourants, transferring and dispensing accurate and repeatable liquids such as syrups or flavourings into beverages, cider and beer, for example. Neil Hannay, Senior R&D Engineer with Titan Enterprises, said: “Our expertise in beverage applications translates robust and compact design into long-term performance. We offer liquid flow measurement solutions to ensure beverage dispense systems
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Titan’s high-performance NSF-approved turbine flowmeters for batch control systems.
operate consistently every time a glass or bottle is filled!” The beverage industry is evolving fast. The alcoholic drinks market is expected to see continuous growth between 2023 and 2027, and the demand for soft drinks, including fruit juices, is at an all-time high. To meet this rising demand, major beverage producers face challenges related to waste reduction, increased throughput, inventory minimisation, and improved Titan’s NSF-approved beverage flowmeters used quality. Accurate measurement of in bar tap dispense systems. ingredients is crucial, especially for high-value constituents used in small quantities. A ’freshly-blended evolution’ approved beverage flowmeters contribute to where flavours and CO2 are added at the efficient and consistent beverage production point of dispense rather than at the bottling and dispensing solutions, and with over plant, is also being seen by drink producers 24,000 sold each year, they are industryas translating into big environmental and proven worldwide. financial savings. The accuracy and reliability of Titan’s NSFwww.flowmeters.co.uk
KMR iisy flexibility and reliability combined KMR iisy : the autonomous mobile cobot as the optimal solution for industrial environments: The KMR iisy, an autonomous mobile robot, revolutionises the dynamic integration of cobots across various workstations, making it an indispensable solution for automation. Our HRCcapable KMR iisy, an Autonomous Mobile Robot (AMR), boasts swift and secure mobility. This is achieved through the seamless coordination of safety scanners and 3D cameras in tandem with the cobot.
Equipped with a lidar scanner, the KMR iisy not only detects the presence of humans around its platform but also anticipates potential collisions with both humans and the cobot LBR iisy itself. The inclusion of 3D cameras enhances its obstacle detection capabilities, extending up to two meters above the ground. To find out more, or to arrange a hands on user experience, please contact sales.uk@kuka.com or call 0121 505 9970
SENSORS & SENSING SYSTEMS
Piezoelectric measurements to go New handheld devices from Kistler allow for quick and easy on-site measurements.
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istler has introduced the new 5811A handheld family of easy-to-handle, in-field measurement devices with integrated charge amplifiers. The devices enable users of piezoelectric sensors to carry out process parameter verification and quality control processes anywhere. Among other innovative features, the 5811A allows the user to directly display the measurement curve. It also includes a recording functionality to save measurement data on the device. Many different industries rely on piezoelectric sensors to measure mechanical quantities, for example during machinebuilding or maintenance processes. However, some environments – such as the cramped quarters on busy shop floors or in laboratories, where space is scarce – don’t lend themselves to the various conventional systems required for data acquisition, monitoring and visualisation. Here is where the new handheld devices come in. With the 5811A handheld family, Kistler is replacing its proven 5995A charge amplifier with manual reading and 5493 insulation tester. The new 5811A devices have been optimised to cater to today’s more complex needs, offering various additional functionalities combined with unique performance and signal quality.
Similar but different The wide measuring range and highperformance signal conditioning make the 5811A family ideally suited to data acquisition for determining in-situ measuring chain requirements. In combination with the accredited calibration service from Kistler, the new handheld devices can be used as a reference tool to verify the correct sensor operation. To date, the 5811A family consists of two devices – the 5811A00 and the 5811A01– which may look similar but are, in fact, designed to meet different requirements. In addition to being a charge
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amplifier, the 5811A00 model can be used as a service tool for testing the insulation of piezoelectric measuring chains (sensor and cable) to verify the measuring chain quality. The 5811A01, on the other hand, comes with three channels enabling multi-channel measurements. Thus, besides being a charge amplifier, this model can be used as a monitoring device wherever mechanical quantities are measured with piezoelectric sensors, transmitters and Kistler IO-Link devices. Both devices feature a rugged, shock-protected housing and have a graphic, touch-operated screen that allows users to configure the device and visualise the acquired measurement data in numerical form, as a bar or y/t graph. Two side buttons allow the main functions to be operated while wearing gloves. At approximately 800g, the new devices provide a handy, lightweight alternative to the more fragmented and functionally limited solutions of the past, allowing for hasslefree measurement and signal recording on site – without the need for power sources. Made to withstand rough conditions with IP54 protection against dust and splashing water, they offer a wealth of measurement options and can be adapted to various measurement tasks.
