MEPCA Magazine June 2024

JUNE 2024

Ready for anything the future may bring – with automated safety solutions

Manufacturing

Engineering

Process

Control

Automation

NOT JUST SENSORS. COMPLETE INSPECTION SOLUTIONS.

VISIT STAND D3 at UKIVA 2024

EV Battery Cells Inspection

Piston Bowl Volume Inspection

BGA Inspection

lmi3D.com/ukiva24

Our “Vision“:

A first class Industrial camera for every application.

Made in Germany

at S D I Meet 4 E h t boo 18 - 19 June 2024 Coventry, UK

CONTENTS Editor Chris Callander chrisc@cimltd.co.uk Publication Manager James Burke jb@cimltd.co.uk 01795 509105 Account Managers James Davies jamesd@cimltd.co.uk 01795 509105 Jim Bearden jim@cimltd.co.uk 01795 509105

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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 © 2024 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.

June 2024

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he role of software in manufacturing has undergone a dramatic transformation over the past two to three decades. Back in the nineties, the use of software in manufacturing was primarily focused on basic automation and rudimentary computer-aided design (CAD). These early systems, while groundbreaking at the time, were limited in scope and functionality, primarily serving to streamline simple repetitive tasks and facilitate basic design work.

Today, software is the linchpin of the manufacturing industry, driving advancements in productivity, precision, and innovation. Modern manufacturing software encompasses various applications, from sophisticated computer-aided manufacturing (CAM) systems and enterprise resource planning (ERP) solutions to advanced robotics and machine learning algorithms. These technologies have enabled manufacturers to achieve levels of efficiency and accuracy that were previously unimaginable.

One of the most significant changes is the advent of the Industrial Internet of Things (IIoT). IIoT integrates machinery with networked sensors and advanced analytics, providing real-time data that can be used to optimise operations and predict maintenance needs before failures occur.

This shift towards predictive maintenance and real-time monitoring has minimised downtime and maximised output, significantly enhancing operational efficiency.

Furthermore, software-driven innovations such as digital twins, which create virtual replicas of physical systems, allow manufacturers to simulate and optimise processes before implementing them in the real world. This capability speeds up the innovation cycle and reduces costs associated with trial and error.

The evolution of software in manufacturing over that timeframe marks a significant leap forward. And with the pace of change we are experiencing today I can only see that evolution accelerating further.

For examples of how software is bringing huge benefits today turn to our Manufacturing Software focus, which begins on page 31.

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 14 OPINION Make UK and Axair

18 MACHINE VISION CONFERENCE PREVIEW 26 AUTOMATION UK PREVIEW 28 COVER STORY Euchner

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31 MANUFACTURING SOFTWARE FOCUS Tascomp & Intoware

38 HEALTH & SAFETY Rockall Safety & Delta Plus

56 EVENT PREVIEW Subcon & Advanced Engineering

PLUS Test & Measurement, Energy Management, Drives, Motors & Controls, and more

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INDUSTRY NEWS

Manufacturers missing out on £10bn investment potential

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he level of investment by Britain’s manufacturers could be boosted by up to £10 billion in the next year if they were to take advantage of the range of public and private finance options available to them, according to a report published by Make UK, NatWest and Lombard.

Such a boost would raise the investment potential of the sector overall by up to a fifth and help address the UK’s long-term productivity weakness. Furthermore, the report shows that more than a quarter of companies (26%) would increase their investment by up to a fifth if access to finance was improved, while more than one in ten (12%) would increase their investment by up to half. In particular, the report shows access to finance will be critical for companies’ investment plans in the next two years in critical categories such as capital equipment, automation, energy efficiency and cyber security. These investments are essential if the UK is not to fall behind in the race to net zero and in areas such as innovation and robotics.

However, the report also shows that barriers to finance remain, with more than half of companies (54%) unaware of the range of public sources of finance and government schemes tailored towards

manufacturers.

Furthermore, domestic economic and political uncertainty (58% and 42%, respectively), together with the threat of increased costs (54%), is also deterring manufacturers from accessing finance in the next two years.

Boosting investment is critical to the sectors’ efforts to improve productivity and innovation performance, given the top priorities for investment are capital equipment (62%), while access to finance will be required for investment in automation and energy efficiency by a third of companies (32% and 31% respectively). Furthermore, the report also shows almost three-quarters of companies (70%) said that investment would not take place without access to finance, while just under a third (30%) said their investment would have taken place without any access to finance.

However, the report shows that, as well as improved awareness of private financial

options available to manufacturers, there needs to be far greater awareness of the public sources of finance and Government schemes. More than two-thirds of companies (67%) have not heard of the Horizon Europe programme, while a lack of awareness of domestic schemes such as the Government’s flagship management Help to Grow scheme (61%) and British Business Bank (58%) is also alarmingly high. By contrast, just 2% of companies have successfully accessed the Horizon programme, 14% accessed the Help to Grow scheme, and 12% accessed the British Business Bank. According to Make UK, this means the Government must be cautious before scrapping schemes that companies are unaware of.

The report can be downloaded from bit.ly/MakeIiM

OMRON included in the S&P Global Sustainability Yearbook 2024

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MRON Corporation has been recognised as a member in the S&P Global Sustainability Yearbook 2024. This report, one of the world’s most comprehensive publications providing in-depth analysis on corporate responsibility, showcases the sustainability performance of the world’s largest companies. OMRON is receiving this international recognition for its environmental, social and governance efforts within the Electronic Equipment, Instruments & Components industry, for the fourth time

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in a row.

The S&P Global CSA Scores are conducted by S&P Global, one of the world’s leading providers of research and ratings in the field of socially responsible investing (SRI). Over 9,400 globally leading companies in sustainability from 62 different industries evaluated in the 2023 Corporate Sustainability Assessment (CSA) were considered for the Sustainability Yearbook.

Only 759 top-performing companies made it into the 2024 Yearbook, including OMRON. Liu Yue, General Manager of the Sustainability Promotion Office at OMRON,

commented: “We are proud to be recognised for our sustainability efforts, and we believe this prestigious recognition is the result of our ongoing efforts to fully integrate the key sustainability issues identified in our long-term vision, ‘Shaping the Future 2030’, into all of our business activities. Our main mission is to innovate for a sustainable future, and we do this by putting people and the planet at the centre of all our decisions and actions. We will strengthen our collaboration with our employees, customers and business partners and promote information disclosure.”

INDUSTRY NEWS

Free white paper supports compliance with machinery safety standard EN 60204-1

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afe Machine Ltd has published a new white paper, ‘EN 60204-1 for machine builders and panel builders – a guide to avoiding common errors’. Running to fourteen pages, the free publication presents many ways in which machinery often fails to comply with this safety standard’s requirements.

It was written by Derek Coulson and the late Paul Skyrme, both highly experienced machinery safety specialists. Derek Coulson is a consultant with Safe Machine Ltd, as was Paul Skyrme prior to his passing. Having inspected numerous machines and electrical panels, the authors concluded that machine builders and panel builders are not all fully conversant with EN 60204-1 (IEC 602041). Worse than that, on some occasions, end-users specify that electrical equipment is installed in ways that do not comply with the standard. Non-compliant machinery can be dangerous and a fire risk.

The white paper will help engineers and electricians comply with EN 60204-1. In most cases, doing so will not cost more or

take longer. Moreover, ensuring machines and electrical panels are standards-compliant helps to avoid issues arising when customers conduct pre-delivery UKCA/CE marking audits.

EN 60204-1 ‘Safety of machinery. Electrical equipment of machines.

General requirements’ is a designated standard. It, therefore, provides a presumption of conformity when machines are UKCA marked to the Supply of Machinery (Safety) Regulations. This is the equivalent of using harmonised standards when CE marking to the European Machinery Directive – which is still required when exporting from Great Britain to the EU. The non-compliances highlighted in the white paper are equally applicable to machines that are UKCA marked for the

GB market and CE marked for export to the EU. Although it is not a legal requirement to comply with designated/ harmonised standards, doing so is the easiest way to meet the relevant essential health and safety requirements (EHSRs) in the legislation.

The new white paper goes through EN 602041 clause by clause to highlight areas where electrical equipment is often non-compliant. It also explains why non-compliance poses risks to machine users and maintainers. In many cases, the electrical equipment itself is also at risk, which has implications for reliability, availability and the cost of repairs.

To download a free copy of the white paper, ‘BS EN 60204-1 for machine builders and panel builders – a guide to avoiding common errors’, go to bit.ly/SM60204

Yamazaki Mazak honoured with fire service award

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amazaki Mazak has been recognised for its ongoing work in the community as one of the inaugural recipients of the Hereford & Worcester Fire and Rescue Service’s Chief Fire Officer’s Employer Award.

The honour is given to businesses in the Worcester and Hereford areas for releasing their employees to work as on-call firefighters. Christian Leatherdale, Technical Support Engineer at the company’s Worcester-based European Manufacturing Plant, is a Watch Commander for the fire service and is responsible for a crew of 17.

Christian has worked for Hereford & Worcester Fire and Rescue Service for seven years and must live and work within five minutes of a fire station. His role as an

on-call firefighter has coincided with his decade working at Mazak, having joined as an apprentice in the maintenance department before progressing to his current position. Balancing his duties has sometimes presented challenges, yet Christian expresses deep gratitude for Mazak’s unwavering support enabling him to combine his professional commitments with his on-call firefighting duties.

“If I’m on duty and my pager goes, I have to be at the fire station within five minutes,” he said. “That’s regardless of whether I’m at home or at work, so there’s been a few meetings cut short while I’ve been at the office.

“The company’s been very understanding and supportive, though – I have a space in the visitors’ car park to reduce any delay in

Andrew Critcher, Service Manager at Mazak, Christian Leatherdale, Technical Support Engineer (centre) and Ryan Milne, Technical Manager at Yamazaki Mazak with the Chief Fire Officer’s Employer Award.

responding which makes it easier to access when I get a call out. I’m very thankful to the business for helping me continue as an oncall firefighter and rise to Crew Commander and then Watch Commander. They’re definitely worthy recipients of this award.”

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SOLUTIONS FOCUS

Thermal transfer printer for high-quality long-lasting printing

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he MG4 is Cembre’s fourthgeneration thermal transfer printer, which launched in the UK in 2022. The MG4 has been designed and developed through Cembre’s expert knowledge and experience, which has been built over many years in supplying identification and labelling systems. As part of the research and development process for the MG4, Cembre identified unique requirements of its customer base, such as portability and connectivity, and developed the MG4 around these important needs. The MG4 is an industrial thermal labelling printer designed to offer high-quality and long-lasting printing for text, logos, electrical symbols, QR codes and all kinds of vector images. Its reliability and robustness mean that the MG4 can be used intensively, making it suitable for all kinds of applications. A first for the MG4 was the large on-board touch screen enabling

quick and easy management of print projects. This touch screen, combined with both mains power supply and Cembre CAS Alliance rechargeable batteries, means that the machine is truly portable and can be used in the office, in production and on-site, right in front of the panel to be wired.

The interchangeable battery is common to all Cembre 18V tools, such as crimping and cutting tools and is therefore ideally suited to panel builders, cable harness companies, OEMs, electrical contractors, power contractors, maintenance departments and many more.

The rechargeable batteries for the MG4 are capable of up to eight hours printing and can be fully charged in as little as 1 hour 45 minutes, which is one the quickest times on the market.

