MEPCA Magazine November 2023

November 2023 www.mepca-engineering.com

The MX-System: A pluggable system solution for control cabinet-free automation

Zebra and Matrox Imaging Are One The Matrox Imaging solutions you know and trust just got better, and they are now available through Zebra.

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

CONTENTS Editor Chris Callander chrisc@cimltd.co.uk Publication Manager James Davies jamesd@cimltd.co.uk 01795 509105 Account Manager Hannah Moody hannah@cimltd.co.uk 01795 509115 James Burke jb@cimltd.co.uk 01795 509115 Design & Production Grant Waters grant@cimltd.co.uk James Taylor james@cimltd.co.uk Administration Manager Natalie Murray admin@cimltd.co.uk 01795 509103 Credit Facilities Manager Gwen Lee creditcontrol@cimltd.co.uk 01795 509103 Marketing Manager Lucas Payne lucas@cimltd.co.uk Sales Director Tom Woollin tom@cimltd.co.uk Chief Executive John Denning © 2023 TGM Publishing Limited,1st Floor, Saphir House, 5 Jubilee Way, Faversham, Kent, ME13 8GD. No part of this magazine may be reproduced or stored in a retrieval system or transmitted in any form – electronic, mechanical or physical – without express prior permission and written consent of the publisher. Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and addressed envelope. Manuscripts should be typewritten. No responsibility can be taken for drawings, photographs or literary contributions during transmission or in the editor’s hands. In the absence of an agreement the copyright of all contributions, literary, photographic or artistic, belongs to TGM Publishing Limited. The publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed do not necessarily represent the views of the publisher. The publisher cannot accept liability for any loss arising from the late appearance or non-publication of any advertisement.

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November 2023

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n the ever-evolving landscape of industrial engineering, few trends have promised as much transformative potential as industrial connectivity. IIoT promises unprecedented efficiency. By interconnecting machinery, devices, and systems, we can harness real-time data like never before.

With the rollout of 5G networks, industries can expect faster, more reliable connectivity. This is a game-changer for applications that hinge on real-time data transfer, opening doors to innovations we’ve only begun to imagine.

By processing data closer to its source, edge computing promises to dramatically reduce latency. This means systems can make quicker, smarter decisions, often autonomously, heralding a new age of intelligent manufacturing.

While with digital twins, which bridge the physical and digital with the ability to create virtual replicas of physical systems, we can simulate, predict, and optimise operations in a risk-free environment.

However, the more we connect, the more we expose ourselves to potential cyber threats.

Industrial systems, once isolated, now face the risk of cyberattacks that can cripple operations, steal intellectual property, or compromise safety.

In addition, as industries adopt various connectivity solutions, there’s an inherent challenge in ensuring that these systems integrate seamlessly. A lack of standardisation can lead to inefficiencies and potential operational silos. Plus, as industries become more reliant on connected systems, any disruption, whether from technical glitches or external factors, can have magnified consequences.

There’s no doubt that advances in industrial connectivity open up many opportunities, but there are threats that need to be managed.

Hopefully, in the following pages, we can begin to help you reap the rewards of better-connected manufacturing.

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 BARA

18 COVER STORY Beckhoff UK

20 ROBOTICS Kawasaki UK, ABB and OMRON

27 CONNECTIVITY FOCUS ifm, Brainboxes, Murrelektronik, Pepperl+Fuchs and Tascomp

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44 MANUFACTURING SOFTWARE Indysoft

50 MATERIALS HANDLING mk Profile Systems, Combilift, Hyster and Logistex

62 EVENT PREVIEW Liftex and Southern Manufacturing

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INDUSTRY NEWS

EngineeringUK launches new five-year strategy

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ot-for-profit EngineeringUK has announced it’s entering a new strategy period – which will set the direction of the organisation over the

next five years.

With a core purpose of driving change so more young people choose engineering and technology careers, EngineeringUK’s refreshed vision is for the UK to have the diverse workforce needed for engineering and technology to thrive and to drive economic prosperity, improve sustainability and achieve net zero.

Engineering and tech are critically important for the UK, with huge opportunities and responsibilities over the coming years, but the sector continues to face significant workforce challenges.

Dr Hilary Leevers, Chief Executive of EngineeringUK, explained: “For engineering and technology to really thrive, we urgently

need more people and more diversity in our workforce. Our new strategy provides us, and importantly all of our partners, with a renewed focus on what we’re trying to achieve, and clarity on how we’re going to get there.

“We’re determined to achieve our mission of enabling more young people from all backgrounds to be inspired, informed and progress into engineering and technology. But this will only be possible by working in partnership - we all have a part to play in this.”

EngineeringUK’s strategy from 2023 to 2028 consists of four key strands of activity, including: Research and evidence – establishing the composition of the current engineering and technology workforce, future workforce needs and how to address them.

Leadership – leading efforts to grow the

collective impact of all engineering and technology inspiration and careers activities with young people of school age.

Activities for schools – expanding its activities to encourage a greater and more diverse number of young people into engineering, technician and tech roles.

Advocacy – providing advocacy and support to address policy and delivery challenges in STEM and careers education and workforce planning for engineering and tech.

Festo apprentice scoops top award

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esto saw its engineering apprentice Olivia Harrison-Hine win apprentice of the year at the prestigious PPMA Group industry awards ceremony held alongside the association’s exhibition in September of this year.

The PPMA (Processing And Packaging Machinery Association) Awards saw Olivia pitted against several other apprentices of exceptional quality and skill, but she managed to shine bright and scoop the coveted award.

Olivia, 21, from Wellingborough, recently gained a distinction in her HNC, demonstrating a constantly improving skill set and leadership potential beyond her years.

One of the qualities that caught the judges’ eyes was Olivia’s eagerness to ‘give back’ and help usher in the next generation of young engineers, achieving this by running stalls and engaging in STEM (Science, technology, Engineering and Maths) activities at her previous school and in the local community.

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Commenting on the award, Olivia said: “I am incredibly honoured to have been awarded the prestigious PPMA’s Apprentice of the Year Award. This recognition means the world to me, and I cannot express how grateful I am for this award.

I owe this achievement to the unwavering support and guidance of my amazing colleagues and my manager at Festo. When I joined the company, I felt like I was part of a family that was genuinely invested in my growth and development. They have been my mentors, advocates, and friends, and I couldn’t have asked for a better team to work with.

“Festo has been the nurturing ground for my professional journey, where my confidence has grown, and my skills have been honed through diverse and challenging projects. I am truly fortunate to have worked on such a wide array of projects.

This experience has not only enriched

my knowledge but has also allowed me to contribute meaningfully to the success of our company. I am excited to continue my journey with Festo, inspired by this recognition, and committed to giving my best to the team and the industry. Once again, thank you to everyone at Festo who has played a part in my growth and to the PPMA for this incredible honour. I am happy to be a part of such a remarkable community that values and nurtures the future generation of engineers.”

INDUSTRY NEWS

Manufacturers call for major MOT of UK’s business tax and regulation system

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ritain’s manufacturers are calling on the Chancellor to announce a major MOT of the UK’s uncompetitive business tax and regulatory environment in the forthcoming Autumn Statement to boost investment planning by business.

The call was made on the back of a major survey published by Make UK and audit, tax and consulting firm RSM, which sets out a daunting challenge to reform the UK regime of business taxation and regulation, with almost half of companies believing the current system is unfavourable and, more than a quarter feel is worse than China and other major competitors.

Furthermore, companies are also reporting that the ‘flip-flopping’ and frequent changes to policies on investment and R&D incentives in recent years have hampered businesses’ investment plans. As a result, Make UK is urging the Chancellor to announce that there will be just a single annual fiscal statement from now on.

Reforms would look at measures, such as business rates, the research and development (R&D) tax credits, the Apprentice Levy and the capital allowances and full expensing system, and whether they are fit for an economy undergoing huge transformational change and encouraging, or hampering, long-term

investment in capital, innovation, skills and moves to net zero.

The findings in the report also support the view that an industrial strategy which encompasses reform of the current business tax and regulation system would lead to greater investment in labour and skills, R&D and decarbonisation.

According to the report, almost half of companies (44%) believe the UK has an unfavourable business tax and regulatory environment, with less than a fifth (18%) believing it to be favourable. On balance, manufacturers say the UK is worse than its competitors, with more than a quarter (28%) believing it to be less favourable than China.

Over a quarter (27%) believe it is worse than the US, Germany (26%), France (23%) and Italy (21%).

Conversely, manufacturers believe that a more favourable environment with the simplification of incentives, tax and regulations would ease the burden on business, while more than half (54%) believe that frequent changes to R&D and investment incentives over the last three years have made it more challenging to plan investments. By contrast, fewer than a fifth (16%) felt the changes had allowed their business to increase investment.

The most effective policy tools to promote investment and growth were capital allowances for plant and machinery (73%), R&D tax credits (65%) and a competitive Corporation Tax system (59%), while more than half (55%) believe the current policy of full expensing should be made permanent.

The survey of 150 companies was carried out between 26 July and 19 August.

New senior general manager for global account business development at OMRON

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MRON Corporation has announced the appointment of Dr. Lucian Dold as the Senior General Manager for Global Account Business Development. Dr. Dold, a leader with over 30 years of experience in industrial automation, brings his expertise and passion for digital transformation to this crucial role.

Dr. Dold’s career has been marked by his commitment to fostering global cooperation among end-users and partners, and driving

innovation and growth in the industrial automation sector. Thanks to his extensive network and in-depth industry knowledge he has played a pivotal role in creating new value in production across the globe.

In addition to his corporate responsibilities, Dr. Dold is a dedicated educator, serving as a lecturer at DHBW University. Here, he imparts his knowledge of digitalisation strategies for production, equipping the next generation of professionals with the skills needed to thrive in the dynamic landscape of Industry 4.0.

www.mepca-engineering.com

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SOLUTIONS FOCUS

IO-Link for industry-standard auto-ID devices

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ICK has pioneered the addition of IO-Link to two of its most compact and industry-standard identification devices. Both the SICK CLV61X fixed-mount 1D bar code reading scanner and the RFU61X UHF RFID read/ write device were first to market with IO-Link variants, enhancing the integration versatility of SICK’s identification portfolio.

The addition of IO-Link opens up opportunities to configure edge integrations with other IO-Link sensors and IO-Link Masters, explained Darren Pratt, SICK’s Market Product Manager for Identification: “It is rare for identification devices to be used in isolation. They are almost always used with presence detection sensors for triggering or measurement sensors for classifying or measuring.