User-friendly consistency The evaluation mode allows periodic tests of a process according to user-defined limits. In addition, it provides the possibility of visualising the measurement signal on a customisable gauge graph. The device
can store presets of user-generated measurement configurations, which not only enables a quick exchange between repeatedly executed tasks but also ensures that these tasks are carried out with identical settings, thereby yielding consistent sets of data. This enables users to easily compare, investigate and verify results. The new 5811A handheld devices from Kistler provide a modern, handy solution for users to acquire and visualise data from piezoelectric measuring chains. They offer customisable measurement modes, including recording functionality and a variety of visualisation options, and come with a user-friendly design. The devices ensure reliable, comprehensive process parameter verification and allow for quality control processes even in the most cramped of spaces as well as in the field. www.kistler.com
Up to 30% less assembly time during onsite installation enables efficient equipment changes. Han® Push-In expands the largest variety of termination technologies for industrial connectors.
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Up to 30% less assembly time with direct insertion of the conductor into the contact chamber Easy handling due to toolless termination Cost savings compared to alternative termination technologies Maximum flexibility - suitable for ferrules, stranded wires and solid conductors Compatible with identical products with other termination technologies
One Range. No Limits: www.HARTING.com/push-in
CABLES & CONNECTORS
Smart connectivity for modular machines Sustainability is one of the most important topics in industrial manufacturing, but it is not just the materials used which must be sustainable. Sustainable processes improve efficiencies and save resources and costs by avoiding or shortening machine downtimes. HARTING explains the role smart connectors play in this important area.
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onnectors play a vital role in the design of sustainable processes by offering flexibility, security, and durability. They allow users to quickly connect or disconnect a machine or an attachment and offer peace of mind that all the connections are secure and error-free. This is particularly important with modern modular systems where reconfiguration is frequent. HARTING is a leading global supplier of industrial technology, and its latest Smart Connectivity solutions are designed to improve safety, identify faults, and ensure modular systems are working efficiently. One of the most important additional functions powered by Smart Connectivity is the signalling of the mating state. The mating state can indicate a range of different parameters, including if the connector is electrically connected and whether it is mechanically locked. It can also indicate if the connector is electrically overloaded and monitor whether environmental parameters such as temperature and humidity are within the permitted range. The plug-in status is indicated using a light. In its simplest case, a red or green display shows whether a fault is present. Modern full-colour LEDs can denote other states, such as the presence of voltage. In addition, a digital interface transmits the information in much greater detail to a control centre. The SmEC (Smart Electrical Connector) from HARTING transmits the data via MQTT or OPC-UA PubSub. The data is available in a JSON format and can be received and processed by any controller. The Asset Administration Shell also provides the live data of the connector as a digital twin
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In addition to signalling the mating status, the SmEC prevents unintentional disconnection of the connector using an integrated locking mechanism. The connector can only be disconnected after it has been de-energised and the active lock has been released. The SmEC also has integrated voltage and current measurement, which monitors the connected machine and provides energy consumption data. To safeguard this information, a data diode in the SmEC ensures the data signals flow in only one direction. This allows data to be sent from a protected network to an unprotected network, such as a dashboard. With a data rate of up to 1Gbit/s, IoT protocols such as OPC-UA, MQTT, or Modbus-TCP can be transmitted. The data diode consists of a laser diode on the transmitter side and a photo diode on the receiver side, preventing data from flowing back. Connectors are currently identified using electrical contacts as coding pins, with the machine control system determining which