With the MG4 printer, Cembre offers

innovative solutions to improve the quality of work of its users by exploiting the technology and experience in industrial marking, which has been gained from 20 years within this business sector. The MG4 printer is the most advanced in the market segment in terms of technology, quality, connectivity, and flexibility. www.cembre.com

Emerging as the new go-to sensor for hydrogen applications

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ilicon-on-sapphire (SOS) pressure sensor technology is emerging as an ideal solution for use in hydrogen applications, offering a unique combination of chemical inertness, thermal stability, sensitivity, reliability, and scalability. By harnessing the synergistic benefits of silicon technology and sapphire substrates, SOS pressure sensors provide robust, high-performance sensing solutions that meet the stringent requirements of hydrogen-related industries, paving the way for the widespread adoption of hydrogen as a clean and sustainable energy source.

First and foremost, hydrogen applications demand sensors with exceptional reliability and stability, as hydrogen is highly reactive and can permeate through traditional sensor materials, causing degradation and compromising accuracy over time. SOS pressure sensors address this challenge by leveraging the superior chemical inertness and impermeability of sapphire substrates.

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Sapphire, a crystalline form of aluminium oxide, provides an excellent barrier against hydrogen diffusion, ensuring long-term sensor performance and accuracy even in harsh hydrogen-rich environments.

SOS pressure sensors exhibit remarkable resistance to temperature fluctuations, a critical requirement for applications involving hydrogen, which is often stored and utilised at extreme temperatures. The crystalline structure of sapphire confers exceptional thermal stability to SOS sensors, enabling reliable operation across a wide temperature range without significant drift or performance degradation. This inherent thermal robustness makes SOS sensors particularly well-suited to monitoring hydrogen storage, handling, and utilisation processes, where temperature variations are common.

In addition to their robust chemical and thermal properties, SOS pressure sensors

offer high sensitivity and accuracy, which is essential for precise monitoring and control of hydrogen-related processes. This highperformance sensing capability allows SOS pressure sensors to detect even subtle changes in hydrogen pressure accurately, facilitating real-time monitoring and rapid response to dynamic operating conditions.

Furthermore, SOS pressure sensors demonstrate excellent mechanical robustness and resistance to mechanical shock and vibration, which are key requirements for applications in hydrogen environments where equipment may be subjected to challenging operating conditions. bit.ly/ESISos

SOLUTIONS FOCUS

Experience SEEPEX pumping solutions at The World Biogas Expo

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mprove biogas plant efficiency and reliability with SEEPEX’s advanced progressive cavity pumping technology. Join SEEPEX at stand B25 during the World Biogas Expo on July 10 and 11 at the NEC, Birmingham, to explore innovative solutions for the biogas industry.

SEEPEX offers a comprehensive range of progressive cavity pumps, macerators, and control systems that are suitable for all biogas applications. Its low-energy pumping solutions for biogas are engineered to enhance biogas plant operations, maximise gas yield through efficient product handling, and enable high solids pumping up to 45% DS while ensuring seamless feedstock handling and mixing and delivering precise, low-pulsation dosing for accurate chemical metering.

With SEEPEX Smart Conveying Technology (SCT), biogas plant operators

can experience up to a 200% longer stator life, 85% reduced maintenance time, and extended maintenance intervals. The company’s innovative pump maintenance technologies offer simplified, fast and proactive maintenance, longer pump lifespans, reduced spare parts consumption, lower life cycle costs and enhanced uptime and efficiency.

Through its comprehensive CARE services, SEEPEX ensures the smooth, uninterrupted operation of critical pumps with planned maintenance and regular updates. This proactive approach not only maintains pump availability but also lowers the overall cost of ownership.

Discover SEEPEX’s robust, energyefficient progressive cavity pumps for high solids content, along with its innovative transfer, maceration, and mixing solutions.

Join the team at Stand B25 to explore innovative solutions for the biogas industry.

SEEPEX low-energy pumping solutions optimise biogas operations, maximise gas yield, and handle high solids up to 45% DS efficiently.

Whether you are interested in learning more about SEEPEX’s products and services, discussing any new or challenging pumping applications, or are unable to attend in person, feel free to contact SEEPEX. The company is committed to meeting customer needs and helping them achieve the best results in their biogas processes. www.seepex.com

All-in-one high-performance industrial sensor for countless applications

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he new SICK touchscreen photoelectric W10 is a great problem solver that takes the headache out of choosing a sensor for a huge range of industrial automation applications.

Developed by SICK, a global leader in sensor solutions and applications, the all-in-one W10 is effortlessly adaptable to specific detection tasks. It features a variety of MultiMode functions and configurations, including ‘Speed’, ‘Precision’ and ‘Standard’ modes, teach-in options, and foreground and background suppression, making it easier to identify difficult to detect objects such as those with reflective, dark or uneven surfaces.

The W10 has just four variants (short or long range, cubic or hybrid), delivering ease of selection and unparalleled convenience in purchasing, administration, training, maintenance, and storage of sensors.

Its intuitive, user-friendly touchscreen

interface is a world-first for a photoelectric sensor, and the W10 couples exceptional versatility with outstanding performance.

Alongside an industry leading sensing range of up to 700mm, the powerful photoelectric sensor provides excellent accuracy via a precise laser triangulation sensor with high-resolution receiver array, and a rapid response time of 1.5ms for reliable switching at high speeds.

The W10 offers an intuitive, manual-free set-up through preconfigured settings and multiple teach-in options, and it is fully customisable when installed. IO-Link connectivity enables sensor data to be shared with Industry 4.0 IoT systems for troubleshooting, diagnostics, remote set-up, and edge configurations.

SICK UK Market Product Manager for Presence Detection David Hannaby explained: “The W10 incorporates all of SICK’s extensive knowledge and understanding of sensors and the industrial

automation market into a single device to provide a world class user experience, high performance and almost limitless applications.” www.sick.co.uk

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OPINION

Take a holistic approach to environmental health and safety With effective environmental, health & safety performance a fundamental responsibility of any organisation’s senior leadership, Make UK CEO Stephen Phipson explains the importance of taking a holistic approach which covers leadership, competency and compliance.

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he most important responsibility a company has is to ensure that its people and environment are kept safe from harm. This is not just simply a box ticking exercise to comply with the law and avoid potential prosecution, but a moral imperative to ‘do the right thing’ by employees and the working environment. Those companies that take this view are far more likely to have better productivity, employee morale and better prospects for recruitment and retention of key staff.

Effective environmental, health & safety (EHS) performance within an organisation comes from the top. Senior leaders have both collective and personal responsibility for EHS and developing a positive workplace culture from the top down, which runs through the DNA of the company. For example, if managers are not seen to be wearing PPE then other employees are less likely to wear it. There is no point in training employees how to do risk assessments if pressure from senior management means there isn’t time to do them or if they are seen as a cost. Put simply, EHS initiatives that don’t have the full and active support of senior leaders who own it and drive it through the organisation are doomed to failure.

Rather than looking at EHS initiatives as ‘we’ll send you on a training course’, the best companies take a far more holistic approach which looks at a training programme at three levels and, which benefits people at all levels of

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the organisation. These are leadership, competency and compliance.

Leadership ensures that any senior management team has a buy-in and becomes an asset rather than an obstacle to organisational change. To get your senior team on board, you need to demonstrate why they should care and then give them the tools to do something about it, not just offer off-the-shelf training.

Additionally, leaders need to make tangible commitments and measure success.

Competence is described as having “sufficient training and experience or

knowledge and other qualities”, which comes from a variety of sources. For EHS practitioners, this is likely to come from qualifications provided by organisations such as the Institute for Occupational Safety & Health (IOSH) or the Institute of Environmental Management and Assessment (IEMA). Both of these organisations provide resources and tools, research and knowledge sharing, along with training and qualifications to meet the real-world needs of employees.

Finally, compliance training is a crucial type of training needed to inform employees of an organisation’s regulations, policies, or adherence to laws.

Compliance training is often mandatory for employees because it serves to protect an organisation’s values, policies, and commitment to the law.

Such training could include data and cyber security, data protection and GDPR, basic health and safety training, environmental management, and anti-bullying. However, it will largely depend on the type of activity your organisation is involved in, and training for banking and insurance will be somewhat different for those involved in manufacturing.

By following these three guiding principles, organisations can make a very real difference to their workplace culture and not just keep their people and environment safe from harm, but make a real difference to their performance. www.makeuk.org

OPINION

Putting an end to complacency Andrew Jones Technical Director at air movement specialist Axair Fans UK, thinks it’s time for customers to stop accepting supplier complacency, and to look for suppliers who value them, however big their budget may be.

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ecognising that there’s a problem in an industry run by giants is the first step to ending customer complacency.

However, recognising that viable alternatives exist without the perceived hassle opens huge opportunities to change how you do business.

As customers, we often get so conditioned to an industry that we assume there is only one way of doing something. But as business leaders will understand, there’s rarely one way. In the HVAC industry, there are a handful of excellent customers who have in-depth fan application knowledge, but there are also smallmedium businesses that don’t have the advantage of being completely autonomous in their component sourcing. They lack confidence in their own technical selections and integration techniques, or have a fear of trusting new, unknown suppliers. This creates barriers to future competitive advantage. Fear is a huge driver that leads to complacency. A procurement department tasked with finding components may ignore a lesser-known company that, in culture, value and service, is a better fit for their needs. The reason? Fear, whether real or perceived, that their job would be on the line if something went wrong. This causes teams to ignore the purpose of their job and even do something that isn’t in the company’s best interests.

When it comes to outsourced technical advice or consulting, services are expensive and rigid. Large in-house teams (where in-house technical teams still exist and haven’t been reduced due to economic and financial issues) of people collaborate and agonise over every little detail when one

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smart specialist could be a far more efficient solution.

Imagine approaching a component sales organisation for technical assistance and having one single contact for technical and commercial questions without getting passed from pillar to post when you just need the answer that enables you to move on to the next step. Large companies struggle with this, especially as they’ve grown quickly and lost that attentive value. Customer requests are initially dealt with by customer service, escalated to senior levels, and then passed to the technical department with weeks of delays and customer chasing before being brushed aside. The same can be seen in multiple industries, where larger companies don’t have the time or care for low-spending customers. It’s inevitable that business standards change if allowed to

when companies start working more with larger customers. The cost of that choice falls on the value-added for customers outside of these large golden eggs. For small-medium companies, this poor level of service continually creates complacency, meaning these large companies stop caring and begin to take customers for granted.

From my experience of working in tech and engineering for my entire career, similar-sized business clients have similar needs – to work collaboratively, to be listened to, to have access to an attentive and focused contact ¬– and they’re reliant on the resourcefulness of the technical team in helping to integrate solutions.

Focusing on our niche clients with the customer-centric approach we have at Axair leads to trust, quick decisions, and, honestly, everything moves faster. Customers are individuals, not the companies they work for. We identified early on that the reason for our existence was to enable customers to build better systems, and almost 32 years after our incorporation, we continue to embed our values into the team, forming long-lasting relationships and partnerships with stakeholders.

If you’re coasting by working with suppliers who haven’t stepped up to the mark, then it’s time to think about how you can end the complacency. Yes, it’s always tempting to go after the biggest fish in the pond, thinking it will clearly be the best, but if elements of this are falling short, then consideration should be given to better value-added smaller players who just might be the right partner for your needs. www.axair-fans.co.uk

Pallet Shuttle: driving space efficiency and reduced costs in manufacturing MAXIMISES YOUR SPACE UTILISATION BY REDUCING THE NUMBER OF ACCESS AISLES INCREASES YOUR HANDLING RATES WITH AUTOMATED PALLET RETRIEVAL SPEEDS UP YOUR ORDER FULFILMENT AND IMPROVES BUSINESS CASHFLOW 2-WAY & 4-WAY SOLUTIONS 100% CUSTOMISED TO YOUR BUSINESS NEEDS OPTION TO ADAPT YOUR EXISTING DRIVE-IN RACKING AND/OR RESTORE END-OF-LIFE SHUTTLES

View video and book a free consultation www.pallet-shuttle.com

Experience Vision without Limits Zebra’s acquisition of Matrox® Imaging expands our industrial automation portfolio to support basic track-and-trace applications to complex inspection, recognition and guidance tasks.