“Using IO-Link results in a common interface infrastructure with low-cost plug-

and-play cabling, while still providing access to diagnostic data and enabling configuration via the communications network.”

THE CLV 61X is used in many industries thanks to its highly reliable 1D code reading performance across a wide reading field, even at short distances, ideal for common identification tasks on a conveyor. With SMART620 code reconstruction, even damaged, contaminated and partially obscured barcodes are read consistently.

The smallest industrial UHF RFID read/ write device of its kind, the SICK RFU61X, achieves an impressive scanning range of up to 0.5m. The innovative design combines an in-built antenna, intelligent control and connectivity in a single, rugged, IP67 aluminium housing.

The SICK RFU61X is ideal for applications such as tracking smaller parts, subassemblies and electronic components, materials handling in e-Kanban processes,

identifying pallets on a roller conveyor, or monitoring consignment transfers onto smaller Automated Guided Vehicles and carts.

Both the CLV61X and the RFU61X offer highly versatile connectivity with Ethernet/ IP and PROFINET protocols, and an option for a single Power-over-Ethernet connection.

Both devices offer a direct connection option for a trigger sensor. www.sick.co.uk

New generation ergonomic optical stereo microscopes

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ision Engineering, a leading provider of innovative inspection, metrology, and digital 3D visualisation solutions, has launched Mantis 3rd Gen, the latest addition to its best-selling and award-winning range of ergonomic optical stereo microscopes.

Mantis is in use in tens of thousands of R&D, manufacturing and analytical sites around the world. Mantis 3rd Gen incorporates the latest developments in optics, digital cameras and fully adjustable LED lighting, to keep Mantis at the forefront of stereo imaging.

Mantis is designed for precision engineering, electronic engineering, medical device manufacture, and a wide range of other applications that require high-quality images and superior ergonomics. It features a unique, patented, eyepiece-less design that delivers a large, high-quality optical stereo image directly into the user’s eyes, making

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it more comfortable and easier to view than traditional microscopes.

Manipulative, rework and restoration tasks need stereo images to allow easy hand-to-eye coordination and depth perception. Mantis 3rd Gen combines stereo optical images with high-resolution camera options for manipulation and recording.

Mantis 3rd Gen features long working distance and excellent depth perception, now with a choice of three magnifications, making it ideal for a wide range of applications. It also now comes as standard with five different ways to illuminate your subject, giving you the flexibility to adjust the lighting to get the perfect image for your needs.

In addition to its outstanding image quality and ergonomics, Mantis also features a powerful digital imaging system that allows you to capture, review, and share highresolution images. This makes it easy to share your work with colleagues, document your findings, and train new employees.

Substantial R&D has resulted in a new range of stand options to allow flexibility, stability and reduced footprint.

“As our customers have told us for the last 28 years, Mantis is an ideal solution for anyone who needs to perform precise work with small objects,” said Mark Curtis, Managing Director at Vision Engineering. “We invest substantial R&D time and effort in exploiting the opportunities that fast-moving optic, digital and lighting technologies offer our dedicated customer base. Mantis 3rd Gen offers the best of both worlds: superior ergonomics and optical image quality, combined with the latest digital imaging technology.” www.visioneng.com/mantis

Contact: YASKAWA.

Tel: 0330 678 1990

www.Yaskawa.co.uk

SOLUTIONS FOCUS

Streamlined data connectivity

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n today’s manufacturing industry, data utilisation is critical for operational excellence. The Bosch Device Bridge, paired with ctrlX core technology, streamlines data connectivity and transformation from diverse Programmable Logic Controllers (PLCs) and devices. This software enhances data collection, reduces network congestion, and empowers Industry 4.0 possibilities.

Efficient data collection: Bosch Device Bridge offers a single, secure connectivity solution for various industrial assets, like CNC machines, PLCs, and sensors. By centralising data sources it simplifies data acquisition and prevents valuable insights from scattering.

Efficient data processing: After collecting data, Bosch Device Bridge applies builtin transformations before transmission, minimising network traffic. Users can implement these transformations without complex coding, swiftly adapting to changing requirements.

No code or low code transformations: Users can choose from pre-built common transformations for popular data types or

formats, eliminating custom development delays and accelerating value delivery.

Custom transformations with Blockly low code: For specific data processing needs, Bosch Device Bridge integrates Blockly low code. This visual programming interface simplifies creating custom transformations without extensive coding, ensuring tailored insights.

Industry 4.0 integration: Bosch Device Bridge bridges industrial assets with IT applications like Manufacturing Execution Systems (MES). It acquires, processes, and delivers manufacturing data, facilitating seamless integration into the Industry 4.0 ecosystem. This real-time visibility enhances decision-making, optimises production, and boosts efficiency.

Scalability and security: The app scales with manufacturing organisations’ growth, connecting to legacy and new assets for future-proof compatibility. Robust encryption and authentication protocols secure sensitive manufacturing data.

Bosch Device Bridge, with ctrlX core technology, provides a comprehensive

solution for industrial data connectivity and transformation. It seamlessly integrates with various PLCs and devices, streamlining data collection, reducing network congestion, and optimising processing. Manufacturers can use common transformations or create custom ones with Blockly low code, unlocking valuable insights and advancing Industry 4.0 initiatives. Bosch Device Bridge empowers manufacturers to embrace datadriven strategies and excel in the evolving manufacturing landscape. www.boschrexroth.co.uk

Back to basics with flow meter sensors

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iquid flow meter specialist, Titan Enterprises, has published a technical review of pulse sensors for flow measurement devices and applications.

Flow meters have developed into many forms over the years, from mechanical devices – such as a turbine or rotating gear – which rely on measurement of a rotational component, to devices that use ultrasound and other advanced technologies. These meters generally use a sensor to relay the flow measurements to a reading device.

Nearly all types of flowmeters, from ultrasonic to turbines, are offered with pulse output flow signals. Sensing components used in a flowmeter measure the movement or flow rate of the liquid or gas passing through the system. The pulse output signal from these devices is, in essence, an on/off switch which changes state at a frequency related to the fluid flow.

As well as discussing the different sensors primarily used in today’s flowmeters and drawing on examples

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of application, a detailed review of the semiconductor sensor components is also included. Titan’s technical review touches on the advantages and disadvantages of each sensor type, along with best practice for connecting sensors to the desired readout device.

Defining some of the key functions and recommended applications of these sensors provides a useful comparison to guide the user’s decision as to the optimum output for their flow measurement requirements.

“Deciding on the best flow meter for a particular application can be problematic,” explained Neil Hannay, Senior R&D Engineer with Titan Enterprises. “There is such a wide array of sensing and output technology combinations, each with its advantages and disadvantages. We wanted to pull together a technical explanation of flowmeter sensors and pulse output types so users can choose the one that will give them the most efficient system operation.” bit.ly/TitanPulse

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Giving sight to robots 3D vision sensor for plug and play integration into gripper applications from Universal Robots The perfect combination of powerful hardware and easy-to-use software makes it possible to easily implement vision sensors in gripper applications from Universal Robots.

The core element of the ifm vision sensor is a 3D camera chip. It creates a 3D image using PMD technology and time of flight measurement.

The UR+ plugin ensures smooth and quick integration of the sensor. It detects any object, even moving ones, and transmits its exact position and dimensions to the robot control.

Never before was gripper navigation so easy! ifm – close to you!

Go ifmonline ifm.com/ uk

SOLUTIONS FOCUS

Save up to 70% with winter deals promotion

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arl Kammerling International has announced the return of its Magnetic promotion, with discounts of up to 70% sure to attract savvy electrical and industrial trade customers.

Magnetic 23 launched on 1 September and offers savings on product lines from brands including C.K Tools, C.K Magma, C.K Classic, avit and Kasp.

To activate promotion offers, customers must make an initial purchase of £350 or more. From that point until 22 December, all future orders submitted through the promotion will benefit from Magnetic savings. The bigger the purchase, the bigger the savings.

Deals apply to much of the brands’ core range, with eight exclusive multipacks available only through the promotion.

Customers placing high-value orders will also be rewarded with exclusive C.K Tools

branded clothing, including a new design bobble hat and a Regatta Microfleece with C.K Embroidery.

This year’s C.K bobble hats – back by popular demand – feature a bold new design. The C.K logo is knit into the hat itself and woven into a small label on the front turn-up.

Each hat is double-layered, making it extra cosy. The brand new black microfleeces have been selected from Regatta’s Professional line for their high quality and functionality, and are available from size M to XXL. Rhiannon Wyn Thompson, Trade Marketing Executive at Carl Kammerling, said: “There are some great savings to be made this autumn and winter for customers who shop smart with Magnetic. Whether you’re slicing the cost of your essentials, making higher-value purchases of new tools and equipment, or both, now is the time to do it.

“We’re doing our best to support merchants and wholesalers through a difficult period.

This promotion could go a long way towards getting customers through the doors and enticing them to invest in their toolkits and equipment. Our products are known for their quality, durability and painstakingly wellinformed designs – and now those qualities are available at a lower price.” bit.ly/CKMagnetic

Rugged, reliable and ready to go

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n a world where adaptability and performance are paramount, Relec Electronics has expanded its display portfolio with an exciting range of portable computing products.

Partnering with MACTRON Group, the company has introduced the MMS and MAV series of rugged tablets to the UK market, setting new benchmarks in versatility and reliability.

“We’re not just selling tablets; we’re offering solutions that redefine what rugged technology can do,” said John Stone, Sales Director at Relec Electronics.

Engineered to meet MIL-STD 810G and IP67 standards, these tablets withstand high levels of shock and vibration and provide protection against ingress from dust and liquids, making them ideal for demanding environments like hospitals and moving vehicles.

Under the hood, the MMS series features Intel Atom processors optimised for medical software. The MAV series, designed for vehicles, runs on Qualcomm processors, perfect for real-time data analytics. Both series

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promise uncompromised speed and reliability.

Technically, these tablets are second to none. MMS integrates high-resolution touchscreens, barcode scanning, and RFID/ NFC for efficient medical data management. MAV offers GPS and 4G LTE, ensuring connectivity even in the most remote locations.

To enhance their functionality, Relec Electronics provides a wide range of accessories, from docking stations to specialised vehicle mounts.