attachment is plugged in. However, this method has its limits, especially with large, flexible systems. The latest solution identifies the connector with the help of a bus system and microcontroller or, alternatively, via NFC (Near Field Communication). This gives each connector a unique ID, which is assigned to the corresponding attachment or tool. HARTING’s Smart ix enables this solution to be used with very small connectors. The Smart ix is a small 10-pole connector with an integrated microcontroller which establishes a link to the connected component. As a result, even simple components such as lamps, door contacts or analogue sensors can be identified. Another smart solution is the Han Protect, which helps simplify onsite maintenance and reduce downtimes. This connector has an integrated fuse, meaning there is no need to open the control cabinet. Instead, simply disconnect the connector to change the fuse. www.harting.com/UK
LIGHTING
LED solutions: Making the right choice Because of the sheer number of LED lighting and power supply products available, and when having to weigh up factors like efficiency, reliability, adaptability and longevity, finding the right solution can be a challenge. Russell Parr, CEO at PowerLed, explains why finding the right supplier can be the key to finding the right solutions.
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o ensure that lighting solutions are fit for purpose, engineers and managers in processing and manufacturing can benefit considerably from working with a lighting and power supply partner that takes a strategic, tailored approach, rather than a generic supplier. Finding a partner with expertise in both power technology and mass production, and that places its clients’ needs at its core, ensuring that every solution is tailormade for its particular application, will result in lighting solutions that are innovative, reliable and efficient. Of course, to guarantee that products will be reliable and durable, that they can meet a wide variety of requirements, and that they can offer lifespans of 50,000 hours, modern lighting solutions need to be built from highquality components, like advanced LED driver technology and superior chipsets. Hand in hand with their lighting fixtures, engineers and managers need top-quality power supplies. The innovative solutions available today are engineered for both indoor and outdoor environments and come equipped with features such as power factor correction, streamlined design and superior efficiency. While durability is vital, a standout supplier will also provide warranties that extend up to five years and ensure the power supply is CE-approved and certificated to meet UK, European and international safety regulations. When it comes to finding quality, it is also beneficial to seek a supplier that has credible partnerships of its own. In the lighting sector, this includes official Tier 1 partners of Mean Well, a global leader in switching power supply equipment. Such partnerships enable suppliers to offer thousands of premium power supply products.
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More than just products Engineers and managers in the process and manufacturing industries often require application-specific solutions, not just products. This makes a client-focused approach to developing tailored solutions coupled with quality customer service, key features when seeking a reliable and trusted lighting partner. Today, despite many suppliers offering extensive lineups of products, customers struggle to make informed decisions due to a lack of detailed technical information. What they need is a supplier that offers expert advice and tailored technical design support, while offering high-quality LED drivers and lighting solutions that cover the spectrum of applications. It is also advantageous to work with a supplier that, in alignment with the Energyrelated Products (ErP) directive, designs products that combine energy efficiency with resource optimisation. Doing so enables the procurement of lighting fixtures that have enhanced performance and achieve environmental standards, resulting in better value for money and improved returns on
investment. With advancements in LED technology producing increased light output for every watt consumed, lumens have now become the primary metric for measuring luminosity. Finding a supplier that uses lumens instead of watts ensures a more precise indication of an LED’s brightness and enables more informed decision-making around light quality and energy efficiency.
A preferred partner With two decades of industry experience, PowerLed is a trusted leader in the LED lighting and power supply industry. Not only are its products equipped with best-of-breed components, innovative technologies, and EU-compliant parts, but its client-centric approach and dedicated customer service ensure that every client’s needs are met. For engineers and managers in the process and manufacturing industries searching for safe, reliable, cost-efficient and tailored lighting solutions, PowerLed should be the preferred choice. www.powerled.uk.com
BESPOKE AUTOMATION SOLUTIONS Designing, developing and producing innovative special purpose and bespoke automated machinery for manufacturing industries.