More choices from the widest portfolio More agility to scale and adapt in the moment More interconnectivity via easier integration More savings with streamlined solutions

Get more from your vision solutions and stay informed

EVENT PREVIEW – MACHINE VISION CONFERENCE ‘24

Machine Vision Conference hosts an impressive line-up of speakers In a few weeks’ time, the UK’s leading Machine Vision Conference will once again showcase the very latest cutting-edge machine vision technologies and solutions at the CBS Arena in Coventry between June 18 and 19, 2024. This annual confex features exciting seminars, delivered by over thirty industry experts throughout the two-day event.

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he UK Industrial Vision Association (UKIVA), the organiser of the Machine Vision Conference (MVC), is excited to reveal the content-led seminar programme. These seminars have been designed to be both thought-provoking and inspiring as they provide visitors with the opportunity to learn and expand their knowledge about new technological innovations.

The seminar programme delves deep into the world of industrial machine vision and imaging technologies with its broad range of expert sessions. The seminar topics include deep learning and embedded vision, vision in robotics, understanding vision technology, systems and applications, 3D vision, camera technology, optics and illumination, and vision innovation.

One of the experts speaking at the event is Neil Sandhu, Sales Manager at IDS Imaging Development Systems, whose presentation will explain how machine vision is able to utilise a new age of deep learning.

This session looks into the newer technology available to utilise deep learning and AI techniques to develop robust systems for inspection, classification, detection and text/ code reading.

There will also be an opportunity to hear from Nathaniel Hoffman, Market Product Manager at Sick UK, who will discuss the need for vision guidance to help robots know where they are going, which is a growing challenge. This presentation explores a range of technologies and interfaces that can help simplify these obstacles.

This year’s confex will feature a wide range of seminars such as ‘Seeing the unseen Capabilities and advantages of hyperspectral imaging in industrial machine vision’. Mathieu Marmion, Lead Application Specialist at

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Specim, Spectral Imaging, will focus on hyperspectral imaging. This is an area increasingly adopted in advanced industrial machine vision for applications where traditional technologies are insufficient.

The bumper selection of captivating presentations will equip visitors with a vast amount of knowledge on the latest machine vision industry developments and trends.

They will be able to utilise this knowledge which can enhance their operations and accelerate the growth of their business.

A visitor to last year’s MVC, Max Varney, Experimental Specialist at Mercedes AMG F1, said: “Presentations were very industrial, which was a refreshing change to other conferences I’ve been to previously, which were much more academic.”

The Machine Vision Conference is renowned for bringing industry expertise and knowledge under one roof. The 8th staging of the event will provide visitors with plenty to discover and explore with over 50 well-known brands exhibiting their cutting-edge solutions, as well as captivating

demonstrations and product launches.

Exhibitors will be on hand to offer advice and solutions that can deliver improvements for businesses through adopting machine vision solutions.

Another of the 2023 MVC visitors, John Grace, Euro Head of Quality, Product Safety and R&D at Loop, said: “A good selection of companies and an opportunity to learn about new developments and find potential suppliers.” www.machinevisionconference.co.uk/

EVENT PREVIEW – MACHINE VISION CONFERENCE ‘24

3D scanning and inspection technology on show On stand D3 at the Machine Vision Conference, being held in the Coventry Building Society Arena on June 18 and 19 this year, visitors will be able to see a selection of the latest 3D scanning and inspection innovations from LMI Technologies.

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MI Technologies works to advance manufacturing quality and productivity with 3D sensor technology. The company’s award-winning, FactorySmart laser, snapshot, and line confocal sensors improve the quality and efficiency of factory production by providing fast, accurate, reliable inspection solutions that leverage smart 3D technologies.

Unlike contact-based measurement or 2D vision, LMI’s non-contact solutions add 3D shape information that is critical to achieving 100% quality control. It also offers turnkey AI-based solutions to deploy the power of deep-learning-driven visual inspection into industrial production processes.

LMI Technologies actively invests in the continued quality of its manufactured products and the future health of the planet through initiatives such as introducing 100% recyclable eco-smart product packaging, as well as securing third-party ISO 9001:2015 (Quality Management Systems) and ISO 14001:2015 (Environmental Management Systems standards for the Design, Development, Assembly, and Servicing of 3D Imaging Products and Software) certification for its manufacturing facility at the company’s headquarters in Canada.

Gocator 2600 Series On the LMI Technologies stand will be the remastered Gocator 2600 Series of 4K+ smart 3D laser profilers, which has been optimised for faster default scan speeds, enhanced data quality, increased scanning versatility, and higher 4K+ resolutions. The series features 9-megapixel images, up to 4192 points per profile for high-resolution 3D measurement and inspection, X resolutions of up to 2.5 microns, and Z repeatability of up to 0.2 microns. Fields of view up to 2m (at 0.55mm X-resolution) are available,

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as are on-sensor measurement tools, I/O connectivity, onboard multi-sensor alignment and networking support.

Gocator 3500 Series Also on display will be the Gocator 3500 smart 3D snapshot sensors, which combine blue-LED structured light with built-in 3D measurement tools for high-precision area scanning and inspection. As opposed to lasers that are used to scan moving objects, snapshot sensors use a single snapshot scan to inspect stationary objects or objects with start/stop motion.

The Gocator 3500 series features a 5-megapixel stereo camera design, fast scan rates (up to 6Hz with PC or GoMax acceleration) and is pre-calibrated, with up to 20 microns XY resolution with 3D data in a single snapshot. A field of view of up to 282 x 175mm is available alongside accurate 3D measurement with blue LED structured light projection, easy robot integration and an industrial design for long life.

Vision inspection software The Gocator 2600 and 3500 sensors on display will both be running GoPxL, LMI’s latest generation embedded software platform for creating end-to-end, webbased inline measurement and inspection solutions deployed on Gocator 3D smart sensors. Vision engineers can use GoPxL to solve a wide range of industrial inspection tasks, leveraging a combination of on-sensor measurement filters and tools running on Gocator’s industry-leading laser, snapshot, and line confocal sensors.

The demos will also showcase GoPxL’s GoHMI custom user interface for reporting Gocator outputs to the end user, visualising scan data, and providing customisable views of inspection and system metrics. The custom HMI is accessible from any PC, touchscreen, or mobile device connected to the sensor network. www.lmi3d.com

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EVENT PREVIEW – MACHINE VISION CONFERENCE ‘24

Machine vision technology driving automation forward On stand E4 at the UKIVA Machine Vision Conference, 2024, being held at the Coventry Building Society Arena on June 18 and 19 this year, IDS Imaging Development Systems will be demonstrating a series of developments which extend the range of applications for industrial image processing.

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isitors to IDS’s stand at the Machine Vision Conference (MVC) will be able to see how quality inspection benefits from OCR (optical character recognition) with powerful, AI-based image processing solutions such as DENKnet. Also on display will be the recently launched IDS NXT malibu intelligent industrial camera, which enables compressed video streaming in 4K. For 3D vision enthusiasts, IDS will present the 3D camera model Ensenso C. It not only provides point clouds but also 2D RGB images thanks to an additional image sensor. IDS will also bring new uEye 2D models with the exceptional Sony sensor IMX662.

Neil-Steven Sandhu, IDS, explained: “We offer different approaches since the right way to use AI always depends on the customer’s requirements and their specific application.

IDS NXT is our all-in-one vision system that requires neither special knowledge in deep learning nor camera programming. All tools work seamlessly together, from cameras to the AI training software IDS lighthouse.

This makes it very easy to get started with AI-based image processing. DENKnet, on the other hand, is a very powerful system where AI doesn’t run directly on cameras but is performed using GPUs. Both excel in user-friendliness, which is a crucial factor in effectively integrating AI-based camera technology.”

IDS expects both a quantitative and qualitative increase in AI-based applications.

Two factors are key to this. Firstly, the technology is developing further, which means that it is superior in terms of stability and performance, depending on the application. One example is error detection during assembly tests and surface

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inspections. With the help of anomaly detection, relatively small and, above all, unexpected defects can be identified. Its advantage is that the AI learns the target state based on good training images and indicates deviations. Another area of application is OCR. Consistently high quality is important for text and character recognition, regardless of whether there are shape errors due to scoring, embossing or laser engraving, or whether characters are overlaid or incomplete. AI can deal with these special cases and deviations. Usability is also an important driver for the growth of AI in image processing. Access is often more intuitive and simpler than with rule-based approaches. All-in-one systems such as

IDS NXT or the AI vision solution DENKnet set standards. After all, what matters is that a machine vision system delivers the desired results - quickly, cost-effectively and precisely.

At the MVC, visitors can talk directly to the experts from IDS and get support in identifying areas where AI – or other machine vision technology – has the biggest impact.

For this, IDS brings more than 25 years of experience to the table. The company develops powerful, easy-to-use USB, GigE and 3D cameras with a wide range of variants. They are being used in a wide variety of non-industrial and industrial sectors. www.ids-imaging.com

AM-T100 3D CAMERA WITH SONY DEPTHSENSE TECHNOLOGY FOR THE AUTOMATION INDUSTRY. The AM-T100 Time-of-Flight camera (ToF) uses a Sony DepthSense™ sensor to create 3D depth images with millimetre accuracy. The ToF technology enables high-speed 3D imagery of the scene.

With powerful IR illumination and a high image rate of up to 60fps at 640 x 480 pixel image resolution, the AM-T100 achieves a 67° x 51° field of view with a range of up to 6m.

This camera can be used to support, box filling, stacking, volume detection and labelling in logistics and packaging as a means of boosting the efficiency and accuracy of processes.

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EVENT PREVIEW – MACHINE VISION CONFERENCE ‘24

Machine vision software solves complex packaged food challenge Zebra Technologies Corporation, a digital solution provider enabling businesses to intelligently connect data, assets, and people, which is exhibiting on stand A3 at the Machine Vision Conference, 2024, has helped an industrial bakery secure lower error rates and higher throughput of goods with a modern machine vision solution using its Aurora Design Assistant machine vision software.

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he bakery which has employed Zebra’s technology can now inspect its full range of breads using a single machine vision solution, and carry out efficient, automated picking with a robotic grip handling between 25 and 30 packages per minute, without damaging bread or packaging. It’s estimated that the new solution has secured a 75% cost saving compared to traditional camera and lighting inspection approaches.

The industrial bakery approached KINE, a Finnish headquartered provider of turnkey robotics solutions for the food and beverage, logistics, semiconductor, and other manufacturing industries. Together with OEM Finland Oy, a Zebra registered industrial automation system integrator and an advanced machine vision specialisation partner, they were tasked with developing a solution that would overcome several challenges.

A manual process was being used to remove and deposit bags of bread loaves and rolls, which was potentially errorprone and less efficient as irregular bread production sizes and shapes made it difficult to determine their location and orientation on the conveyor belt. Transparent plastic packaging also made detection difficult with optical sensors due to low contrast levels and partial reflections.

“We decided to leverage Zebra’s Aurora Design Assistant machine vision software for its versatile, powerful capabilities that provide the robustness and integration needed to visually inspect the variations in packaged bread,” said Kimmo Salonen, Chief Technology Officer at KINE. The new system consists of a programmable logic controller (PLC), robotic

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grip, 3D time-of-flight camera and Aurora Design Assistant software, which has eliminated the need for multiple cameras and lighting and reduced contrast and reflection problems.