In healthcare, the MMS series meets 60601 standards with medical-grade power supplies and antibacterial screen protectors. Available in 5”, 7” and 10.1” options, they serve various medical needs, from Radiology to Bedside Terminals.

For vehicles, MAV is available with customisable mounts and CANBus communications for seamless integration with modern engine control units. Running on an Android platform, they allow quick development of customised apps.

Relec Electronics takes pride in offering MACTRON’s MMS and MAV series as part of its commitment to deliver reliable and innovative solutions. The technical merits of these rugged tablets, combined with an extensive array of accessories, make them a compelling choice for professionals in need of robust, high-performance devices.

“The MMS and MAV series are more than just tablets; they’re a commitment to innovation and reliability,” concluded John Stone. www.relec.co.uk

The NEW ImageIR® 6300 Z

Compact zoom camera and new SWaP detector (Size, Weight and Power)

Smaller, lighter and without time-consuming lens changes. The ImageIR® 6300 Z is predestined for demanding applications in research and development as well as for stationary or airborne inspection and monitoring tasks. Further applications can be found in quality assurance, materials testing or in a wide range of OEM integration solutions.

Features: ■ Cooled focal plane array photon detector operating in snapshot mode

with (640 × 512) IR pixels

■ Standard built-in 7.5x zoom lens with motor focus ■ Focal length of (15 ... 115) mm or (25 ... 170) mm ■ Operation via smartphone or tablet with integrated web interface ■ Compact size and low weight for space-saving system integration ■ Storage of large amounts of data on the integrated SSD

FOR MORE INFORMATION

InfraTec distributor in the UK and Ireland: Quantum Design UK and Ireland Ltd, 1 Mole Business Park, Leatherhead, Surrey KT22 7BA Tel: +44 (0)1372 378822 | Email: info@qd-uki.co.uk

OPINION

EU trade is vital for continued manufacturing success As the public perception of the UK manufacturing sector improves, Stephen Phipson, CEO of the manufacturer’s association Make UK, believes it is vital that trade barriers with the EU are smoothed out if the sector is to continue to thrive.

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s they say, do you want the good news or the good news?

The good news is that the UK manufacturing sector has climbed one place in the world rankings above France to become the 8th largest manufacturing nation. This is according to the latest data from the United Nations for 2021 (the latest year available). This comes with a large degree of caution, given it is only the third time in the last twenty years that the UK has been above France, and the difference is very marginal.

Both countries are still some way behind seventh-placed Italy while, to no surprise, Germany remains the largest European manufacturing nation with a sector around three times larger than the UK and more than twice the size of Italy.

Separate data for 2022 from the ONS places UK manufacturing output at £224bn, and Make UK believes that, if the Government commits to its call for a manufacturing target of 15% of GDP, (which Make UK estimates would add £142bn to the UK economy) then the sector could aim to match seventh-ranked Italy.

The analysis of official data also shows that the United States remains the dominant export market for UK goods worth £56.7bn in 2022. While Germany has lost its place as the second highest destination (£33.3bn), having been overtaken by The Netherlands (£37bn), Make UK cautioned that trade with the

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Netherlands could be inflated artificially by goods being routed through Rotterdam for onward travel to other destinations.

Ireland is the fourth largest export market (£30.3bn), with six of the top ten export markets being in the EU. Together, they are worth approximately £150bn, almost three times the exports to the US and around four times the amount to China. This highlights the continued importance of the EU for UK goods and the need to smooth out trade

barriers with what remains overwhelmingly its dominant market.

The second piece of good news is that the majority of the public believes manufacturing is critical to the future of the UK economy and vital to delivering solutions today to the societal challenges we face. The findings came in a poll Make UK carried out of over two thousand people using comparable questions to a similar survey five years ago. The survey shows that 93% of people believe manufacturing is critical to growing the UK economy, compared with just 70% five years ago. Furthermore, the gender divide was stark in 2018 when nearly a quarter of parents (24%) would encourage their sons to work in manufacturing, and just 14% for daughters.

However, more than a third (36%) of parents would now be happy for their daughters to work in the sector, while almost half (44%) of parents would encourage their sons to work in manufacturing.

However, the bad news is that the survey shows the dial has not shifted significantly in the last five years in terms of the public’s perception of the UK as a manufacturing power. Five years ago, the public believed the UK was 56th in the world ranking of manufacturing nations, the position occupied at the time by Kazakhstan. In the latest survey, the public believed Britain ranked 43rd, the position actually held by the United Arab Emirates.

It shows that the sector still faces huge challenges in changing public perception and emphasising its importance.

What happened?

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OPINION

Certification for systems integrators BARA, the British Automation & Robot Association, has introduced a new scheme designed to certify systems integrators. George Thompson, the association’s Chairman, shares details.

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f you have read my recent articles, you will remember that I believe that the system integrator is the most important part of choosing an automated solution for your production challenges.

I have explained that if you choose the right one, they will be able to provide an efficient solution that meets the agreed scope of supply. That being said, how do you know how to choose a reputable company that will deliver on its promises? Well, that is the tricky bit!

If only there was an independent body that could provide some suggestions based on a defined set of criteria. Well, that is exactly what the BARA System Integrators Certification Scheme is designed to accomplish! We have partnered with A3 Robotics, which is the BARA equivalent in the USA, to set the benchmark to evaluate the integrators’ technical knowledge and safety practices.

We have collaborated with the association to agree on the framework for the certification here in the UK. The scheme is designed to evaluate the integrators’ knowledge of robots, controls architecture, best practices, and most importantly, safety standards, which is far more than ‘just’ the Machinery Directives (Directive 2006/42/EC – also known as Supply of Machinery (Safety) Regulations 2008: Great Britain) and CE Marking, as well as a myriad of other legislation that may apply depending on the application and/or solution. Each of the certified integrators has completed a 25-point self-assessment and,

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assuming it meets the required criteria, is then subjected to a formal audit.

This audit is carried out by an independent auditor and follows a set process and covers areas such as their ISO certification status, customer service and reporting, safety training and risk assessment methodology, service and maintenance procedures, employee satisfaction, factory assessment test procedures and most importantly their processes around robot programming, engineering, controls, vision solutions and network capabilities.

The scheme is also not a ‘one-and-done’ audit; they will need to be recertified every two years. So, if the solution provider is one of our certified integrators, you can rest assured that they continually meet or exceed the high standards set by A3 / BARA. Our aim is to ensure that end-users of

automation solutions can rest assured that the integrator will deliver the solution to a suitable standard.

Please do not misunderstand our intent; there is a large number of integrators that will deliver a very high-quality solution without being one of our certified integrators.

The intent of the scheme is to help end-users to be able to filter out the solution providers that may not follow the standards to the same level as those that provide high-quality solutions.

After all – not all integrators are created equally, or so they say. Those of us who are privileged enough to visit lots of manufacturing facilities around the country, I’m sure we’ve all seen existing solutions that have either been cobbled together by an end-user or not delivered well by a provider that perhaps doesn’t fully understand the application or perhaps has what I’ll refer to as an ‘alternative interpretation’ of the required legislation.

If you are an integrator, why not see if you can meet our exacting standards. Perhaps you are an end-user looking for a solution provider but aren’t sure where to start.

In either case, there is more information available in the integrator certification area on the BARA website.

If you would like to start your automation journey but don’t know where to begin – I would highly recommend visiting the BARA website (https://www.ppma.co.uk/bara. html), where we have outlined several topics under the expert advice section to give some initial information.

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COVER STORY

Flexibility in food manufacturing To further its modular packaging solution portfolio, processing and packing technology partner, Syntegon, brought automation technology provider Beckhoff UK on board to co-develop a machine that could be integrated anywhere into a production line, without compromising on footprint due to bulky control cabinets.

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s an entry-level machine, the new BEC endload cartoner’s recent upgrade includes the Beckhoff AMP servo motors instead of mechanical drive technology – a key requirement for stable processes. Switching to servo technology allows Syntegon to ideally synchronise different drive components, securing repeatable product placement. Flexibility and reliability are key to the success of its equipment.

Changing customer and economic requirements mean that in food manufacturing, consistency wrestles with flexibility at every turn. From adapting recipes based on changing ingredients to navigating supply chain demands and limitations, flexibility in food manufacturing is the name of the game. Yet it is not without risk; big hitters in the industry will reject products that don’t hit the correct, consistent quality every time.

Packaging is a critical part of this procedure, especially when the packaging machine is required to load the food product into the packaging before sealing. This is a

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critical moment in the process; tolerances for variation are extremely low, so machines must be optimised for light handling of products and flexible enough to carry out multiple functions so as not to lose valuable time in the manufacturing process.

Historically, while the main components of a cartoning solution are made to be modular, traditional machines rely on a lot of wires connected to a control cabinet, something that greatly increases the footprint of the machine while also decreasing the flexibility it can offer within the factory. Beckhoff’s expertise and dedication to its Automation Without Cabinets concept, where the control cabinet is not needed, was something Syntegon wanted its customers to benefit from.

Long-standing partnership Beckhoff and Syntegon’s partnership goes further back than developing this new modular machine together. The two companies are global technology partners, and Beckhoff partners nationally with Kliklok — part of the Syntegon Group — in the UK.

The Kliklok ACE Topload Carton Former, Syntegon’s most advanced carton erector, also performed beta tests for some of Beckhoff’s most recent technologies, including the AMP8000 servo drive system.

However, with all the tests and new offerings, there were obstacles along the way. “Because Syntegon were beta testing the components, there were many changes required to accommodate continuous improvement,” said Pete Hyde, Electrical and Software Engineering Manager at Syntegon.

“It was obviously being developed and designed to our needs as we were testing it.

We agreed that we would be a beta tester, so we knew there would be challenges along the way. When we hit problems, we would liaise with the Beckhoff team in Germany as well as the UK. We would have regular meetings between both Beckhoff sites, and the team would make changes that we wanted to be implemented; any updates would also be done, and they would be done quickly.”

With these initial obstacles overcome, the tests’ results and feedback from ACE end-users determined the machine a win.

COVER STORY Following this, Syntegon began building a new machine, the Basic End-Load Cartoner (BEC), from the ground up and co-developing with Beckhoff the design from an electronic angle.

The new BEC machine is a cartoner, loading products into a carton from several in-feeds — automatic loading systems that load straight into the pockets of the BEC, which then loads the product into the carton and seals with glue.