Committed to learning and at the forefront of technological developments, our team has diverse experience in specialist technologies such as mechatronics, production automation, vision inspection, robotics, control systems engineering, and so much more, including: • Creating more productive and sustainable businesses through green technology solutions. • Designing manufacturing automation equipment for medical device product assembly and testing. • Bespoke special purpose-built machinery. • At the forefront of technology advances with best-in-class performance solutions in laboratory automation. Our multi-disciplinary team are highly experienced in: • Delivering solutions in regulated industries. • Mechanical, Software and Electronic Engineering. • Expertise in a broad range of advanced manufacturing technologies.
+44 1353 667394
info@innomechgroup.co.uk www.innomech.co.uk
PACKAGING & INSPECTION
Automated labelling for complex packing line Print and apply labelling solutions specialist, Cobalt Systems, has helped a food supply company increase capacity and improve efficiency on a complex packing line with a range of knock-on benefits for the company and its customers alike.
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eynolds Catering Supplies is one of the UK’s best established food supply companies. With nine locations across the UK, and decades of experience, the business delivers high-quality fruit, vegetables, meat, fish, cheese and dairy to the food service industry, from pubs and restaurants to food outlets and contract caterers. The core of the business is greengrocery, which is run from the operational base and company headquarters in Waltham Cross. Delivering fresh fruit and veg to businesses of every size daily requires an efficient pick list system to sort orders into cardboard boxes or plastic totes, depending on customer preference. Every day, Reynolds receives orders totalling circa 8,000 boxes and totes, which need to be labelled at the start of the
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packaging line with pick lists that instruct staff what items need to go in which containers. In the past, Reynolds relied on a very manual process to print and label each tote or box by hand at the start of each shift. They used desktop printers separate from the conveyor line to print the labels before a worker would take each label and apply it manually. This resulted in low-quality labelling, with labels being poorly applied, incorrect, or falling off before they reached the pick lines. Due to labour shortages following Brexit and a drive for greater economic efficiencies, Reynolds turned to Cobalt to automate its labelling. Cobalt implemented an automatic labelling solution capable of labelling both types of containers – totes and boxes – correctly each time. A single machine labels both
the front face and side face as they pass along an inbuilt conveyor. This posed several challenges. The different surface materials, differing angles of applications (with boxes being flat while totes are angled) and the different weights of the boxes themselves. These challenges are dealt with by: 1. Specifying that the right media is used that can cope with both surfaces 2. Using a foam applicator pad that has sufficient leeway to allow for changing angles 3. Physical stops which are built into the conveyor and pop out to hold the different containers in their respective places and ensure enough pressure can be applied The machine is fed data from Reynold’s ERP system, Infor M3. Pick lists are ordered within the ERP and sent to the print and apply machine along with instructions as to whether a box or tote is to be used. These
PACKAGING & INSPECTION are automatically fed onto the conveyor, and a box-making machine sits ahead of the print and apply machine making up boxes in real-time as they are needed. Infor holds the order data and makes up pick lists initially, deriving the order in which each box and tote needs to be packed and picked. This information is then sent to Loftware’s NiceLabel software to prepare the labels and, from there, integrates with the Cobalt machines to print and apply labels. The team at Reynolds determined that more control over the process was needed, especially for more granular changes and for on-the-fly adjustments. As a result, the in-house business development team developed a secondary queueing system before the labelling occurs to allow for manually sorting the totes and boxes, prioritising the items that need to be sent out first and enabling further efficiencies down the picking lines. This combination of technologies and understanding of their operational requirements meant the Reynolds team was able to integrate NiceLabel into its ERP system to efficiently manage the queue at
the beginning of the shift, creating an intuitive workflow for packing produce into the boxes and totes. Secondary to the barcode labelling, each tote box is RFID tagged. This serves two purposes with the data on the tags linked to the barcode data to ensure that the correct items are sent to the correct customer, and so that the totes can be accounted for properly when they return. The finished system can print and apply labels on totes and boxes and label each at a speed of 23 to 26 per minute while applying the labels in the correct orientation. A second machine sits in series with the first but is dormant – only being used if an error occurs with the first, which would stop production. As a result, the capacity of Reynolds’ production lines has increased greatly, with shifts starting later and ending earlier than previously and opening up the potential for fulfilling more orders as the business continues to grow. The changes to their labelling system, and particularly the integration of Loftware’s NiceLabel solution into its ERP system, has