“Basic implementation of the vision system took about one day,” said Sami Sinisalo, Robotic Specialist at KINE. “Testing, adjusting, and fixing took about 80 hours, including time calibrating the robot. That’s a great turnaround and drastically less than what we’d typically have to do for a new 3D install without powerful and user-friendly software.”

The camera is placed above the conveyor belt, with inspection flowcharts created inAurora Design Assistant. The camera takes up to 30 frames per second, recording the bread surfaces as a point cloud with over

300,000 XYZ coordinates. The data is sent to Aurora Design Assistant which converts the data into a depth map for analysis, using 2D vision tools to determine grip points for the robot.

“Challenging manufacturing environments with high levels of compliance and wide variations in components and finished products require powerful machine vision systems to deliver needed outcomes,” said Jason MacDonald, Senior Account Manager, Machine Vision EMEA at Zebra Technologies. “Zebra’s high-performing Aurora machine vision software is moving industries forward and overcoming the problems of legacy systems faced by customers and machine builders.” www.zebra.com

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EVENT PREVIEW - AUTOMATION UK ‘24

Bringing robotics and industrial automation to life The highly anticipated return of Automation UK is fast approaching, with the show once again taking place at the Coventry Building Society Arena, between 18th and 19th June 2024.

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t is expected that this year’s staging of Automation UK will attract a large number of visitors eager to discover the very latest in business solutions offered by the exciting technologies that are an integral part of automation and robotics.

The event is organised and owned by the British Automation and Robot Association (BARA), part of Automate UK, and promotes the uses and benefits of automation and robotics in the UK. Automation UK brings together a wide range of well-known brands to showcase their cutting-edge products and services to visitors who are keen to explore solutions that will deliver improvements to their business operations.

Over 50 companies will be exhibiting their innovative solutions, including robots, robotics systems, systems integration, automation control parts and systems, and sensor and machine safety. Visitors will be able to benefit from meeting exhibiting experts, suppliers, technicians and advisors, all of whom will be on hand to offer their valuable expertise and support.

Commenting on last year’s event, Paul Smith, Product Manager for Mobile Robotics and Automation at RM Group, said: “This is a one stop shop for automation whether that is for an integrator looking for suppliers, or an end-user looking for a solution such as palletising, or any other type of automation, then this is the place to come.”

Visitors will have a fantastic opportunity to learn from the content-rich seminars held throughout the two-day event. These sessions will be delivered by leading industry experts who will share their in-depth knowledge about the latest captivating technologies and solutions. Seminars are designed to inspire visitors to think about how they can put what they have learned into practice in their businesses.

BARA recently announced Vanessa Loiola, the founder of Valoy Automation as a keynote

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speaker at the seminars. Her session will go into detail about enhancing robotic cell performance with strategic programming solutions.

The second keynote session will be delivered by Mike Loughran, Director of Intelligent Devices, Software & Control Business – EMEA North Region at Rockwell Automation. This session will explore how companies can quickly, and easily deploy emerging technologies to support their smart manufacturing goals, whilst helping them overcome some of the challenges facing UK manufacturing.

The packed seminar programme offers something for everyone with its wide range of topics, such as the process of deploying MiR robots successfully, the impact of AI in the food industry, time-of-flight sensors in factory automation, and saving energy using vacuum automation.

Some of the guest speakers include: • Josh Roberts from Festo who will explain how selecting the appropriate field-level control architecture for your machine can influence the performance and build and commissioning time, which has a significant impact on the total machine cost.

• George Thompson, UK Sales Manager at Gudel Lineartec (UK), who will discuss alternative types of industrial robots such as linear robots (gantries). George’s presentation will go into detail about the different sizes of gantry robots and the sectors in which they are used.

• Phillipa Glover from Omron who will focus on manufacturers who are looking to enhance production agility and maximise value at every stage of their processes, including innovative and flexible manufacturing strategies.

The comprehensive seminar programme is available to view here.

Automation UK provides visitors with a great opportunity to network with a broad range of experts, exhibitors and industry peers throughout the show. In addition, visitors can take advantage of visiting the co-located Machine Vision Conference, which is organised by the UK. Industrial Vision Association (UKIVA), which is also part of Automate UK MVC, is a well-established industrial vision and imaging systems event that perfectly complements Automation UK. For more information and to see the full seminar programme, visit the event website. www.automation-uk.co.uk

COVER STORY

A comprehensive approach to safety-related control systems In the dynamic world of industrial engineering, safety is paramount. Yet, a significant gap persists in the knowledge and competence required to design and maintain effective safetyrelated control systems. This gap often leads to inadequate safety measures, risking both personnel and operational integrity. Euchner provides valuable insights into some of the common challenges encountered and offers effective solutions to address them.

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he increasing complexity of modern industrial machinery, combined with the stringent demands of national and international safety standards, including EN 13849 and IEC 62061, presents substantial challenges for organisations.

Many facilities struggle with a fundamental lack of understanding regarding the design, implementation, and maintenance of safetyrelated control systems. This knowledge gap can lead to safety systems that are either overly simplistic or excessively complex, both of which jeopardise safety and operational efficiency.

Common issues Misidentification of safety functions: Without a comprehensive understanding, essential safety functions may be overlooked or improperly defined, leading to ineffective risk mitigation. It is crucial that each safety function is assigned a specific Performance Level (PLr) according to EN 13849. This ensures that the safety measures are adequate and effective. In practice, many engineers mistakenly assign a single Performance Level to an entire machine rather than evaluating each safety function individually. Even functions relating to guardlocking or reset need to be considered when they apply to the safety integrity of the equipment.

Inappropriate selection of safety devices: Choosing incorrect or incompatible safety devices can cause system failures and result in non-compliance with critical safety standards. Examples include the selection of ‘Energise to Lock’ guard interlocks where residual hazards remain, e.g. a running down

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saw blade, the use of easily bypassed lowcoding devices, series connected devices without fault detection.

Insufficient integration and testing: Inadequate integration, a lack of validation planning, and a lack of rigorous testing can render safety systems unreliable, increasing the risk of failure during actual operations. This is especially necessary when programmable or configurable safety controllers are used with software.

Maintenance practices: Without adequate training, maintenance personnel may neglect essential checks and updates, leading to the deterioration of safety system performance over time. Production pressures compound these issues; unfortunately, often the safety interlocks are overridden when issues do occur.

addressed and that the safety measures are proportional to the risks involved. Engineers often make the mistake of defining a single PLr for an entire machine, which can lead to inadequate safety measures. Each safety function may have different risk parameters and, therefore, may require different PLr’s.

Proper training and a clear understanding of EN ISO 13849 guidelines are essential to avoid this common pitfall.

Documenting and verifying safety functions: It is vital to document each safety function and its corresponding PLr, showing how the PLr has been achieved. Verification and validation processes should be in place to ensure that the safety functions meet the required performance levels and that the protective measures are effective.

Safety function identification

Getting it right

Comprehensive risk assessment: Conducting a thorough risk assessment is the first step in identifying all potential hazards associated with machinery operations. Each hazard should be evaluated to determine the necessary safety functions to mitigate the associated risks effectively.

Assigning appropriate Performance Levels (PLr): Once safety functions are identified, it is crucial to assign a Performance Level (PLr) to each control-based function based on the severity of potential harm, the frequency of exposure to the hazard, and the possibility of avoiding the hazard. You wouldn’t normally use a washing machine door switch to protect an operator from entering a robot cell, so how do you determine the required integrity? This detailed assessment ensures that each safety function is adequately

David Dearden, Country Manager at machinery safety expert Euchner, said: “Ensuring a safe machine hinges on the backbone of competence and knowledge, stretching from equipment designers to machinery operators. Organisations must prove their teams are equipped with the essential skills and expertise to design, build, and test robust safety-related control systems. This is where comprehensive training makes all the difference.”

Recognising the need for enhanced competence in the industry, Euchner offers a range of training programs designed to equip engineers and technicians with the knowledge and skills required to design, implement, and maintain effective safetyrelated control systems.

Euchner’s training programs have a proven track record of enhancing safety

COVER STORY

competence across various industries. By empowering engineers and technicians with the necessary knowledge and skills, these programs help organisations achieve higher levels of safety and operational efficiency.

Case study A large manufacturing facility was facing significant challenges with its safety systems due to a lack of knowledge and competence among its engineering staff. The facility had experienced several near-miss incidents, highlighting the need for improved safety measures.

Challenges identified by the company included: • A single PLr applied to all machinery functions, generally misapplied.

• Inadequate risk mitigation for specific high-risk functions.

• Non-compliance with EN 12100 (Risk Assessment), EN 13849 (Control Systems) & EN 14119 standards (Interlocking).

The solution identified included: • A detailed risk assessment. With the assistance of Machinery Safety expert Euchner, the site team conducted a comprehensive risk assessment, identifying distinct safety functions and

their specific risk parameters.

• Assignment of PLrs. Each safety function was assessed against the contribution made to the reduction of the risk, and then assigned an appropriate PL based on its unique risk profile.

• System redesign and training. The safety system was redesigned to incorporate the new PLs, and facility engineers were trained on the proper identification and application of the Performance Levels in accordance with EN 13849. This includes wiring structure and device selection.

The results achieved included: • Enhanced safety compliance. The facility achieved full compliance with the relevant aspects of the legislation in place, including the Provision & Use of Work Equipment Regulations (PUWER) and the Management of Health and Safety at Work Regulations.

• Improved risk mitigation. Safety measures were tailored to each function, significantly improving risk mitigation.

• Increased operational efficiency. The facility experienced reduced downtime and improved overall efficiency due to more effective safety systems.

Unnecessary costs were avoided through

the use of safety solutions designed at a more granular level on the machine determined by the risk being safeguarded, e.g. not using a fully coded RFiD locking device when a simpler low-coding device is adequate.

The future of industrial safety As technological advancements like safety networks, e.g. PROFISAFE, and Safety over IO-Link, become more prevalent, there is an increasing emphasis on the need to demonstrate competence in safety system design and implementation. Regulatory bodies and industry standards now require organisations to validate that their engineers possess the necessary expertise to handle advanced safety technologies and software.

This shift underscores the importance of comprehensive training programs that equip engineers and technicians with up-to-date knowledge and skills. By staying abreast of these evolving trends and ensuring their teams are well-trained, organisations can effectively meet the challenges of modern machinery safety and maintain compliance with stringent safety standards. www.euchner.co.uk

www.mepca-engineering.com

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Focus On: Manufacturing Software

MEPCA explores the latest in manufacturing software

P32 – Real data, real improvements: Empowering manufacturers to make the right decisions

MANUFACTURING SOFTWARE

Real data, real improvements Scott Fletcher, Head of Sales and Marketing at manufacturing software specialist Tascomp, explains how the company’s PlantRun OEE, Machine Downtime and Manufacturing Information System can empower businesses to make the right manufacturing decisions at the right time.

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e all know there are common challenges and goals no matter what industry sector we are in.

We need to become leaner, more efficient, produce far less waste, and ultimately improve productivity throughout.

To top this off, we have limited resources and pressure from our end customers to deliver more, ideally at a lower cost.

Businesses must make tough decisions to move forward. But how do you know it is the right thing to do? Your gut will get you so far, but good data will answer the real questions.