The difference between the BEC and other alternatives is that it is panelless, allowing the wiring to be much simpler than traditional packaging machines on the market, as well as offering a complete plug-and-play solution for a food manufacturer’s production processes.

AMP Technology The BEC carton loader makes full use of Beckhoff’s AMP8000 servo drive system, which was tested on the ACE Topload Carton Former and used in the build of this machine.

The system is designed to relocate the servo drive from the traditional control cabinet to the machine.

The AMP8000 distributed servo drive consists of a combination of the proven AM8000 servomotors with a highly efficient servo drive, and innovative power electronics with cold switch technology that limits power loss to unprecedentedly low levels.

At the same time, the mounting space required for the electronics is reduced to an absolute minimum. The motor retains its original frame size, negating the need for a larger drive train and achieving almost the same performance data as a comparable motor/servo drive combination without attached power electronics.

EtherCAT The BEC carton loader also reaps all the benefits of Beckhoff’s industrial Ethernet technology, EtherCAT. The EtherCAT real-time Ethernet system was developed by Beckhoff in response to the drawbacks of conventional Ethernet-based industrial networks. Before EtherCAT, most industrial-focussed network protocols had a long update or cycle times of more than 10m/s — EtherCAT, with its cycle times down to <100uS using XFC (eXtreme Fast Control Technology) and distributed clocks, realises real-time synchronous data, aligning with Industrial Internet of Things (IIoT) strategies of modern machine architectures.

Beckhoff’s EtherCAT also has a flexible topology and simple line or tree structure that requires no expensive infrastructure

components. This replaces the costly Ethernet star topology — where all nodes are connected to a central connection point.

The result is outstanding, cost-effective performance paired with highly dynamic servo drives enabling an integrated, fast control technology, and a simple configuration, with up to 65,535 connected devices without placing restrictions on their topology.

TwinCAT Beckhoff’s TwinCAT 3 automation software has also been used in the BEC carton loader.

With this software, it’s possible to turn a compatible PC into a powerful real-time controller. EtherCAT, in combination with TwinCAT, offers the foundational technologies and tools needed to implement Industry 4.0 concepts and IIoT connectivity — all via one PC-based control platform.

The Beckhoff TwinCAT real-time kernel can seamlessly pass data to the OS, Windows or BSD applications, leveraging the full power of the IPC from visualisation programs, Office programs, Microsoft/BSD (Linux) interfaces and command line executions, while also executing the IEC 61131-3 software for PLC, motion control and robotics in real-time.

Furthermore, TwinCAT saves the process data locally, on the server or in the cloud, in synchronisation with the machine cycle.

TwinCAT’s IoT communication supports common protocols for cloud communication and pushes messages to smart devices for real-time monitoring and maintenance. The software is quick and easy to configure and, together with a supplied Industrial PC (IPC) as the IoT controller, establishes a seamless connection between all components of the BEC loader.

“The Beckhoff UK team regularly visited and helped us to develop the software and setup,” continued Pete. “We also had regular team calls with Beckhoff Germany. Jon Hampshire (product specialist for motion at Beckhoff Automation) would visit during the commissioning time and support us in achieving our goals. If we hit an issue, Jon would setup a quick Teams call with Germany, so we had a good number of Beckhoff specialists involved in the process.

“For Syntegon, the development of this new machine also allowed us to align the components with other machines in our portfolio, simplifying our stock offering and supply chain processes,” added Pete.

“For the end-user, the BEC provides easier maintenance by using fewer electronic components and connections, making the

machine simpler and easier to integrate.

“The BEC is based on the OMAC PackML standard, so that it can easily be integrated into customers’ lines, and can communicate across their network to pass PackML details, efficiency reports and smart machine data.

“A number of sensors have been added to detect vibration and temperature of mechanical parts which are displayed on the HMI. For ease of maintenance, a full 3D model is displayed on the HMI, showing all components within the machine. These will then show trends to the end-user, providing a real-time picture of how the BEC is running,” continued Pete. “For example, for a bearing within the machine, we can show trends on what its temperature is and how much vibration it is generating. From that, we can detect if the bearing is at risk of failing, or whether the chain tension is too loose or too tight.”

“Modularisation is something that we’ve been exploring with Syntegon on other machines in its portfolio, but co-developing the BEC carton loader has taken both companies’ offerings to the next level,” said Brad McEwan, Business Development Manager at Beckhoff UK. “The way that we co-developed the electrical drawings and the software already offered modularity. Now, because of the new way the machine is wired, it is fully modular and can adapt to any production line.

“It also allows manufacturers to see which hardware works better where, by temporarily repositioning modules rather than exhausting the capacity of the entire production line,” continued Brad. “Modules can be used to create a smaller version of the production line, allowing manufacturers to build a mental picture of what production could look like going en masse. For instance, should a food manufacturer want to begin production of a brand-new product, it is beneficial to run a test batch of this first. This also helps demonstrate how to scale up for larger production, whilst accurately determining a time to market estimation.”

Syntegon and Beckhoff are planning to extend the new machine into a range, with the BEC currently being tested and earmarked for the basic end, and future integration of more features planned to create mid-end and high-end models. This will provide a real option for true modularity within the food manufacturing industry, no matter the size. www.beckhoff.com

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ROBOTICS

Vision-guided box packing With the help of robots and software from Kawasak Robotics, a food manufacturer is overcoming labour challenges and improving the flexibility and adaptability of its packing process.

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oday’s labour market is changing; Deloitte projects as many as 2.4 million manufacturing jobs will go unfilled by 2028. As human workers become increasingly difficult to find, automation gives manufacturers the power and flexibility they need to grow their business without depending on scarce human labour.

To avoid this issue, a customer reached out to Midwest Engineered Systems (MWES), a Kawasaki Robotics Preferred Integrator based in the US state of Wisconsin, to automate the box packing process for their packaged food product.

MWES listened to the customer, and designed a custom box packing cell that utilised Kawasaki’s high-performance robots and software to surpass initial objectives.

The customer came to MWES Engineered Systems seeking an automated solution that would allow it to rely less on human labour, which had proved to be scarce and unreliable. This growing manufacturer also needed a system that facilitated growth through form and function: the design needed to be mobile, compact, and able to handle a variety of different product and box sizes.

The customer’s existing bagging machine places bags onto a conveyor that feeds into the cell. Once the product reaches the Kawasaki K-VFinder vision system, a camera takes a photo of the product. The vision system passes this data on to the first robot along with the conveyor tracking data, which is used to determine the position and series of pick points for each bag.

Simultaneously, boxes are loaded onto a secondary conveyor underneath the robots, which runs alongside the bag conveyor.

Once a bag has been picked, the robot drops it into the box below. The second robot picks up the remaining bags left on the conveyor, finishing out each box.

and box size into the HMI, and assign a new product number. MWES installed a hand crank that adjusts the box conveyor’s place in the cell, allowing for different sized boxes and giving the customer the flexibility it was looking for. When the operator needs to pack a different product, it just updates the product number on the HMI and turns the hand crank to the correct count.

To add to the cell’s flexibility, its compact size makes it possible for a forklift to pick it up and move it anywhere in the customer’s facility. The cell only needs power, air and an Ethernet connection, so the customer can get started in as little as one day. This is key for a growing manufacturer, said Steve Phelps, MWES Sales Engineer: “This is typical for a packaging environment, and with a customer that’s just getting used to automation and is in a growth phase, it may need to move things around the facility periodically.”

Flexibility achieved

The right robot

reach, payload and high-speed capabilities.

The robots’ 7kg payload, 730mm reach, and flexible mounting options made them ideal for this compact cell, in addition to their through-arm cable design. The robots’ design enables the housing of vision cables, sensor harnesses, air lines, and other components inside the arm structure.

This prevents interference with peripheral equipment, and allows for operation in tight installation spaces.

MWES says the Kawasaki RS007L robots can pack up to 80 bags per minute without drops, which exceeds the throughput and equipment effectiveness goals set by the customer. The system allows the customer to redeploy two to three workers each shift to higher-level roles better suited to their skills. According to the integrator, this system is conducive to further automation.

A downstream palletising system could prepare the boxes for distribution, or box erectors could be installed upstream for increased efficiency.

When operators need to add a new product, they simply type the bag dimensions, weight

MWES chose Kawasaki RS007L robots for this box packing cell because of their

www.kawasakirobot.co.uk

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ROBOTICS

Accelerating the robotics revolution with AI AI is making robots easier to use whilst enabling them to take on more challenging jobs. As the capabilities of the technology continue to expand, it will create the momentum for a surge in robotic automation, predicts Julian Ware, UK & Ireland Sales Manager for ABB Robotics.

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ndustrial robotic systems are already highly adaptable and capable, contributing to their rapid growth across the globe, but with artificial intelligence (AI), this growth looks set to move to a whole new level, with recent estimates from global research firm Statista predicting a 13.5% increase in the AI industrial robotics market, from US$8.49bn in 2023 to US$20.64bn by 2030.

Although robots bring flexibility, resilience and sustainability and help meet changing customer demands while addressing labour and skills shortages, many UK companies have yet to embrace robotic automation. In our recent survey of 250 UK industrial companies, 59% of respondents currently do not use robots, citing lack of experience and perceived complexity as their key reasons for not investing in robotic solutions.

Developments in AI are steadily sweeping this away by making robots much easier to train and use. AI-enabled robots can see, act and reason in the world around them. Using reinforcement learning, these robots can adapt to new tasks and help open new opportunities and applications over and above those available with conventional programmed robots.

These developments, together with tools such as easy programming and simulation software and controllers offering enhanced functionality, are helping to remove many of the skills barriers that have hampered the adoption of robots. As such, we can expect to see robots employed in far greater numbers outside of their traditional roles in manufacturing and distribution, with companies in industries including electronics, healthcare, e-commerce, pharmaceuticals, and food service already finding ways to incorporate robotic automation into their operations.

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All-seeing AI Many AI and vision-based robotic installations are related to sorting and picking. For example, ABB’s Robotic Item Picker features a robot, suction grippers, and a proprietary machine vision sensor to automate complex picking tasks for cuboids, cylinders, pouches, boxes, polybags, and blister packs, among others.

Combining machine vision and artificial intelligence, the Item Picker determines the optimal grasp points for each item before the suction gripper picks up and places the item into designated bins.

The system doesn’t need any human supervision or information about the physical attributes of the items it picks. With a picking rate of up to 1,400 items per hour, the Item Picker enables businesses to handle more orders without increasing headcount or time, directly addressing the labour shortage challenges increasingly facing businesses.