allowed Reynolds to reduce the number of staff needed in this part of the picking line from five to just one, allowing staff to be redeployed elsewhere in the operation. The changes to Reynolds’ operation have also brought about savings in space on the operations floor and created a calmer, more pleasant working environment. Richard Calder, Reynolds’ IT Director, said: “Prior to implementing the Cobalt Print and Apply system, the process was extremely manual, with multiple people tearing off and sorting labels every single day. It was very time-consuming, and we needed to replace it with sensible, cost-effective automation. We’ve achieved that aim, and there is now just one person who oversees that part of our operation.” “Cobalt has a really cohesive team; they all work very closely together, and what’s more, they were imaginative and adaptable. Things change during a project, and Cobalt was very flexible when it came to meeting our requirements. That’s really all you can ask for, and it met that.” cobaltis.co.uk
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CALIBRATION
The crucial role of temperature calibration In our precision-driven world, temperature ranks as the second most measured parameter after time, underpinning industries from medical labs and climate research to manufacturing. David Southworth, Sales and Marketing Director at temperature calibration and measurement specialist Isotech explains how accurate temperature calibration can be assured.
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n a world driven by quality, precision and accuracy, few parameters are as universally measured as temperature. Ranked second only to time, temperature measurement is foundational to a multitude of sectors, from efficient manufacturing to the controlled environments of medical labs and the study of climate change. This underscores an undeniable fact: temperature calibration isn’t just a technical necessity; it’s pivotal to the fabric of modern industry. At its core, calibration ensures that measurements taken by an instrument can be both relied upon and have traceability to a known standard. In the realm of temperature, such calibration ensures that when a device reads 100°C, it genuinely is 100°C, not 99°C or 101°C. For many industries, minor inaccuracies may seem inconsequential. However, as we delve deeper into specific sectors, the magnitude of precision becomes apparent. Temperature calibration is necessary for manufacturing industries to maintain precise and dependable temperature control in various processes, such as the curing of plastics and the heat treatment of metals. This helps ensure optimal accuracy and reliability. Manufacturing companies may encounter several challenges if they do not calibrate temperature correctly; these include inconsistent product quality, safety hazards, failure to comply with regulations, increased costs due to wasted materials, and the requirement for costly equipment repairs or replacements. The food and beverage processing sector also presents unique challenges in temperature calibration and validation, primarily due to the nature of the products
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being handled and the strict hygiene requirements. One major issue is the need to use specialised sensors that can be easily removed for cleaning. These sensors are often mounted using clamp or plug-in style arrangements. However, a common problem arises due to the sensor retention disc’s larger dimension compared to the dry block calibrator used for calibration. Additionally, some sensors have short lengths below the clamping disc, making it difficult to calibrate them accurately.
Temperature calibration challenges In temperature calibration, it’s relatively easy to calibrate the electronic instrument by applying electrical signals to simulate the temperature sensor. But in doing this, you are only validating the instrument – and most instruments are very good and have low drift. Temperature sensors tend to drift more than measuring instruments. However, using a stable heat source allows the whole measuring loop to be calibrated. Isotech has been instrumental in refining the calibration process. With a wide temperature calibration spectrum, ranging from -196°C to +1,300°C, the company’s approach ensures both the sensor and the measuring instrument are accurately calibrated. To handle the more application-specific challenges, for instance those in the food and beverage sector, Isotech develops innovative solutions such as customisable dry block calibrator inserts that enable precise calibration of the short and stubby sensors common in the industry. Additionally, in these applications using a liquid bath as a
heat source, along with reference probes, offers even higher calibration accuracy.