For example, with one timber mill, it was presumed that the operator on one of their stackers was stood waiting for about an hour and a half in an eight-hour shift. After an automatic OEE system was installed, it became clear that it was actually four and a half hours. As a result, the company’s process was adjusted to build up a buffer, and the operator redeployed to other tasks during their ‘newly available’ time.

PlantRun is a manufacturing information system that connects direct to your assets, and delivers live information to where you need it. The information PlantRun can cover includes OEE and other KPI measures, automated data flows, production traceability, the digitising of paperwork, real time visualisation and more.

We are often asked, why implement a system? Is this just another cost, and how will it make a difference? Unless you have a site that is already extremely efficient, in most cases it is possible to get a payback on PlantRun in just a few weeks. After that you are saving money and improving your bottom line.

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Implementing an OEE system will not inherently make you more efficient or save you money. The only way to make it work is by actively using the data it generates.

PlantRun is not a cure-all but will provide accurate, real-time information about your manufacturing process.

One packaging manufacturer told us: “PlantRun has been giving us good meaningful data. In the past we did not

PlantRun will fit to any type of asset, whether that is a machine, production line, work cell, or even a manual operation, and it can be scaled up from monitoring one, to hundreds of assets.

We don’t want to provide a system that creates more data islands. In addition to our extensive machine interfacing capabilities, our software can integrate with a wide range of third-party software around the factory (ERP, MES, CMMS, WMS, etc.).

This ensures that your factory is truly connected.

Growing with you

have such data available. A quick one is that we now know what the biggest time wasters are”. As a result the company has now implemented a callout system for parts, reducing waiting times and improving productivity.

Connect your factory There are numerous examples of business decisions being backed by good PlantRun data.

Throughout our 40 year history, we have seen improvements with all sizes of organisation, regardless of type or location.

You may think manufacturing information systems serve a purpose and are not a long-term solution.

While that may be the case for many on the market, PlantRun has been developed to grow with your needs.

It can be expanded with functionality to remove paperwork and manual data entry from the shop floor. With automatic production tracking (allowing you to respond to stoppages more rapidly), with alerts via text messages, email, public address, or shop floor TV screens.

Energy monitoring can be added (to help you understand the true cost of manufacturing a product), and the list goes on. Not only that, but we can provide bespoke features specific to your needs, to make the system truly yours.

We can also go further. Our Prodigy SCADA System seamlessly integrates with PlantRun – allowing you to mesh process control and monitoring data with production performance data.

All of this allows you to make great decisions, consistently. plantrun.co.uk

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MANUFACTURING SOFTWARE

Digital automation: The key to upskilling the workforce Keeping on top of training and compliance requirements can bring with it a wealth of paperwork and complexities. Keith Tilley, CEO at Intoware, explores the role digitalisation and workflow automation can play in the upskilling of employees.

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t’s no secret that the manufacturing industry is in the grips of a skills crisis.

Since the pandemic, the number of people retiring from industry has soared by more than 87,000 according to Make UK’s Skills 2030 report, meaning the more experienced workforce is declining rapidly, leaving a gap in knowledge and expertise.

The same report acknowledges the impact of automation and digitalisation on the industry, stating that six in ten (59%) of manufacturers identify automation as a ‘trend that is changing jobs and skills needs for their business’.

However, when deployed in the right way, with employees placed at the heart of its implementation, automation and wider digitalisation of workflows can actually help improve the skills of the workforce and ensure quality and compliance standards are met consistently, in the most effective way possible.

But how? With news headlines warning the world of technology’s ability to replace jobs, how can digitalisation be harnessed to retain and upskill staff?

Firstly, digital workflows standardise the steps required to complete a task.

Users can simply move through each instruction, verifying what they do using the digital technology to record images or video.

This immediately removes room for error. Connected frontline workers are each following the same instructions, in the same way, providing peace of mind and accountability when it comes to compliance, ensuring less experienced workers who are new to the company, or who’ve been redeployed, remain consistent and learn fast.

Secondly, the process of following a digital workflow means data is continually being captured in real time.

This data provides valuable insights into the operations of a manufacturer – from the

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time taken to complete tasks to identifying any bottlenecks that are occurring – allowing changes to be made to the workflow to improve the way staff are working.

Changes can be made quickly and easily and pushed out to all workers at the touch of a button, with each worker’s device notifying them immediately of the change.

And, thirdly, training can be rolled out quickly and easily.

Compliance Compliance often requires employees to undertake specific, regular training and hold relevant certifications.

Digital workflows can be used to create training programmes so it’s easy to track and manage what training has been completed by which user.

So, if there’s a clear skills gap within the team, training can be implemented quickly and recorded digitally, ensuring all workers are equipped with the knowledge they need to do their jobs well and can enhance their development regularly without the need for a

wealth of paperwork.

Additionally, as the older workforce retires, digital workflows can offer companies the chance to capture the knowledge of longstanding employees who often have their own tried and tested ways of getting tasks done.

When included in the development of a digital workflow, this expertise, as well as their insights and tips, can be harnessed and included as a step within the digital process, allowing less experienced workers and new recruits to benefit from their knowledge for years to come.

Introducing any new technology to the workforce can be a daunting prospect but, with the right processes in place to ensure employees feel engaged and informed about the changes, digital workflows can be the key to not only increasing productivity and efficiency, but ensuring the team has the skills it needs to do the job well, every time – now and in the future. www.intoware.com

TEST & MEASUREMENT

Qualitative thermography for easy inspections Thermal imaging can provide a fast overview of electrical installation conditions in many applications, with hotspots offering a good indicator of faults when performing comparative thermography. Dr Luke Nicholls, Technical Sales Manager at Quantum Design, outlines key considerations when selecting a thermography solution for electrical installation inspections.

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nspections of electrical installations often focus on detecting hotspots – areas with excessive temperatures.

These can often be found by comparing the same kind of components and identifying different temperatures. For example, one phase can have a higher temperature than other phases due to poor insulation, which results in a creeping current. In many inspection situations, a comparative analysis called qualitative thermography is a suitable option.

Pixel count To provide a clear conclusion in a qualitative thermography inspection, the infrared camera being used needs to come with an adequate resolution. Faults can only be identified by having a sufficient number of pixels.

When inspecting electrical installations, the geometrical resolution, which is the number of pixels available for measurement, should be a particular consideration. The more available pixels, the smaller the hotspots that can be detected from a certain distance and the earlier a developing fault can be discovered, resulting in a more secure inspection result.

Therefore, an infrared camera with a correspondingly large detector format does not determine average values from hotspot temperatures and lower ambient temperatures. Taking average readings would prevent the reliable detection of a hotspot.

Load The load behaviour also plays a vital role in the thermographic analysis of electrical installations as temperature measurements are influenced by the load situation of electrical installations.

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When thermographic measurements are done in low-load situations, hotspots will not be accurately detected as those areas will appear much colder than when the installation is running at full load. Therefore, either the measurements should be carried out at full load, or the measured lower temperatures can be converted to the temperatures that would be measured when running at full load.

Interchangeable lenses Interchangeable lenses allow the flexible usage of infrared camera systems. Often, thermography is used for controlling highvoltage installations outdoors. To do those measurements correctly, full-signal telephoto lenses should be used to measure the smallest details. In contrast, limited space indoors could well result in the need to use wide-angle lenses for coverage of complete switchboards. The ability to change lenses offers the flexibility to adapt to changing applications as needed.

The InfraTecrange of thermography solutions available from Quantum Designs offers a number of advantages for qualitative thermography applications.

All interchangeable standard lens systems of the ImageIR series can be combined with a motor focus unit, which is controlled by the camera operating software. This enables precise, remote, and fast focusing. In addition, an autofocus function is available that operates reliably

even with low image contrasts.

The very robust light metal housing is available with the protection degree IP67 and protects the camera against mechanical and thermal stress. In conjunction with protection degree preserving LEMO connectors, it is excellently suited for use in harsh industrial environments. Suitable protective housings are also available, e.g. made from stainless steel, which can optionally be equipped with a cooling and heating system.

InfaTec’s infrared cameras with cooled and uncooled detectors have native resolutions of up to (1,920 x 1,536) IR pixels.

Spatially high-resolution thermograms ensure that components and assemblies are imaged down to the smallest detail and thus defects can be reliably detected and precisely localised. www.qd-uki.co.uk

HEALTH & SAFETY

Key benefits of a fixed gas detection system Gas detection specialist Rockall Safety explores five key benefits of a fixed gas detection system and outlines key steps to help identify the most appropriate detection solution.

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n certain industrial situations, fixed gas detection solutions may offer advantages over portable alternatives.

Here are five key benefits.

Continuous protection: Fixed gas detectors continuously monitor the surrounding environment to detect specific gases promptly. They utilise various sensing technologies such as electrochemical, infrared, catalytic, or photoionisation detectors.

Cost-effectiveness: The initial investment in installing fixed gas detectors may seem significant, especially for large facilities or complex environments, but the long-term benefits outweigh the costs. Fixed systems provide continuous monitoring, require minimal maintenance, offer scalability and flexibility, ensure regulatory compliance, and enhance safety and productivity in the workplace.

Customisable: Fixed gas detectors offer tailored solutions by providing customisable detection capabilities, flexible sensor technologies, integration with existing systems, environmental adaptability, and application-specific configurations. Fixed detectors enhance safety and mitigate risks by offering flexibility, reliability, and confidence in gas detection.

Seamless communication: Fixed gas detectors are designed to integrate with existing management and safety systems, such as building management systems (BMS), supervisory control and data acquisition (SCADA) systems, emergency shutdown systems (ESD), and fire alarm systems.

Gas detectors can exchange data and trigger coordinated responses with other safety devices and control systems in real time through standardised communication protocols, such as Modbus, BACnet, or OPC. Environmental compliance: Fixed gas detectors facilitate compliance with regulatory reporting requirements by providing accurate and reliable data on gas emissions and exposure levels. Many regulatory agencies

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require organisations to monitor and report emissions of specific gases, such as volatile organic compounds (VOCs), sulfur dioxide (SO2), nitrogen oxides (NOx), or carbon monoxide (CO). Most fixed detectors generate comprehensive records of gas detection events, alarms, and trends, which can be used to demonstrate compliance during regulatory audits or inspections.

Other considerations Each fixed gas detection system is unique, requiring a site survey by a qualified installation engineer. It is strongly advised to consider the following factors during the survey: Location: Assessing the monitoring location, including airflow patterns, is imperative. For fixed-point detection sensors, effective detection relies on gas passage across the sensor.

Hence, if there’s a consistent airflow direction, positioning the gas detector downwind of the suspected leak source is essential.

Alarm functionality: Determining the purpose of the fixed gas detection system is pivotal. In scenarios involving explosive gases or oxygen depletion, the system aims to alert of a gas leak, often through audible or visual alarms signalling a ‘safe – not safe’ status, regulated by the controller’s relay output.

Selection There is a wide range of fixed gas detection equipment, and while many may appear similar at first glance, upon closer inspection, each device boasts distinct functionalities and features, providing unique advantages. It’s crucial to identify your specific requirements before deciding on the most suitable gas detector.

The first step when searching for a fixed gas detection solution involves clarifying the objective such as the health and wellbeing of site personnel, legal compliance or insurers’

requirements. Once the objective is defined, you should have a clearer understanding of what equipment is required.

The next step is to identify the gases requiring detection and their potential hazards.

A well-suited gas detection solution will effectively identify specific gases and prompt warnings before they reach hazardous concentration levels.

Once this information is confirmed, the following steps should be taken.

To determine suitable sensor types, recognise the types of risks present (flammable, toxic, and/or asphyxiant gases).

Define the critical concentration levels that could pose a danger to establish alarm thresholds, sensor placement for fixed gas detection systems, etc.