Another use of machine vision is in Autonomous Mobile Robots (AMRs), which can move independently around a facility.

ABB Robotics is transforming its AMRs by adding Visual Simultaneous Localisation and Mapping (Visual SLAM) technology that enables them to make intelligent navigation decisions based on their surroundings.

Visual SLAM combines AI and 3D vision technologies, with cameras mounted on the AMR to create a real-time 3D map of all objects in the surrounding area. The system can differentiate between fixed features such as floors, ceilings, walls, and objects such as people or vehicles that can move or change position. The cameras detect and track features in the environment, enabling the

AMR to dynamically determine the safest and most efficient route to its destination.

Visual SLAM has several benefits over alternative AMR navigation systems, with inflexible forms of navigation such as magnetic tape, QR codes and traditional 2D SLAM all requiring additional infrastructure to function. Unlike 2D SLAM, Visual SLAM requires no additional references such as reflectors or markers. This saves cost and space and offers accurate positioning to within three millimetres.

With no need to stop production or add infrastructure such as reference points, Visual SLAM can reduce commissioning time by up to 20% compared to 2D SLAM and can also be deployed at scale by updating entire AMR fleets remotely.

Thanks to AI’s ability to make robots easier to use, integrate, and access, the use of AI and autonomous technologies at scale will be a major trend for robotics, with new applications unfolding as new capabilities are added.

By making established applications easier to program, operate and maintain, autonomous technologies should prove instrumental in helping many more companies to make their first investments in robots or to use them in new applications. new.abb.com

ROBOTICS

Smooth material flow with autonomous mobile robots With help from OMRON, a chip manufacturer has streamlined its materials transport processes within its production facility. MEPCA found out how.

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olar Semiconductor, a manufacturer of semiconductor chips for the automotive and white goods industries based at the heart of the US automotive industry, recognised the need to optimise its production processes. With the goal of reducing transportation distances within its facility and enhancing workforce efficiency to accommodate its expansion needs, Polar turned to OMRON’s robotics technology for a flexible and cost-effective solution.

Polar added OMRON’s LD 60/90 Mobile Robots to expand its workforce. Finding skilled workers is an industry problem at the moment, and the solution enables Polar employees to utilise their skills and keep the tools running and not worry about the transport of the product. The LD is a selfnavigating Autonomous Mobile Robot (AMR) designed for dynamically moving material in challenging environments. It is capable of manoeuvring through confined passageways and dynamic areas in the presence of humans.

Before starting the project, Polar mapped out its current processes, for example, how long the materials were travelling within the factory. This was over 40 miles throughout the life cycle of the product. Polar carried out detailed simulation and mapping exercises in collaboration with OMRON. The company analysed the entire facility and evaluated the speed at which products could be transported throughout the production line.

The results provided valuable insights into the feasibility and benefits of integrating OMRON’s robotics solution, thereby justifying the investment.

Despite initial concerns regarding operator acceptance of the robotics technology, Polar’s operators quickly realised the advantages it brought to their work. The robots simplified their tasks, allowing them to

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focus on critical activities such as keeping the equipment running while the robots ensure uninterrupted and timely material flow.

The implementation of the solution involved deploying a fleet of seven robots that efficiently transported materials from the main work-in-progress (WIP) storage area to various points within fabrication.

OMRON’s robots autonomously handle the transportation of materials over long distances, significantly reducing the need for manual intervention and improving overall efficiency in Polar’s manufacturing process.

Throughout the setup phase, OMRON played a pivotal role in supporting Polar.

OMRON’s team of engineers provided quick assistance whenever challenges arose.

The availability and expertise of OMRON ensured the successful implementation and continuous improvement of the project.

Darren Desmarais, Industrial Engineer at Polar, highlighted the transformative impact of OMRON’s robotics solution, stating: “Having these robots available to move work-in-progress quicker, easier, without

relying on operators to move from the equipment they’re working on. The biggest advantage I’ve seen is that we’ve been able to have the robot manoeuvre more like a person does.”

The initial reluctance from operators and engineers to embrace the robots has evolved into high acceptance and appreciation. The seamless integration of OMRON’s robotics solution has resulted in operators relishing their interactions with the robots and appreciating the timely delivery of lots to their respective tools. By eliminating the need for thousands of miles of walking within the facility each year, valuable time is saved for the operators, enhancing productivity and efficiency.

Thanks to OMRON’s mobile robotics solution, Polar has successfully achieved its objectives of enhancing productivity, optimising workflows, and creating a more streamlined and efficient semiconductor manufacturing process. industrial.omron.co.uk

AUTOMATION

The importance of strong relationships in manufacturing Innomech and iFast Diagnostics demonstrate how a good working relationship between supplier and client can have a huge impact on innovation and success.

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nnovation is an inevitable and necessary part of the evolution of healthcare.

Since healthcare is an inevitable part of life, the real challenges for the industry are meeting patient needs and controlling costs. The use of automation and robotics in the medical field supports the industry in many ways, including reducing labour costs while providing both flexibility and repeatability.

Developing and designing new machinery to encompass new and novel technologies isn’t a simple process; it takes time and a lot of work. However, Innomech and companies like it exist to help smooth that process. The company’s technical expertise allows it to work with companies to develop and design purpose-built machines to meet the needs of their clients. It’s integral to any design and build process that the supplier and client have a well-rounded and trusting working relationship. Developing machinery involves constant adjustments, developments, and build(s). Without good communication and trust, the relationship between manufacturer and client can have a negative impact.

One client Innomech is proud to have developed this type of relationship with is iFAST. iFAST is at the forefront of addressing the current $4bn Antimicrobial Susceptibility Testing (AST) market. Based at the University of Southampton, the company approached Innomech at the end of 2022, looking for support in building novel technology for the detection of antibiotic (AB) resistance.

The company looks to address a big problem in the healthcare industry. Bacteria are increasingly resistant to antibiotics – resistance levels are 20%-98% and unpredictable. Current Antimicrobial Susceptibility Testing (AST) takes 48-72 hours, and patients can deteriorate whilst waiting for the correct drug.

To address this, iFAST wanted to create

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a machine that reduces the AST time from 48+ hours to four. They began with a consultation between CEO Toby King and Innomech to discuss what exactly they needed from the machine. This was followed up by the development of the machine and, finally, the design and build of the first machine (Mk I) delivered by May 2023. Mk I had a tight deadline, and despite supply chain issues, Innomech delivered.

In response to the project, iFAST CEO Toby King commented: “Innomech’s flexibility and pragmatism enabled iFAST to keep the project on track without constant changes to the scope, costs and timescales. Similarly, when things didn’t work quite as expected, we were happy to muck in and help fix them. Weekly project update calls throughout the project definitely helped with this.”

Ongoing development continued, leading to further Mk I machines being made. Units 1.2 and 1.3 were developed and delivered by the end of summer 2023. Further development work was undertaken to create Mk 2 to increase the capacity and automation level of the machines, and the

first Mk 2 machine was delivered by the end of September 2023.

According to Toby King, since the design, build and development of the first unit, the machines have already demonstrated that the iFAST technology can speed up AST testing so patients can receive the right antibiotic sooner.

In their very first hospital evaluation in Southampton General Hospital, iFAST achieved around 95% agreement with the current ‘gold standard’ method, but in four hours instead of 48 hours, across a total of over 600 tests. Once the product is approved, fewer patients will die as a result of antimicrobial resistance, which currently kills well over a million people a year.

Innomech continues to support iFAST through ongoing discussion and collaboration. With vital technologies such as this, the communication and forwardthinking needed to develop the best possible technology cannot be understated. Only through an effective working relationship can this be achieved. www.innomech.co.uk

Focus On: Connectivity

MEPCA explores a range of topics on connecting the factory environment P28 – Connected condition monitoring solution reduces downtime

CONNECTIVITY FOCUS

Condition monitoring solution reduces downtime.

Sheard Packaging, the UK’s largest independent corrugated cardboard box manufacturer, is using the moneo RTM condition monitoring system from ifm electronic as an aid to reducing costly and disruptive downtime. MEPCA found out more.

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ince starting to work with the moneo system from ifm, which is specifically designed to be easy to implement without the need for specialised programming knowledge, Sheard Packaging has detected and remedied a number of incipient faults which, if they had developed to the point of failure, could have cost the company hundreds of thousands of pounds in lost production.

Rapid growth in the demand for its products, driven in part by the increase in online shopping triggered by the COVID pandemic, meant that it was more important than ever for Sheard Packaging to ensure that its production plant was able to operate with a minimum of unplanned downtime. The company was, therefore, interested in implementing a monitoring system that would provide an early warning to its maintenance team if the operation of a machine started to deviate from normal, as this would allow remedial action to be implemented before a breakdown occurred.

While traditional condition monitoring systems would have performed this function, they have a reputation for being costly, difficult to install and complicated to set up. moneo RTM from ifm electronic has, however, been developed from the outset with cost-effectiveness and ease of use in mind. In particular, it connects easily with sensors that have IO-Link interfaces, and it allows users to set up application-specific dashboards so that they can see key plant information at a glance. It also provides flexible alarm functionality that instantly alerts users to anomalies in plant operation.

As a pilot project to determine just how useful moneo would be in its own plant, Sheard Packaging purchased a moneo software licence and a moneo hardware starter kit. The kit includes two vibration

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sensors, a speed sensor, a temperature sensor and a four-way IO-Link master, together with a moneo processing unit with the moneo IIoT platform pre-installed, and a Wi-Fi access point. Also included are a power supply and all necessary interconnecting cables to ensure that the kit offers a ready-to-use plug-and-work solution.

The initial set-up used the two vibration sensors on a Göpfert automatic high-volume cardboard forming machine. In a very short time, it was apparent that the moneo system was delivering invaluable information. As a result, within a month of the trial installation going into service, the moneo system had been extended to monitor data from no fewer than 60 sensors. Many of these were additional vibration sensors installed using glue-on studs, which made them fast and easy to fit without taking the machine out of service. Installation was further simplified by the use of pre-terminated plug-in cables to connect the sensors to the moneo system.