UKAS accreditation Isotech stands out with its ISO/IEC 17025 accredited laboratory and has exceptionally low uncertainties. Such accreditation means businesses can trust in the reliability and accuracy of the calibrations, ensuring that the certified temperatures are as precise as they claim to be, with international traceability. Temperature calibration is not just a technical procedure; it’s a linchpin holding together numerous industries’ efficiency, safety, and accuracy. By addressing common pain points and offering comprehensive solutions, Isotech reinforces the critical nature of temperature calibration and its role in shaping a precise and efficient future. isotech.co.uk
EVENT PREVIEW
Cutting-edge silicone, adhesive, tape and functional film solutions on show With just over two months to go until the 2024 Silicone Expo Europe, co-located with Tape & Functional Film Expo Europe, the events’ organisers are urging interested delegates to register now ahead of the event, which promises to shape the future of engineering.
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ark your calendars for February 28-29, 2024, as the RAI Amsterdam transforms into the epicentre of innovation and expertise at Silicone Expo Europe, co-located with Tape & Functional Film Expo Europe. All engineers, innovators, and industry leaders are invited to a remarkable event that brings together top exhibitors, industry pioneers, and thought leaders. Visitors can discover the latest advancements, gain insights from influential speakers, and forge invaluable connections. Join the industry in shaping the future of engineering. Among the distinguished exhibitors at Silicone Expo Europe and Tape & Functional Film Expo Europe, Elkem, TESA, Wacker, and UTH stand at the forefront of innovation. These industry giants will showcase their cutting-edge silicone applications, adhesive solutions, and functional films. Delegates at the show can explore their booths to witness first-hand the transformative technologies that are reshaping various sectors, from automotive and electronics to healthcare and beyond. Knowledge will be unleashed, and ideas ignited at the Technical Conference, where visionaries from renowned companies will share their expertise. The event boasts a keynote address from Dow, with other sessions delivered by Momentive, HÜBNER, and Sigmasoft, offering profound insights into the latest developments in the industry. Additionally, visitors are encouraged not to miss the engaging panel discussion focusing on the future of 3D printing – a session sure to spark innovative ideas and collaborative discussions.
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Forge connections, fuel collaborations Silicone Expo Europe and Tape & Functional Film Expo Europe offer more than just a platform for learning; they provide unparalleled networking opportunities. Visitors can engage with fellow attendees, industry experts, and exhibitors to exchange ideas, establish partnerships, and explore potential collaborations. The event’s interactive atmosphere fosters connections that can propel projects and initiatives to new heights. “The quality of the conversations on our booth was on a high level, and the organisation of the show was outstanding. Putting the hat of a visitor on, you got the
complete Silicone competence within a manageable size. The Expo exceeded our expectations, and we are more than happy to participate in 2024,” Said Rico Group’s Markus Landl following the 2023 Expo. Anyone with an interest in the silicon, tape and functional film sectors is urged to take this opportunity to be a part of the future of engineering, and visitors can register now to attend Silicone Expo Europe and Tape & Functional Film Expo Europe 2024. Those who do visit the show can embrace the chance to explore groundbreaking technologies, gain insights from industry leaders, and network with likeminded professionals. www.silicone-expoeurope.com
INDUSTRY UPDATES
Intoware launches digital transformation podcast
Five days to complete heat exchanger conversion project
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orkflow automation specialist, Intoware, has launched a new industry podcast to aid businesses embarking on a digital transformation journey. ‘Digital Transformation Bytes’ is available via Spotify and explores the benefits of digitalisation across sectors, including manufacturing, engineering and MRO. It will also include exclusive interviews with companies who’ve already undertaken steps towards digital systems and processes. The first episode is available now, hosted by Intoware’s sales director Brad Flook, discussing how the company’s flagship product, WorkfloPlus and the adoption of digital workflows across industry can enhance efficiency, quality and compliance. Keith Tilley, CEO of Intoware, said: “Our new podcast aims to support businesses looking to move closer towards a more digitalised business. “We know from our work with industry that digitalisation can feel overwhelming, with concerns about employee buy-in as well as data security commonly raised. “This podcast aims to dispel the myths surrounding digital transformation and help industry really reap the rewards of a more efficient and secure way of working, empowering frontline workers while also improving customer satisfaction and quality.” The podcast’s launch comes just weeks after Intoware’s WorkfloPlus was named the first third-party app to be certified by handsfree wearable technology pioneers RealWear for use on its devices. bit.ly/IntoDTB
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ore than 40 years of experience, combined with great teamwork, paid off earlier this year when HRS Heat Exchangers met an extremely tight deadline to convert an existing heat exchanger for a key client.