Identify potential sources of gas leaks to determine the quantity and placement of sensors needed for a fixed gas detection system. If leak sources are unknown, utilising portable gas detectors is advisable. www.rockallsafety.co.uk

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HEALTH & SAFETY

Protective equipment that people want to wear In January 2023, Delta Plus revealed its new slogan, ‘Enjoy Safety’. In just two words, this slogan embodies all the challenges facing professionals who use safety equipment: to benefit from innovative, high-quality, easy-to-use, affordable, stylish and durable solutions.

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ecause personal protective equipment is still too often perceived as a constraint, Delta Plus works alongside its customers to identify and understand their issues and recommend the most appropriate solution for their needs.

As an independent player, it is essential for the company to work hand in hand with its cus-tomers, users and partners, to develop today’s and tomorrow’s products and to have full con-trol over production in its factories.

Because safety is the driving force behind Delta Plus’s commitment, it’s also its trademark. The company takes care of its customers’ safety and creates protective equipment that allows them to concentrate fully on their core business, facilitating their movements or their produc-tivity equipment that people want to wear.

The company’s ambition is to make protection easier in terms of quality, use, choice, availabil-ity and recyclability.

More than just a signature, the slogan is a real promise made by this French independent PPE supplier, and it’s reflected in products at the cutting edge of innovation. Such is the case with the new XTREM LIGHT harness, light as a feather and strong as a rock. With its metal-free back system, it’s the lightest harness on the market. Very comfortable, it adapts to all body shapes and is certified up to 150kg. In addition to its lightness, the strength of this harness lies in its ease of installation. With its two-tone straps (black underneath/yellow piping above), there’s no risk of putting the harness on the wrong way around. And thanks to its side plates, two additional adjustment buckles are all you need for optimum adjustment. Whether you’re wearing gloves or not, the harness is easy to use and manoeuvre, so you can move around safely and easily.

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Delta Plus relies on expertise and technical know-how to fuel innovation and improve performance at its production sites.

To this end, it has set up Centres of Excellence, where technicians and engineers are commit-ted to bringing together the best expertise and resources to advance knowledge in the field of protecting men and women in the workplace.

In the safety footwear segment, Delta Plus naturally turned to Italy, the world’s leading centre for premium footwear in terms of both quality and style.

The company then initiated synergies with players from both within and outside the footwear industry in the form of partnerships or company acquisitions. An example of this cutting-edge technology is the new Aerofit range. Indeed, Delta Plus is revolutionising the PU boot market with its new Aerofit range. The Aerofood model is an S4 CI SRC boot designed for the food industry. It is 45% lighter than PVC, thanks to the new ‘spray injection’ technology. It com-bines comfort and ergonomics with a second-skin effect that moulds perfectly to the shape of the foot. This boot offers excellent performance, with slip resistance 70% above SR standard requirements. What’s more, thanks to its ankle support, the Aerofood prevents premature fa-tigue and musculoskeletal disorders. Last but not least, the Aerofood model is easy to clean, with a sleek design and a style tailored to the food industry.

In 2024, Delta Plus continues to strengthen its brand image with its new website. In addition to its modern design

and technical performance, its ambitions are numerous: to make it easier to choose the right PPE thanks to a simple and comprehensive selection guide, to indicate where to find Delta Plus products, to present each product in the manner of a B2C site, to offer an online ordering space for its distributors, to offer all its media resources via a download centre, to present the latest news from the Delta Plus Group and to facilitate the application process for future talent. Everything has been thought out to ensure that this digital experience is a success and makes customers want to go further with Delta Plus. www.deltaplus.eu

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SUSTAINABILITY

All-plastic bicycles to hit the UK roads The first batch of the all-plastic igus bicycle is in production, while igus builds a high-volume production line.

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he day has finally come. After months of development, the igus:bike, a bicycle made of 92% plastic with a high proportion of recycled material, is in production. The first 100 bikes are being produced while igus is building a dedicated line to increase production to 10,000 bikes per year within two years. This is a step closer to the vision of using plastic waste for future urban mobility solutions in a circular economic model.

Nearly four years ago, Frank Blase, Managing Director of the igus group, started a sustainable project to use mountains of plastic from the world’s rubbish dumps to make plastic bicycles. Durable and maintenance-free urban bikes that are corrosion-free and dirt-resistant, resistant to weather and corrosion for many years, and which could help revolutionise mobility in cities, hotels, exhibitions, campsites, and company premises. A win-win solution for the environment and people.

“I am delighted that we have come a great deal closer to this vision,” said Frank Blase.

“The igus:bike is finally hitting the road under a new brand name, RCYL. After approval for road use, rapid delivery of the first 1,200 pre-orders is planned.”

“To reduce waiting times when orders increase, we are building our own igus bicycle production line at our factory in Cologne. The goal is to produce 10,000 bicycles per year,” said Matthew Aldridge, Managing Director of igus UK. The price for this unique plastic bike is around £1500.

World first The green light for volume production should have been given a few months ago. However, some optimisations for the igus:bike to be as sustainable as possible were time-consuming but necessary. Among other things, igus wanted to increase the

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proportion of plastic in the bike. The few parts made of metal in earlier prototypes, such as the seat post and brake lever, are now made of plastic in the latest version. In addition, the design engineers have increased the steering angle of the handlebars to make the bike easier to turn.

Other new features include a freewheel using longer life xiros ball bearings that allow the wheels to run both lubrication-free and more smoothly, and a bipod stand to park the bike safely. “The igus:bike, which weighs around 17kg, is now 92% plastic – we believe a world first for a production bicycle,” added Matthew. “From the frame to the bearings, it is all plastic and largely recycled.

Even the drivetrain is polymer, which was considered almost impossible in the bike industry for a long time.”

Both rotational and injection moulding are used to manufacture bicycle components from granulate made from recycled plastic waste, including fishing nets classed as plastic ocean waste. In the process, the project’s engineers and materials experts have succeeded in reducing the proportion of virgin plastic mixed in to just 50%.

“We are continuing to invest in research and development to increase the recycled content to 75% as quickly as possible, and even to 100% in the future,” continued Matthew. “With this high recycled content, we are accelerating the circular economy for plastics – and transportation. This means that plastic in the world’s waste stream can become an increasingly valuable resource.” www.igus.co.uk

DRIVES, MOTORS & CONTROLS

Decentralised drive technology with controlled frequency inverters Heavy loads, high forces, long travel distances and lower requirements for precision and dynamics are characteristic of end-of-line packaging. Drive technology specialist NORD DRIVESYSTEMS outlines how, depending on the type of system and application, the use of decentralised drive solutions with controlled frequency inverters can achieve cost benefits of up to 50%,

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rives with centrally controlled servo motors are commonly used in end-ofline packaging. However, in applications with large inertia or long movement distances – for example palletising, stabilising or handling – they are usually not required. Decentralised drive solutions, for example with controlled asynchronous motors, are an efficient and economical alternative in this context. NORD DRIVESYSTEMS is very familiar with the industry’s requirements and implements modular drive concepts that are precisely tailored to the specific application and customer requirements.

Asynchronous motors Due to their higher inertia, NORD asynchronous or permanent magnet motors offer decisive advantages for end-of-line packaging. When moving heavy loads, they ensure better (movement) control than conventional servo solutions that must be adjusted to the respective application via large gear ratios. Furthermore, they enable the highest process stability, reduce vibrations, and reduce the risk of damaging the load or packaging machine. A further advantage is that NORD asynchronous or permanent magnet motors are available everywhere in a wide range, are easy to maintain and can be combined with different types of gear units and frequency inverters.

When used with decentralised frequency inverters, such as NORDAC FLEX SK 200E, NORDAC LINK SK 250E or NORDAC ON SK 300P, components such as control cabinets and wiring are eliminated and the setup effort is significantly lower. An additional important advantage is space saving. With a modular concept, the

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Decentralised asynchronous drive systems with controlled frequency inverters offer decisive advantages in end-of-line packaging.

drive also remains maximally flexible, as changes to the system architecture can be made at any time without large structural modifications, and additional drives can be easily added later without changes to the control cabinet.

Cost benefits of up to 50% Thanks to low procurement costs, constructive freedom in machine design, faster commissioning, simplified maintenance and repair processes, asynchronous motors with decentrally controlled frequency inverters and encoder feedback via absolute or incremental encoders enable highly economical and

precise positioning applications and dynamic movement of large and heavy packaging units. This makes this technology a real alternative for application fields such as endof-line packaging, where heavy loads and high forces are the norm. Depending on the system type and application, the savings can amount to up to 50%.

A white paper titled “Drive technology in end-of-line packaging: Advantages of decentralised drive solutions with controlled frequency inverters”, is available for free download from NORD by following the link below. bit.ly/NORDeolDrives

www.mepca-engineering.com

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INNOVATIONS

Autonomous flying in a swarm With the BionicBee, Festo’s Bionic Learning Network has now for the first time developed a flying object that can fly in large numbers and completely autonomously in a swarm, which the company recently presented at the Hannover Messe 2024.

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or more than 15 years, the Festo Bionic Learning Network has been focusing on the fascination of flying. In addition to the technical decoding of bird flight, the team has researched and technologically implemented numerous other flying objects and their natural principles.

At around 34 grams, a length of 220 millimetres and a wingspan of 240 millimetres, company’s latest project, the BionicBee, is the smallest flying object created by the Bionic Learning Network to date. For the first time, the developers used the method of generative design: after entering just a few parameters, a software application uses defined design principles to find the optimal structure to use as little material as necessary while maintaining the most stable construction possible.

This consistent lightweight construction is essential for good manoeuvrability and flying time.

The bee’s body forms the compact housing for the beating wing mechanism, the communication technology as well as the control components for the wing beats and the adaptation of the wing geometry.

A brushless motor, three servo motors, the battery, the gear unit and various PCBs are installed in the tightest of spaces.

The intelligent interaction between the motors and the mechanics means that the frequency of the wing beats can, for example, be precisely adjusted for the various manoeuvres.

If the bee is supposed to fly forward, the geometry is adjusted so that the lift in the rear wing position is greater than in the forward position. This causes the body to tilt forward (pitch), and the bee flies forward.

If the geometry is adjusted so that the right wing generates more lift than the left wing, the bee rolls around the longitudinal axis

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to the left and flies off to the side. Another option is to adjust it in such a way that one wing generates more lift at the front, and the second wing generates more lift at the rear.

This causes the bee to rotate (yaw) around the vertical axis.

The autonomous behaviour of the bee swarm is achieved with the help of an indoor locating system with ultra-wideband (UWB) technology. For this purpose, eight UWB anchors are installed in the space on two levels. This enables an accurate time measurement and allows the bees to locate themselves in the space. The UWB anchors send signals to the individual bees, which can independently measure the distances to the respective transmitting elements and calculate their own position in the space using the time stamps.

To fly in a swarm, the bees follow the paths

specified by a central computer. To ensure safe and collision-free flight in close formation, a high degree of spatial and temporal accuracy is required. When planning the path, the possible mutual interaction through air turbulence “downwash” must also be taken into account.

As every bee is handmade and even the smallest manufacturing differences can influence its flight behaviour, the bees additionally have an automatic calibration function: After a short test flight, each bee determines its individually optimised controller parameters. The intelligent algorithm can thus calculate the hardware differences between the individual bees, allowing the entire swarm to be controlled from outside as if all bees were identical. www.festo.com/bionicbee

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SENSORS & SENSING SYSTEMS

Conductivity sensor for energy-saving dairy CIP system Sensor specialist Baumer has supplied a Swiss dairy manufacturer with a conductivity sensor which is supporting the phase separation of food materials, water and cleaning agents during a critical Clean In Place stage, and enabling the company to significantly reduce chemical and water usage.