“The moneo system is very easy to retrofit to existing machines,” said Dean Sherman,

Electrical Maintenance Manager at Sheard Packaging. “Once it’s functioning, it makes it simple to visualise exactly what’s happening on the machines, which is an enormous operational benefit. We can see instantly, for example, if a bearing is starting to fail, which means we can schedule replacement work for a time when it will have minimum impact on production. A really excellent feature of moneo is that ifm provides a complete end-to-end solution: sensors, analytics and dashboard displays – it’s all done for you.”

To ensure that it gets the best from its moneo systems, Sheard Packaging has invested in training from ifm electronic, which covers topics that include custom dashboard configuration, detailed interpretation of results and analysis of historical data as an aid to maintenance planning. The company also plans to roll out moneo monitoring across its whole factory, with the next step being the installation of the system on an EMBA high-speed converting machine. ifm.com

CONNECTIVITY FOCUS

Future-proof your industrial networking Connectivity specialist, Brainboxes, explores how fibre optics and small form-factor pluggable technology can combine to enable the data demands of modern industrial automation systems.

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s digital transformation continues to drive efficiency and productivity across industry, increasing the demand for faster and more reliable data transmission, fibre optic technology has emerged as a crucial component in industrial networking infrastructure.

While closely related, SFP (Small FormFactor Pluggable) and fibre are not the same thing. As a transceiver (both transmitter and receiver in a single package), SFP interfaces with networking equipment such as Ethernet switches and PLCs to enable the transmission of data signals.

Where SFP is a specific type of transceiver module, fibre optics refers to the underlying technology; the entire system of transmitting data through optical fibres. Fibre optics offer higher bandwidth, faster speeds, and longer transmission distances compared to traditional copper cables.

During the 3rd industrial revolution, fibre optics revolutionised telecommunications by utilising thin strands of glass or plastic to transmit data as pulses of light. Today, this technology offers industry the ability to transform the factory floor, with numerous advantages over traditional copper-based wiring, including higher data transfer speeds, greater bandwidth capacity, immunity to electromagnetic interference, and longer transmission distances.

SFP is not a type of fibre optic cable itself, but rather a standardised, hot-pluggable transceiver module that allows for the flexible use of different types of cables. SFP modules are widely used in networking equipment, such as switches, routers, and media converters, to enable connectivity by supporting various optical and electrical interfaces, including Ethernet, Fibre, and SONET/SDH. One of the key benefits of SFP modules

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is their ability to support various types of cables depending on the application’s specific requirements.

This flexibility allows organisations to adapt their network infrastructure to different scenarios without replacing entire systems. By simply swapping out the SFP modules, businesses can easily reconfigure their networks to accommodate distance, bandwidth, or transmission technology changes.

SFP modules are hot-pluggable, meaning they can be inserted or removed from network devices without the need for powering down or interrupting the entire system. This feature provides immense convenience and flexibility in maintaining and expanding network infrastructure, minimising downtime and enhancing overall system reliability.

As technology evolves and network requirements change, SFP modules enable organisations to upgrade their network capabilities by simply replacing or adding compatible modules. This scalability allows businesses to adapt to growing demands without significant investments in new equipment, ultimately reducing costs and improving network performance.

SFP in industrial automation Modern manufacturing facilities rely on high-speed data transmission and seamless connectivity to support automation, realtime monitoring, and control of production processes. SFP modules are essential components for establishing reliable and high-

speed communication networks as they offer the flexibility to connect industrial devices, such as programmable logic controllers (PLCs), industrial Ethernet switches, and other automation equipment, to fibre optic networks, enabling efficient data transfer, remote monitoring and control.

The integration of SFP fibre with Gigabit Ethernet technologies enables efficient communication between various machines, sensors, and control systems, leading to improved productivity and reduced downtime. Brainboxes’ newly launched SFP Gigabit Ethernet switch range combines the scalability, centralised monitoring and control, and ease of installation and maintenance associated with SFP, whilst leveraging the advantages of fibre over copper in industrial applications: higher data transfer speeds, greater bandwidth capacity, immunity to electromagnetic interference, and longer transmission distances.

By adopting SFP and fibre optics, businesses can support the high-speed data transmission, seamless connectivity and improved network reliability essential to optimise today’s operations whilst futureproofing for the demands of tomorrow’s industrial automation market. www.brainboxes.com

NCC 8-pole bayonet locking > 5000 mating cycles Panel mount parts unplugged IP67 Solder and dip solder contacts

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CONNECTIVITY FOCUS

Plug-and-play connectivity from the sensor-actuator to the cloud Murrelektronik’s IO-Link portfolio includes the IP67-rated MVK Pro and IMPACT67 Pro Fieldbus modules. The robust modules provide on-board diagnostics and 4A per port output current.

They are available in all common protocols and can also be used independently of the Fieldbus.

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O-Link stands for ‘plug-and-play’ installation in automation technology.

Against a backdrop of increasingly complex production processes and plants, in which more and more data is being collected and networked, the communication standard creates maximum transparency from the sensor-actuator level all the way to the cloud. Murrelektronik has expanded its IO-Link portfolio with the IP67rated MVK Pro and IMPACT67 Pro Fieldbus modules. The new modules have eight multifunctional class A/B master ports, two L-coded M12 ports for supplying up to 16A of power, and are available for PROFINET, Ethernet/IP and EtherCAT. Fieldbus independent use is possible through OPC UA, MQTT, and JSON REST API – thanks to the integrated Standardized Master Interface (SMI). All in all, these devices lower costs and increase productivity while offering new options for service and maintenance.

Installation and start-up times are shortened because these modules can replace complexly wired, space-consuming control cabinets.

In addition to pure process data (I/Os), the new MVK Pro and IMPACT67 Pro modules also provide additional diagnostic data (voltage, current and temperature) for each port as well as for the entire module.

This enables operators to detect anomalies and optimise their processes using data analytics. Thanks to the IIOT protocols, this is standardised and does not require a controller.

The integrated A/B ports are real multitalents: The function can be configured at each pin – IO-Link, DI, DO, DIO or a combination. Automatic supply voltage switching means that the correct voltage supply, actuator supply for DOs, and sensor supply for DIs, is always used. Devices with higher energy demand are also powered directly from the module. Thanks to the 4A

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rating on each port, the need for an external power source is eliminated for such devices.

The L-coded M12 ports allow for daisychaining and provide up to 2 x 16A power, which simplifies installation and reduces cable runs. A plastic and metal housing and IP67 rating make these robust master modules.

The MVK Pro and IMPACT67 Pro Fieldbus modules round out Murrelektronik’s broad IO-Link portfolio that includes masters, hubs, converters, devices and connection technology. The new hub devices offer maximum flexibility to suit your application with input/output, so each pin on each port can be configured as the user needs. There is also now an added advantage of an M8 port offering for the IO-

Link hubs, enabling a more compact fieldmounted device. This adds more flexibility for mounting position and easy connection to M8 sensors.

Specialist Support Murrelektronik offers a free system consultation service and can help users add IO-Link to their system. For example, a spare port can expand the basic IO, connect to a smart sensor, or be used as an analogue converter. Alternatively, if the focus is industry 4.0 or IIoT, then IO-Link can handle the additional information contained within IO-Link / smart sensors to make these goals a reality. www.murrelektronik.uk

CONNECTIVITY FOCUS

Data foundations for networking and in-depth analysis With modern industrial sensors providing the data for the control system and a wide range of additional information, they form the basis for in-depth status analysis and data-driven decisions. The Sensorik4.0 concept sees Pepperl+Fuchs spotlighting communication technologies and aligning its portfolio with IIoT and Industry 4.0 requirements.

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raditional plant and process architecture involved the field devices – i.e., sensors and actuators – communicating only with the relevant control system, and only this control system was connected to other higher-level instances.

In the networked world of IIoT, this division has been eliminated. In essence, sensors can exchange data with a PC on a remotely situated office desk, provided that suitable connection technology is installed. IO-Link and OPC UA are established worldwide as uniform standards. IO-Link enables cost-effective, bidirectional connection of simple field devices. Ethernet-based protocols provide the basis for communication with more complex components, even over longer distances.

The IO-Link master with MultiLink technology from Pepperl+Fuchs Comtrol offers a proven solution for connecting the sensors by linking IO-Link and Ethernet technologies. It forwards the process data from IO-Link-capable sensors to the control system via PROFINET or EtherNet/IP and simultaneously transfers data from Indexed Service Data Units (ISDU) to SCADA systems or IIoT clouds via MODBUS TCP, OPC UA, or MQTT. The parallel transfer of process data is possible. All field-level information can be used in IT systems and cloud-based applications.

The new Pepperl+Fuchs IIoT starter kit was designed around the IO-Link master.

It supports the simple implementation of solutions for visualising and analysing sensor technology and RFID data and allows their seamless integration into Industry 4.0 applications. In addition to the master module, the kit contains IO-Link-capable sensors, an RFID read/write device, a tag, an Ethernet switch, the electric power supply, and all necessary cables. Software interfaces connecting to various platforms such as AWS, PTC, and AVEVA are already integrated into IO-Link master firmware. The starter kit highlights the possibilities offered

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by Sensorik4.0 and gives users an easy introduction to the digital transformation.

Sensors in IIoT Applications One component must meet two requirements to conform to the concept of Sensorik4.0: identifiability and the ability for bidirectional communication with a standard protocol. The component, therefore, bears an individual product identifier, which can be accessed via a suitable interface. In addition to reading out the sensor data, the interface allows intervention in the sensor configuration to parameterise or reparameterise the sensor. With simple sensors, this happens via IO-Link.

Identifying via RFID One example of this is the IUT-F190-B40 UHF RFID read/write device which features an integrated industrial Ethernet interface and communicates via a REST API. It can, therefore, be integrated directly into IT networks without an additional analysis unit.

The device can be fully parameterised and operated from there, eliminating the need for PLC programming. It can be quickly adapted to dynamically variable identification tasks and can be parameterised and commissioned via the integrated web interface. The IUT-F190-B40 is a flexible solution for production control and monitoring, trackand-trace applications, and other Industry 4.0 applications in factory automation.

Monitoring Machine Health The moving components in intact machines usually exhibit characteristic vibration patterns.

If these patterns change, conclusions can be drawn about damage and unavoidable wear. Vibration sensors detect such patterns and provide highly differentiated information about machine health. The sensor can equally

monitor the machine’s functional safety. In the VIM32PL vibration sensor, Pepperl+Fuchs offers an IO-Link-capable component suitable for numerous applications.