The project involved a standard BEM-type heat exchanger, which needed converting to make it suitable for high-pressure chemical use. The unit had to be collected from the client’s site, 1,300 km away from the HRS factory in Murcia, Spain; the necessary materials had to be procured; and once the modifications were complete, the unit had to be tested and returned to the client. And all in just five working days. www.hrs-heatexchangers.com
New lighting range shines
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mong a raft of product innovations from C.K Tools, the brand’s all-new lighting range shines bright, with six new, top-of-therange, IP-rated products designed to tackle a multitude of situations for trade professionals, industrial workers and keen DIYers. Three new inspection lights boast robust, durable bodies, supreme battery life, the latest charging technology and ultimate flexibility whether held, magnetised or hooked to an object or standing tall on a swivel base. The T4926USB Mini Inspection Light is a hand-held pocket torch, with an 85lm top light and 150lm main light. The T9427USB Midi shines bright with a main light capable of reaching 400lm. It can also be set to 250lm and includes a 360-degree rotatable hook. Meanwhile, the T9428USB Maxi boasts 750lm, 350lm, and 175lm settings on its main light and a 150lm top light. Two new waterproof site lights join the top-flight of worksite lighting options, with the T9740 capable of 5000lm, and the T9741 reaching a spectacular 10,000lm. Finally, C.K Tools’ new T9429USB Neck Light is a lightweight tool that allows freedom of movement, ultimate convenience, and steady, targeted lighting without placing undue pressure and weight on the head and neck. www.carlkammerling.com
CONNECTIONS 3D Print Manufacturing
Machine Safety
Midlands 3D Printing Units 6-7 Emerald Way, Stone Business Park, Stone, Staffordshire, ST15 0SR T: 01785 594389 E: sales@midlands3d.com W: www.midlands3d.com
Anti Vibration Products, Mounts & Bushes
Schmersal UK Ltd Sparrowhawk Close, Malvern, Worcestershire, WR14 1GL T: 01684 571980 E: uksupport@schmersal.com W: www.schmersal.co.uk
Pipework Systems Jacob UK Ltd Laundry Bank, Church Stretton, SY6 6PH T: 01694 722841 E: sales@jacob-uk.com W: www.jacob-group.com/uk
Fibet Rubber Bonding (UK) Ltd Unit 9 Dale Mill, Hallam Road, Nelson, Lancashire, BB9 8AN T: 01282 878200 E: sales@fibet.co.uk W: www.fibet.co.uk
Control Systems
Robotics & Automation KUKA Robotics UK Ltd Great Western Street, Wednesbury, West Midlands, WS10 7LL T: 0121 505 9970 E: sales.uk@kuka.com W: www.kuka.com
Beckhoff Automation Ltd The Boathouse, Station Road Henley-on-Thames, Oxon RG9 1AZ T:+ 44 (0)1491 410539 E: info@beckhoff.co.uk W: www.beckhoff.co.uk
Dust & Fume Solutions
Rotation Monitoring Equipment Rotech Systems Unit 57, Canal Bridge Centre, Ellesmere Port, Cheshire, England, CH65 4EH T: +44 (0)151 356 2322 E: sales@rotechsystems.co.uk W: www.rotechsystems.co.uk