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he food industry is a very important contributor to the Swiss economy, generating around CHF 35 billion, or 3% of its GDP, and the manufacture of dairy products is a major part of producing products which are very popular within the country and abroad.

Züger Frischkäse AG is one of the country’s largest dairy manufacturers, employing around 300 people at its main plant, turning approximately 2.8 million litres of milk into more than 150 different types of cream cheese products, such as cottage cheese, mozzarella and mascarpone.

The familiar challenges of achieving ongoing sustainability and improving processing systems whilst meeting strict legal requirements were the key factors helping Züger to explore and exploit technical advances. A particular focus was how could they optimise their CIP (CleaningIn-Place) processes, and this has resulted in them achieving considerable savings in water and cleaning media, thanks in part to sensor specialist BAUMER. Baumer’s wide range of sensors, encoders, and measuring instruments includes the CombiLyz conductivity sensor, a sensor designed to provide industry-leading precision combined with impressive speed.

Züger use the CombiLyz sensor for the phase separation of food materials, water and cleaning agents, during the critical CIP stage. Thanks to the short reaction time of the temperature compensation, the CIP control system receives an exact measured value from the sensor in just 15s. This ensures that the control system can react promptly to the individual phases by actuating valves quickly and precisely, something which is critical in helping to avoid the serious consequences of a faulty

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or delayed measuring signal. For example, in worst cases the CIP tank can become flooded and the system goes down.

Urs Koster, Divisional Manager for Technical Maintenance at Züger, commented: “Whilst our priority was to avoid the consequences of a faulty or delayed measuring signal, we also wanted to optimise efficiency, which is why the quick and reliable reaction of the CombiLyz sensor is so important.

“The success of the optimisation of our CIP procedures is significant; now we consume up to 30% less in cleaning agents, up to 50% less disinfectant and up to 100,000l less water every day”.

The design of the CombiLyz features a probe made of PEEK plastic as part of a one-piece hygienic design, and an important

factor is its ability to provide fast temperature compensation, as well as housing the inductive sensor elements for measuring the electric conductivity and the temperature sensor. The sensor tip has a low thermal mass and low thermal transition resistance, enabling the sensor to react very quickly, even at significant temperature fluctuations.

Whilst sensors with two-part probes, where the temperature sensor is located underneath metal, are a little faster, the frequent temperature fluctuations in these types of CIP applications put additional thermal strain on the transition between plastic and metal. As a result, frequent cracks can occur, causing sensor failure, making them unsafe for use in food processing applications. bit.ly/BaumerDairy

MAY 2024

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HANDLING & STORAGE

Sustainable warehousing: Five manageable steps Industrial racking specialist Rack Group outlines five key steps that can be taken in any warehouse to drive sustainability, improve efficiency, and reduce long-term costs.

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n the fast-paced world of warehousing, sustainability is emerging as a key priority for businesses looking to reduce their environmental footprint while improving efficiency and safety.

While grand initiatives like installing solar panels or implementing robotics and AI are commendable, there are smaller, more manageable steps that warehouses can take to reduce their ecological footprint. These steps not only contribute to a greener planet but also often result in cost savings and improved efficiency. Here are five such steps that any warehouse can implement:

Optimise energy consumption One of the simplest yet most effective ways to enhance sustainability in the warehouse is by optimising energy consumption. Start by conducting an energy audit to identify areas of inefficiency. Switching to energy-efficient lighting such as LED bulbs, installing motion sensors to control lighting, and ensuring equipment is powered down when not in use can significantly reduce energy consumption without requiring substantial investment.

Implement waste reduction measures Waste management is another area where warehouses can make significant strides towards sustainability. Implementing a waste reduction strategy that focuses on recycling, composting, and minimising single-use plastics can drastically reduce the amount of waste sent to landfills. Encouraging employees to use reusable containers for lunches and providing recycling bins throughout the facility are simple yet effective measures.

Promote sustainable transportation practices Transportation is a significant contributor to carbon emissions in the supply chain.

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Warehouses can reduce their environmental impact by promoting sustainable transportation practices such as consolidating shipments, optimising delivery routes, and using fuel-efficient vehicles. Investing in alternative fuel options or electric vehicles for transportation within the warehouse premises can further reduce emissions.

Optimise inventory management Effective inventory management improves efficiency and contributes to sustainability efforts. By optimising inventory levels and implementing just-in-time inventory practices, warehouses can minimise excess stock and reduce the need for storage space and transportation. This reduces waste and lowers energy consumption associated with storage and transportation activities.

Invest in proper equipment maintenance Maintaining work equipment in good working order is crucial for operational efficiency and sustainability. Regular maintenance ensures that equipment operates at peak performance, minimising energy consumption and reducing the likelihood of breakdowns.

By extending the lifespan of machinery and

equipment, warehouses can decrease the need for frequent replacements, ultimately reducing waste and conserving resources.

When it comes to maintaining work equipment in optimal condition, Rack Group offers comprehensive services, including installation, inspection, and repair of racking systems with a focus on sustainability and longevity. Its team of experts not only ensure that racking equipment is safe and efficient but also provide specialist training for teams to inspect and repair racking in-house. By partnering with Rack Group, warehouses can take proactive steps towards sustainability while maximising the lifespan of their equipment and reducing repair bills in the long term.

In conclusion, sustainability in the warehouse is not solely about implementing large-scale initiatives but also about embracing small, manageable steps that collectively make a significant impact. By optimising energy consumption, reducing waste, maintaining equipment, optimising inventory management, and promoting sustainable transportation practices, warehouses can become more environmentally friendly, efficient, and cost-effective in their operations. www.therackgroup.com

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CABLES & CONNECTORS

Han: The industry standard connector Industrial connectivity specialist HARTING looks back at the early development of its popular Han range of connectors and how consistent connector innovation and expansion has helped customers keep pace with industrial transformation.

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he HARTING Technology (including STP files) and share configurations Group has been established for within a team. over 75 years and is a leading The development of Han-Modular global supplier of industrial improved the flexibility of the range, opening connectivity technology. The up applications and opportunities in new company is probably best known for its markets. For example, the increased Han range of connectors, which have been contact density and option for signal and supplying industry with the three lifelines of power transmission made it perfect for data, signals and power since 1956. robot controller cabling, whilst the modular The Han (meaning HARTING Norm) aspect was ideal for wind turbines, as their connector was patented in 1956 and officially registered as a trademark in 1957. Into the 1960s, the production of Han had increased to encompass products for various voltages and currents, meaning all areas of industrial application could be catered for.

Over the following decades, the Han range continued to expand alongside the demands of industry, ensuring customers had the correct solution for their needs.

In 1993, HARTING launched HanHARTING’s first patented connector Modular, a direct response to the increasing was the Han A in 1956. modularisation of mechanical engineering.

This innovation allowed contacts for the transmission of different media, such as data, signals, power and compressed air, to be placed side by side in a housing with the aid of a mounting frame. This meant customers could optimally design solutions for the supply of machines and systems using connector housings in standard sizes.

HARTING also launched the Han Configurator, an online 3D tool that allows designers to build modular connectors. The smart assistant feature suggests alternative interfaces and provides an onscreen 3D visualisation of the current configuration, meaning customers can view their creations from a range The Han-Modular Domino modules from HARTING, patented in 2018, offer significant space saving for of angles. It’s also extremely easy machine builders. to download all documentation

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components are manufactured in different locations before they are joined together on site. Han-Modular is currently used in generators, pitch control systems and wind tracking, as well as transmitting power, data and signals from the nacelle to the rotor hub.

Some 30 years on from the launch of HanModular, the next development stage of the modular connector is upon us with the new Han-Modular Domino range, which offers significant improvements for machine building thanks to space savings of up to 50%, compared to existing designs.

Just as dominoes have two separate squares, a domino module is made up of two building blocks or ‘cubes’. The Han-Modular mating face is divided into two, resulting in an almost square surface in which even larger contacts can be accommodated. These cubes allow users to configure customised connectors which are exactly tailored to their design requirements. Power, signal, data or compressed air can now be combined in one module, reducing the total number of interfaces required.

With the addition of the new Domino range, there are now over 250 modules to choose from, and many thousands of potential combinations are available, increasing design flexibility. The new Domino modules are also compatible with standard components of the Han-Modular series, so they can be easily integrated into existing systems and machinery.

That brings us up to date with the Han story so far, but as the HARTING slogan ‘Pushing Performance’ suggests, the ongoing challenge is to constantly innovate and help push developments further. www.harting.com/UK

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JUNE 2024 NEC, Birmingham, UK

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ENERGY MANAGEMENT

Energy loggers help optimise solar PV system designs A Kenyan electrical engineering and contracting company, Central Electricals, has used data from Tinytag Energy Loggers to identify its clients’ peak power demands and inform the design of solar PV systems.

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entral Electricals International Limited (CEIL) is a 70-year-old electrical engineering and contracting company based in Kenya.

Qualified and certified, CEIL has a regional footprint with operations across six countries in East and Central Africa. David Lumatete, General Manager – Solar Division at Central Electricals, uses Tinytag Energy Loggers, available in the UK from Gemini Dataloggers, to monitor the periodic energy consumption of prospective clients.

Tinytag Energy Loggers are used to establish the daily load profiles of Central Electricals’ clients, showing the variation in electrical load versus time. This daily profile is an important part of solar photovoltaic (PV) system designs as it validates whether the proposed system will satisfactorily meet the client’s power needs.

Discussing why he chose the non-invasive Tinytag Energy Logger for monitoring client load profiles, David said: “Tinytag Energy Loggers are small, portable, and fairly easy to install on-site. Also, the recorded data can be simply downloaded and exported to third-party software for analysis.”

The data recorded by the Energy Logger is used to identify the peak power demands of the client and is then exported to Microsoft Excel to determine daily energy consumption. Data is also transferred to PVsyst, a specialist software for architects, engineers, and researchers.

Importing the data to PVsyst allows David to determine the renewable fraction (the fraction of the energy delivered to the load that originated from renewable power

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sources) for reference during the design of commercial and industrial solar PV systems.

Central Electricals recently purchased additional Tinytag Energy units to expand its power monitoring capabilities and maintain accurate data collection to inform solar power solutions.

Tinytag Energy Loggers The Tinytag Energy Logger monitors voltage (V), current (AC) and power (kW) and determines power factor and energy usage (kWh) data. Designed to monitor

single and three-phase power supplies, the energy logger is commonly used in high-consumption premises such as factories, manufacturing plants, distribution warehouses, retail units, and hospitals to assess energy usage and help identify areas in which to improve energy efficiency and cost-effectiveness. Easy to use, compact, and hand-held, the Tinytag Energy Logger is safe and simple to use for spot checks and long-term monitoring. www.geminidataloggers.com

EVENT PREVIEW

Driving progress Simon Farnfield, Event Director at the Advanced Engineering show shares some of the highlights from the 2023 staging of the event and looks at what’s in store for the 2024 event which takes place at the NEC, Birmingham, on October 30 and 31 this year.

MEPCA: What were some of the highlights from Advanced Engineering 2023?

Simon Farnfield: Last year, almost 9,000 people attended Advanced Engineering at the NEC, including representatives from Airbus, Rolls-Royce, IBM, Boeing, McLaren, BAE Systems, Catapult HVM, Department for International Trade, Jaguar Land Rover and many more.

Advanced Engineering visitors were treated to a fresh look thanks to the recent rebrand. This was coupled with a new crossindustry floor layout, which allowed for a more diverse range of exhibitors from various industries including newly added sectors such as marine, motorsport, construction, medical, rail and sport.