The device outputs a data set with averaged peak speed, acceleration, and temperature values. This data set enables specific vibration patterns to be assigned to individual machine parts. A justified alarm is triggered, or a servicing operation is initiated in time, as and when required. The machine control can switch to the safe state if critical limit values are exceeded. The IO-Link interface provides the information digitally for visualisation and analysis.

Radio Connection for Stand-Alone Units Stand-alone functional units in different areas can be connected to communication networks. The autonomous WILSEN ultrasonic sensor detects tank fill levels and transmits them wirelessly to LoRaWAN networks. Entire fleets of tanks, containers, and silos can be centrally recorded and managed in widely distributed process plants, municipal supply and disposal facilities, construction-site logistics, and agriculture.

Due to comprehensive communication capabilities, Sensorik4.0 provides the data foundation for cross-linked structures. www.pepperl-fuchs.com

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MANUFACTURING SOFTWARE

The key to excellence in the food and drink industry PlantRun, a production monitoring solution from industrial automation software specialist Tascomp, is helping food and beverage manufacturers achieve manufacturing excellence.

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n today’s highly competitive food and drink industry, delivering exceptional products efficiently is the ultimate goal. Achieving improvements hinges on data, and while manual data collection methods have been the norm, they have inherent limitations due to their time-consuming nature and potential for inaccuracies. Enter PlantRun, the production monitoring solution that transcends traditional OEE and downtime monitoring systems by seamlessly integrating live machine data with production information.

Developed by Tascomp, an industrial automation company based in Teesside with over 40 years of software development experience, PlantRun has been quietly transforming the industry.

The key to PlantRun’s success in achieving manufacturing excellence lies in its ability to collect data directly from machines and make it readily accessible to everyone in the most suitable format. Whether it’s through integration with third-party systems or triggered notifications displayed on TV screens or sent as text messages, PlantRun offers a range of practical features to suit the unique needs of each user.

PlantRun has successfully served numerous companies in the global food and beverage industry, from monitoring sparkling wine bottling lines in Turin to overseeing sandwich sealers and flow wrappers in Croydon. Each system is meticulously tailored to meet specific customer requirements, with a variety of optional features available. PlantRun’s in-house programming team can also create bespoke functionalities for users seeking unique solutions.

Closer to home, a sausage and burger manufacturer in Thirsk implemented PlantRun for production monitoring and continuous improvement. In addition to standard functionality, the company

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requested various features, including onthe-fly translations, foreign body alerts, and a banger counter.

Visualisation plays a crucial role in Lean techniques, aiding in the identification of areas for improvement.

PlantRun introduced a “Time of First Pack” Key Performance Indicator (KPI), which highlights the time elapsed from the start of a shift to the arrival of the first product in the packing area.

Quality In the food production sector, product quality is of utmost importance, given the stringent requirements that can lead to product rejection for issues such as underweight products or the presence of foreign bodies.

PlantRun enables real-time tracking of scrap costs throughout a shift, allowing for proactive resolution of emerging issues.

Notifications through email and priority messages on TV screens facilitate faster responses from key personnel.

By delving into the data collected from their production processes, a local bottling plant is now reaping the benefits of implementing PlantRun on their site.

When questioned about how PlantRun has streamlined its operations, the manufacturing manager offered insights: “Initially, in the early rollout of PlantRun, we were unaware of the lost time that issues with line build back, and constant stop-starting of the production line were amounting to. PlantRun enabled us to see that short stoppage was the main driver. By analysing and utilising this data,

we found that achieving an overall balance in the production line was crucial to minimising short stoppages.”

Examining the optimal run rates identified by the data collected by PlantRun, they successfully synchronised the speeds of the filler, labeller, and packing machines, resulting in a substantial reduction in downtime.

The manufacturing manager added: “Immediately, we witnessed improvements in output, and short stoppages dwindled from hours lost to minutes per week.”

Looking ahead, the bottling plant is expanding PlantRun’s functionality to focus on changeovers and ensure visibility across all key elements. Thanks to its seamless integration with the site’s ERP system, SKUs are automatically imported, and PlantRun uses the works order data to notify relevant staff about upcoming changeover events.

In a landscape marked by intense competition, PlantRun stands as the essential tool for achieving excellence in the food and beverage industry, bridging the gap between data-driven insights and tangible operational improvements. plantrun.co.uk

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IMAGING & VISION

Optimal control of laser applications Quantum Design, the UK distributor of the InfraTec Image IR Series of thermography cameras, explains how the technology can be used for the optimal control of a series of laser applications.

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aser applications are of vital importance in today’s industry, science and medicine, because the properties of laser radiation result in numerous different applications. Among numerous industrial lasers, there are those that involve the application of thermal energy for material processing. This is where permanent monitoring and control of the heat development play an important role in order to process materials in accordance with their properties and comply with quality and safety standards.

Laser applications that use ther¬mo¬graphy successfully include laser sintering, laser cutting, laser welding and laser soldering.

Thermography enables the non-contact visualisation and analysis of the heat flow in the respective measurement and test objects or components. The temperature measurement on their surface allows the energy input of the laser to be controlled and ensures that the object to be processed is heated optimally.

The advantages of process control with thermography include non-contact and non-reactive temperature measurement, and the mapping of heat flows in components to gain a complete understanding of the process. Thanks to high measurement accuracy, the control of precisely adjusted energy input and a reduction of thermal load is possible with the exact calculation of the final energy input by laser into the component due to complete geometrical and temporal recording of temperature distributions in highly dynamic processes.

The optimum positioning of non-visible lasers (UV laser, IR laser) is also possible, as is the reliable monitoring of the heating and cooling processes of materials.

The overarching benefits of using thermography include the possibility for

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the early detection of errors in production, active avoidance of rejects and minimisation of returns, plus the optimisation of process and cycle times as well as pre- and postprocessing. The non-destructive testing of laser welded joints is also possible, as is direct laser control based on the observed object temperature in real-time. While the derivation of correlations between process parameters and (melting) temperatures also offers advantages.

Infrared cameras for the investigation of laser applications have to meet very specific requirements. This applies, for example, with regard to the temporal resolution: it is characteristic for working with a laser to have short laser action times, where heat input takes place within fractions of a second.

This requires measurements with high image frequencies in full and partial images.

Especially in micro-material processing with pulsed laser light, the demands on thermography systems – such as the ImageIR 8300 hs – are very high because the processes run at high speeds.

The thermal and geometric resolution of infrared cameras is equally important.

Depending on the process and material,

lasers can be used to generate very large and small temperature differences, which must be monitored precisely and continuously.

Here, InfraTec offers different functions of the cameras, such as HighSense-mode, HDR function, binning mode and geometric resolutions in the HD range.

Often, it is necessary to monitor very precisely – even on fine structures or locally – which input of thermal energy is induced and what the processing temperatures of all materials involved in the process are.

Consequently, the combination of geometric and thermal resolution of the camera determines the success of the respective application.

Infrared cameras for laser materials processing include the new InfraTec ImageIR 6300 Z – a small, lightweight, compact system for universal use in thermographic temperature measurements in a wide range of applications. Its excellent priceperformance ratio and user-friendliness result from the systematic use of the latest technologies in optics, detector and electronics. qd-uki.co.uk

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VALVES & ACTUATORS

Connecting with our digital future Rotork, a global provider of mission-critical intelligent flow control solutions, has introduced a mobile app that has integration with its new IQ3 pro range of electric actuators. MEPCA found out how the app opens up new control and communication options for the new actuator.

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he IQ3 range is renowned for being one of the most robust and intelligent actuators in the industry, and Rotork is excited to introduce the new IQ3 Pro with full mobile app integration. This evolution enables the continual development of new features that drive digitisation and future-proofing of electric actuation.

A new Rotork App provides intelligent control and communication capabilities for the IQ3 Pro and is a handy way to operate and configure the actuators using a smartphone. The new app introduces smart features, including a virtual Rotork Bluetooth Setting Tool Pro (BTST), a valve configuration setup wizard, which streamlines commissioning and data logs from the IQ3 Pro actuators, which can be extracted via the app and exported to Rotork Insight 2 software or sent to Rotork’s cloud-based intelligent asset management (iAM) system.

The app features ‘PIN pairing’ between the actuator and the app to gain access,

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which ensures the security of the installed actuators. Once logged in, a user-friendly dashboard shows the actuator details, and users can easily navigate to all App functions. A virtual setting tool provides full access to the actuator on-screen setup menus, so you always have it to hand.

An intuitive valve configuration wizard allows users to streamline the process of commissioning valves. Alternatively, those engineers who are comfortable with commissioning valves can use the built-in manual configuration, which brings all valve and actuator settings into one place.

The data logs function simplifies the process by allowing flexible download, export, and upload. Users can export the data logs to Rotork’s Insight 2 software for further analysis or send them to Rotork’s cloud-based intelligent asset management (iAM) system.

The IQ3 Pro data logger can record up to 3,000 events, providing a comprehensive record of actuator performance. The data log files include torque and operation,

temperature, vibration, and event log information. Other metrics, such as partial stroke profile, maximum starts per hour, and motor run time, are also available.

Rotork’s Insight 2 is a software application that helps users review, configure, and analyse data logger information for Bluetooth wireless-enabled Rotork actuators. The logged data is time- and date-stamped and can be viewed event-by-event. iAM helps businesses manage their intelligent actuators and the flow control equipment they operate. iAM is a robust, safe, and secure platform with a user-friendly interface. It uses colour-coded maps and summary views to simplify complex analytics into easy-to-understand visuals. iAM eliminates the need for manual data review, saving time and reducing asset failures. iAM helps reduce unplanned downtime by using analytics based on data taken from intelligent actuators to create a maintenance plan. www.rotork.com

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CALIBRATION

Enhancing calibration efficiency and compliance IndySoft outlines how its calibration management solution supports the modernisation of calibration practices for customers who prioritise efficiency, accuracy, compliance and precision.

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n today’s rapidly evolving technological landscape, precision and accuracy are paramount across various industries. The need to ensure that measurement and test equipment (MTE) are calibrated and maintained at optimal levels has led to the emergence of robust calibration management software solutions. One such industry leader in this field is IndySoft’s Calibration Management Software, renowned for its multifaceted benefits that streamline operations, enhance compliance to many international ISO and FDA standards, and foster a culture of quality assurance within a business.

At the heart of IndySoft’s value proposition lies its ability to centralise and automate the calibration process. This automation translates to improved efficiency, reduced human errors, and significant time savings.