Impact Technical Services 3 Kingsley Street, Leicester, LE2 6DY T: 0116 244 8855 E: enquiries@impactts.co.uk W: www.impacttechnicalservices.co.uk
Flow Meters
Sensors Titan Enterprises Ltd Unit 2, 5A Cold Harbour Business Park, Sherborne, Dorset, DT9 4JW T: +44 (0)1935 812790 E: sales@flowmeters.co.uk W: www.flowmeters.co.uk
High Shear Mixing Equipment Silverson Machines Ltd Waterside, Chesham, Buckinghamshire, HP5 1PQ T: +44 (0)1494 786331 E: sales@silverson.co.uk W: www.silverson.co.uk
Industrial Communications Brainboxes T: + 44 (0) 151 220 2500 E: sales@brainboxes.com W: www.brainboxes.com
Industrial Fans Axair Fans UK Limited Lowfield Drive, Wolstanton, Newcastle-under-Lyme, ST5 0UU T: 01782 349 430 E: aj@axair-fans.co.uk W: www.axair-fans.co.uk
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Carlo Gavazzi UK Ltd 4.4 Frimley Business Park, Frimley, GU16 7SG T: 01276 854110 W: www.carlogavazzi.co.uk IFM Electronic Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD T: 020 8213-0000 E: enquiry.gb@ifm.com W: www.ifm.com PLUS Automation Ltd Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire, WR9 0LG T: 0121 58 222 58 E: Sales@PLUSAutomation.co.uk W: www.PLUSAutomation.co.uk
Test & Inspection Cupio Services Ltd T: 01256 262800 E: info@cupioservices.co.uk W: www.cupioservices.co.uk
FARNBOROUGH | Hants | GU14 6TQ 6th - 8th February 9.30am - 4.30pm
(3.30pm close Thurs)
Where Industry and Innovation converge
FREE SEMINARS FREE PARKING
Incorporating The Subcontract Engineering Exhibition
Over 600 national and international AUTOMATION suppliers come together to exhibit at DEFENCE Farnborough International Exhibition and Conference FOOD & DRINK Centre this February for Southern Manufacturing AUTOMOTIVE / AUTOSPORT and Electronics (inc AutoAero) 2024. Meet the ELECTRONICS power behind UK manufacturing industry and see AEROSPACE live demonstrations and new product launches of TRANSPORTATION machine tools & tooling, electronics, factory & PACKAGING process automation, packaging & handling, ELECTRICAL & MECHANICAL ENGINEERING labelling & marking, 3D print technology, test & measurement, materials, composites & adhesives, ADDITIVE MANUFACTURING LOGISTICS rapid prototyping, ICT, drives & controls, plastics & MARINE polymers and laboratory equipment. ENERGY
Free industry seminar programme online @ www.industrysouth.co.uk
SPACE ENGINEERING R&D MEDICAL
The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 6th February.
PRE-REGISTER TODAY for your Fast Track Entry Badge, Preview Magazine and Event Catalogue at:
www.industrysouth.co.uk
MATERIALS / COMPOSITES CONSTRUCTION PLASTICS & POLYMERS
SOUTHERN MANUFACTURING & ELECTRONICS is an ETES event organised by European Trade & Exhibition Services Ltd
01784 880890 | philv@etes.co.uk
READY TO ROAR? The new platform for electrifying mobile working machines: Bosch Rexroth brings you eLION www.boschrexroth.co.uk sales@boschrexroth.co.uk