For companies targeting the aerospace and defence sectors, the aerospace, defence and security trade association, ADS, returned with its Meet the Buyer programme, during which 90 brands participated in 105 supplier engagements, which was a 132% increase on last year and will no doubt go on to become partnerships that enable huge engineering breakthroughs in the sector.

Attendees also had access to over 150 industry-leading speakers across its forums.

In 2023, Advanced Engineering introduced a main stage, which was sponsored by Lloyds Bank and supported by Make UK, where speakers such as Richard Noble OBE, former holder of the world land speed record and serial innovator at ThrustWSH, and Stephen Phipson CBE, Chief Executive of Make UK took to the stage. There were also several panel discussions, including one on women in manufacturing, which was led by Dr Megan Ronayne and supported by some of the leading female figures in the industry.

Across the exhibition’s four other forums, automotive, aerospace, composites and advanced materials and technologies, visitors could hear from industry experts on topics ranging from supply chain management, digitalisation, and the skills gap.

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M: How important are events like Advanced Engineering for the UK’s manufacturing and engineering sector?

SF: Make UK’s Stephen Phipson summed this up perfectly when interviewed at last year’s exhibition. He said: “Shows like this are absolutely vital because it is an opportunity to network to learn from each other. It is an opportunity to think of something or see something you never thought would happen.

It is the sense of community and collaboration that is very important for our industry.”

M: What can we expect from Advanced Engineering 2024?

SF: In three words: inspiration, innovation and excitement. We want to showcase how much is happening in UK engineering and manufacturing, so once again we’ll be having dedicated areas for the nation’s most impressive products.

This year, we’ll be welcoming an even wider range of exhibitors by incorporating new sectors such as marine, rail and motorsports. This diversification will also be present across our four forums, with talks from industry leaders across a wide range of industries. ADS’s Meet the Buyer scheme will be expanded, and the Society for the Advancement of Material and Process

Engineering (SAMPE) will return with its design and build competition for students.

On top of this, the show will be co-located with Lab Innovations, giving visitors and exhibitors more opportunities for crossindustry collaboration.

M: If a company wants to exhibit but is concerned about the environmental impact, what can they do to limit this?

SF: We have lots of tips available on our website for ensuring that exhibitors are as sustainable as possible. This includes selecting a reusable all-in stand model rather than a disposable stand created for just one event.

Avoid having any dates on signage so that it can be reused and use recyclable materials, eco-friendly ink and LED lighting where possible. Also, if you choose local suppliers and consolidate shipments, you can help reduce transport.

When travelling to the event, either as an exhibitor or visitor, we’d recommend using car sharing or public transport — the NEC is extremely accessible by train.

Advanced Engineering is taking place at the NEC, Birmingham, on October 30 and 31, 2024. For more information, visit the exhibition’s website. www.advancedengineeringuk.com

EVENT PREVIEW

Subcon: Discover your next manufacturing partner Subcon 2024, scheduled for June 5-6 at the NEC, Birmingham, is the premier event for manufacturing buyers across all sectors.

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s a cornerstone event for the industry, Subcon provides an unrivalled opportunity to source manufacturing solutions from a variety of world-class exhibitors. With over 150 subcontractors and outsourced engineering services, the event is packed with possibilities for everyone. This year’s event promises a refreshed and innovative format, with new developments introduced to adapt and enhance the experience for both visitors and exhibitors. Attendees can look forward to a dynamic programme featuring interactive CPD-accredited workshops, cutting-edge product demonstrations, and insightful keynote presentations. Additionally, visitors can engage in meaningful discussions through roundtable sessions that are designed to foster collaboration and idea-sharing.

Manufacturing solutions Over 150 leading UK and international suppliers will be gathered under one roof, showcasing the latest innovations and solutions available from sectors such as CNC machining, metal fabrication, electronics, component parts, and more, all dedicated to advancing the capabilities of your supply chain.

Thousands of new products and innovations will be on display across the full range of advanced engineering technology, systems and services – from additive manufacturing and metrology solutions to frictionless bearings, cables and controls, and everything in between.

This is a show geared to helping attendees to increase capacity, optimise productivity, improve flexibility and remain competitive.

Innovation and learning New for 2024, Subcon has announced a significant enhancement to its conference and workshop programme, with the introduction of a variety of different session formats that take place within three specialised areas designed to cater to a diverse range of interests and professional needs within the manufacturing

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industry: the Innovation Zone, Workshops and Learning Space, and the Manufacturing Insights Theatre.

Additionally, the programme is now officially CPD accredited, ensuring attendees can gain valuable professional development credits while engaging with top industry experts and cuttingedge technologies.

Manufacturing Insights Theatre: Visitors to this area can explore insightful keynote presentations and engage in lively panel discussions. This forum features thought leaders discussing the latest trends and challenges in manufacturing. Each session includes interactive Q&A segments, making it a dynamic platform for learning and engagement.

Workshops & Learning Space: In this area, there will be opportunities for hands-on learning with roundtable discussions and sector-focused peer-to-peer meetings. Tailored to address specific industry challenges, these sessions will offer practical insights and networking opportunities, facilitated by industry experts.

Innovation Zone: This zone is dedicated to hands-on demonstrations, showing how new technologies and products operate in real time. It’s the perfect place to see the newest innovations in action and discover how they can enhance your manufacturing processes.

More new features have been added, including: Motorsport simulators with a prize draw where visitors can compete in professional motorsport simulators operated by FP Zero and dive into the thrilling world of Formula 1 racing right on the exhibition floor. The fastest lap will not only boast bragging rights but will also win a PalmerSport driving day experience valued at over £600.

Dedicated work and meeting spaces that provide a quiet spot for a meeting or just to catch up on emails. Visitors can stop by to meet with peers or to take a break and grab a coffee.

Networking drinks and entertainment where all visitors, exhibitors, and speakers are invited to unwind at a welcome drinks reception, complete with entertainment, starting at 5pm on the first day of the exhibition.

Registration is free Registration for Subcon 2024 is completely free, offering an invaluable opportunity to connect with industry leaders, explore cuttingedge innovations, and participate in a variety of sessions designed to drive your manufacturing capabilities forward. bit.ly/SubconMEPCA

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INDUSTRY UPDATES

Unify to amplify

Revolutionary mobile system for automated food conveyor cleaning

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eading materials handling company Cablevey Conveyors has announced the launch of Cleanvey – a groundbreaking development in the automation of Clean-in-Place (CIP) processes for tubular drag conveyors.

Cleanvey is engineered to automate the CIP process, allowing for efficient, thorough cleaning of tubular drag conveyors, which is crucial in maintaining sanitary compliance and ensuring the safety of food products. Designed with integrated water line hookups and pre-programmed cleaning options, this mobile unit simplifies the cleaning process, enabling a technician to initiate a comprehensive cleaning cycle with just the press of a button.

Cleanvey significantly reduces the time and effort traditionally required for conveyor cleaning, offering a customisable, user-friendly approach that enhances productivity and minimises downtime. In addition to its cleaning capabilities, the solution offers advanced features such as optional sprayballs for targeted cleaning of residues and a sanitary blower that drastically reduces drying times, both further accelerating the readiness of conveyors for subsequent use.

ontrol Techniques and KB Electronics have announced that with effect from May 1, 2024, they have come together under the new brand name of Nidec Drives.

This decision has been made with strategic initiative and progression in mind. Control Techniques and KB Electronics, with over 50 years of experience, represent innovation and trailblazing in the drives sector; becoming Nidec Drives aligns with their forward-thinking approach and dedication to staying ahead in an everevolving market.

It’s important to emphasise that this change will not affect any of the products or services currently offered by Control Techniques or KB Electronics.

Their product lines will remain at the same high level of quality, innovation, and service, which their customers have come to expect. There will be changes to branding on social media channels, product labelling, and brochures, but customers can rest assured; the same team of drive obsessives are behind the wheel.

This strategic decision signifies greater collaboration with Nidec, a global brand, giving further opportunities to produce more of what customers want and need. Becoming Nidec Drives enables Control Techniques and KB Electronics to harness the strength and resources of Nidec, meaning greater prospects and collective possibilities. This change will not only strengthen their valued stakeholder relationships, but also ensure a more efficient and effective experience for all.

n recent revisits to two Steelcoat 100/400 System applications in the Northeast of England, Winn & Coales (Denso) Ltd. was proud to confirm that both applications were performing as expected over a decade since their installations.

The Steelcoat 100/400 System consists of Denso Hi-Tack Primer, Denso Profiling Mastic, Denso Hi-Tack Tape, Denso Ultraseal Tape and Denso Acrylic Topcoat and offers an excellent long-term coating solution for exposed steel and pipework – particularly in areas faced with damp conditions. The system requires minimal surface preparation and is easy to apply, making it ideal for use in remote or difficult-to-access areas where preventing contamination of the surrounding environment is of the utmost importance.

Winn & Coales prides itself on the longevity and effectiveness offered by the complete and correct applications of its innovative products and systems. The revisited Steelcoat systems – originally applied in 2008 and 2010 respectively – serve as demonstrable proof of their enviable track record of success and affirms their position as industry leaders.

www.ControlTechniques.com

www.denso.net

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cablevey.com/cleanvey

Denso Steelcoat Systems standing the test of time

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CONNECTIONS 3D Print Manufacturing

Machine Safety Schmersal UK Ltd T: 01684 571980 E: uksupport@schmersal.com W: www.schmersal.co.uk

Midlands 3D Printing T: 01785 594389 E: sales@midlands3d.com W: www.midlands3d.com

Anti Vibration Products, Mounts & Bushes

Marking Solutions T-Mark T: 0330 153 8320 E: sales@t-mark.co.uk W: www.t-mark.co.uk

Fibet Rubber Bonding (UK) Ltd T: 01282 878200 E: sales@fibet.co.uk W: www.fibet.co.uk

Connectors & Cabling Solutions

Pipework Systems Jacob UK Ltd T: 01694 722841 E: sales@jacob-uk.com W: www.jacob-group.com/uk

CEMBRE Ltd T: 01675 470 440 E: sales@cembre.co.uk W: www.cembre.com/en

Drives, Motors & Gears

Pressure Measurement Specialists ESI Technology Ltd T: +44 (0)1978262255 E: sales@esi-tec.com W: www.esi-tec.com

Nord T: 01235 534404 E: GB-sales@nord.com W: www.nord.com

Robotics & Automation

Flow Meters

KUKA Robotics UK Ltd T: 0121 505 9970 E: sales.uk@kuka.com W: www.kuka.com

Titan Enterprises Ltd T: +44 (0)1935 812790 E: sales@flowmeters.co.uk W: www.flowmeters.co.uk

High Shear Mixing Equipment Silverson Machines Ltd 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 Intoware T: 0115 977 8969 E: hello@intoware.com W: www.intoware.com

Industrial Fans Axair Fans UK Limited T: 01782 349 430 E: sales@axair-fans.co.uk W: www.axair-fans.co.uk

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Sensors IFM Electronic T: 020 8213-0000 E: enquiry.gb@ifm.com W: www.ifm.com PLUS Automation Ltd T: 0121 58 222 58 E: Sales@PLUSAutomation.co.uk W: www.PLUSAutomation.co.uk

Storage Solutions BITO Storage Systems Ltd. T: 02476 388 852 E: Info.uk@bito.com W: www.bito.com

Test & Inspection AMETEK Land (Land Instruments International) T: +44 1246 417691 E: land.enquiry@ametek.com W: www.ametek-land.com