The software facilitates the scheduling and tracking of calibration events, alerting users well in advance to impending deadlines.

This proactive approach helps organisations avoid costly downtime due to expired calibrations, ensuring that equipment is always in peak working condition. By eliminating manual tracking methods, IndySoft empowers technicians to focus on tasks that truly require their expertise, thereby boosting overall productivity.

The software’s user-friendly interface provides a clear overview of the calibration status of all equipment within an organisation. This transparency fosters accountability, as responsible parties are easily identifiable and held to their duties. Moreover, the system generates comprehensive reports and certificates,

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serving as a digital trail of the calibration process. This documentation is invaluable during audits and regulatory inspections, streamlining the compliance process and mitigating risks associated with noncompliance.

IndySoft’s versatility shines through its adaptability to various industries, ranging from manufacturing and aerospace to healthcare and energy. Its customisable features allow organisations to tailor the software to their specific needs, accommodating unique calibration requirements and workflows. This adaptability ensures that IndySoft remains an asset regardless of the industry’s intricacies, contributing to its widespread adoption and reputation for excellence. The software developed today has evolved as a direct result of many customer requests and also

by IndySoft keeping an eye on emerging technologies.

The software’s remote capabilities add a layer of convenience and accessibility. With the ability to access the system from any location, technicians can perform calibrations in the field, reducing the need for equipment to be transported back to a centralised facility. This not only saves time and resources but also enables rapid response to

calibration needs, particularly in industries where mobility is crucial.

In an era where data security is paramount, IndySoft shines with its robust security measures.

It employs encryption protocols to safeguard sensitive calibration data, protecting against unauthorised access and potential breaches. This focus on data security not only aligns with industry best practices but also provides organisations with peace of mind, knowing that their critical calibration data is shielded from potential threats.

IndySoft’s calibration management software is a sustainable solution that aligns with eco-conscious initiatives. By reducing paper-based processes and minimising the need for physical transportation of equipment, the software contributes to a greener approach to calibration management. This aligns with the growing corporate emphasis on environmental responsibility and sustainability.

In conclusion, IndySoft Calibration Management Software emerges as a pivotal tool in modernising calibration practices across industries. Its comprehensive suite of benefits, including streamlined efficiency, enhanced compliance, adaptability, remote capabilities, data security, and sustainability, positions it as a market leader. As organisations continue to prioritise accuracy, precision, and compliance, IndySoft’s software becomes an indispensable asset, propelling businesses toward higher levels of operational excellence and quality assurance. www.indysoft.com

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TEST & MEASUREMENT

X-ray inspection system delivers improvements The Electronics Group chose to buy a new Nordson X-ray inspection system from Cupio because of the company’s service quality as well as the machine’s capabilities, a decision that proved to be well-justified.

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he Electronics Group is an IPC & Electronics Training Centre that also offers technical inspection services for the electronics industry. Launched in 2003, the Group has been an Authorised IPC Distributor since 2016 and has had X-ray inspection capability since 2008.

The Electronics Group provides IPC and bespoke electronics training to companies of all sizes throughout the UK and abroad.

Courses are offered at its Leeds training centre, as well as remotely and on customers’ premises. The company’s expert team provides technical inspection services, including X-ray and BGA rework, specialist electronics recruitment, and supplies IPC Standards, workmanship kits, and CQI credits.

X-ray inspection capability has always been an important part of the Group’s offering. However, its incumbent machine was becoming increasingly unreliable and expensive to operate. Dan Bloyce, General Manager at The Electronics Group, estimates that repair costs exceeded £50k over recent years, so a new system was essential.

Choosing the Quadra 3 About four years ago, senior Group members visited Cupio’s Basingstoke facility, where MD Andy Bonner demonstrated the Quadra 3 X-ray inspection system and discussed its potential benefits. More recently, after comparing proposals from Cupio and the existing X-ray inspection system supplier, Dan spoke to Fermionx Ltd – a contract electronics manufacturer who also owns and operates a Quadra 3 – which not only recommended the Quadra 3’s capabilities but also Cupio’s training and service quality. Accordingly, Dan decided on a Quadra 3 system from Cupio.

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“Even the best technology will never be entirely free of issues,” Dan commented, “What matters is how the supplier supports us when problems arise.

After getting good vibes from our discussions with both Fermionx and Cupio, I believed we had found the right product and the right supplying partner.”

Productivity and quality benefits The Group’s subsequent experience has fully justified its decision. From the outset, Cupio ensured that the Group rapidly benefited from the new system’s capability. After full installation and commissioning, Cupio provided on-site training. This went quickly because The Electronics Group already understood X-ray inspection – it simply needed to appreciate the specific features of the Quadra 3. However, the comprehensive instruction allowed the trainee, in turn, to educate the Group’s four specialists who would be providing student training.

“Since installation, we have already seen huge benefits,” Dan added. “A large regular customer sends us typically 12,000 boards per shipment, arranged on trays of about 30. Previously, it would take about 90 minutes to inspect each tray. Conversely, the Quadra 3 took about 15 minutes to set up, and then the runtime for inspection was about 10 minutes – a huge productivity and timesaving benefit. We can just load and run a tray without the need for supervision, so we can perform other tasks. Previously, we had to use contractors to operate the machinery and manually inspect everything.

“The new system also offers significant business development advantages. We can complete inspections much more quickly, enabling us to offer more attractively-priced

proposals – and when customers see the results, they are more inclined to provide repeat orders.

“This highlights how the Quadra 3 offers greatly superior quality and productivity.

Customers have already commented on the image quality, which they regard as a vast improvement over that of the previous machine.

“We also believe we are enjoying these benefits at an optimum price point. We considered the more powerful Quadra 5 and Quadra 7 systems but decided their capabilities are surplus to our requirements; we are not a full production facility regularly processing thousands of boards. The Quadra 3 handles all our needs and more, at a price we are happy to pay.

“The machine will contribute significantly to The Electronics Group’s strategy as we expand our market and seek new business.

Additionally, we know we can rely on Andy’s advice to help us along. It has always been straightforward, unambiguous and truthful, whether the situation is good or bad.” www.cupio.co.uk

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LINEAR ACTUATORS

Lifting column takes cobot palletising to new heights Electric linear actuator specialist, LINAK, is using its technology to add value to cobot-based palletising solutions, as MEPCA found out.

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here is an untapped automation potential for palletising goods in production and other industries. Realising this potential requires flexible, easy-to-use and affordable cobot solutions that can adjust to different palletising setups and generate rapid return on investment.

To meet these demands, LINAK has launched the ELEVATE lifting column, a new product that extends the reach of cobot palletisers in height where it is especially relevant. It also delivers on speed, flexibility and precision to optimise the palletising process and ease the setup, programming and monitoring of the system.

Heiko Kleineder, Business Development Manager at LINAK, explained: “ELEVATE extends the reach of your cobot and enables it to palletise higher. This not only optimises the stacking process, but it can also reduce freight costs as each pallet carries more goods. With ELEVATE, we tailored a lifting column for cobot palletisers with a focus on fast lifting speed, interfaces, stability and compactness. The fact that it can be combined with a regular cobot makes it an affordable solution.”

New levels of performance With its fast lifting speed and optional simultaneous run, ELEVATE boosts palletisers to match the cycle time of the production line. The lifting speed is constant with up to 100mm/sec. and independent of load. With a brushless motor and an integrated controller, ELEVATE provides high position accuracy. Proven slider technology keeps the cobot steady and able to withstand high bending moments while moving.

The integrated controller allows for compact size and eliminates the need for external control boxes. This makes ELEVATE extremely space-saving and easy to

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integrate and even reduces the complexity of the whole palletiser system.

Three interface options – ELEVATE Easy, Pro or Modbus – offer the level of control and feedback required by a specific task, and data enable smooth troubleshooting, diagnostics and optimisation of performance. Due to these interfaces, ELEVATE is compatible with a wide range of cobots. Accessories like cobot mounting plates make it easy and fast to set up.

Markus Hofmann, Product Manager at LINAK, added: “ELEVATE comes with an accessory kit for easy setup. The kit includes mounting plates, cables, and, in individual cases, a cobot brand-specific driver software, such as a URCap for cobots from Universal Robots. Furthermore, you can use ELEVATE with your preferred power supply and safety relay. This makes ELEVATE an adaptable component within multiple palletiser setups.”

A match for modern production The Danish system integrator BILA A/S is one of the customers that got to test the product before launch, and Product Manager Brian Spetzler was impressed: “Our experience with the ELEVATE lifting column has only been positive. It is easy to set up, and the intuitive software plays a key role, as it enables fast configuration as well as re-configuration. This is important in production environments, where the setup is not permanent, and needs can change. In modern production production environments and warehouses, we see a trend towards automated palletising, and with increasing freight costs, palletising at height has become vital. These are some of the reasons we are excited about the ELEVATE column.” linak.co.uk/elevate

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MACHINING

Milling instead of drilling Using a milling cutter instead of a drill to drill bores into a workpiece is a suggestion that takes some getting used to and initially causes many manufacturers to frown. However, the technology change makes sense for some parts, especially in the field of e-mobility. MAPAL shows that this not only allows greater process reliability, but even shorter machining times.

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he fastest way to drill a bore is using a suitable drill. A milling cutter with a smaller diameter that enters the material circularly covers a significantly longer distance during machining, which results in a higher cycle time. However, certain materials can cause non-productive times that cancel out the drill’s time advantage.

During the course of the transformation to e-mobility, welded designs or structural parts are to be machined that consist of long-chipping aluminium. Battery housings, for example, are often made from extruded profiles that contain either no silicon at all or only a very small amount. That makes chip breaking more difficult and leads to nests of chips that can get stuck in the machine or on the tool. The same problem comes up when machining chassis parts made of forged aluminium, where manufacturers also struggle with long chips. If they settle on the shank of the tool, an automatic tool change may no longer be possible. Chip clusters cause disruptions that have an adverse effect on the machining time.

Especially during drilling from solid or certain boring operations, a burr can form, which is pressed out and wraps around the tool as a ring. “These rings accumulate at the tool cutting edge and can damage the workpiece and the tool”, explained Leander Bolz, Sales Manager of PCD Tools.

In principle, drills can be equipped with chip breakers, but these usually impair the tool life. In addition, with the materials used, it is not always guaranteed that the chip breaker will reliably do its job. Aluminium with a low silicon content can display different properties depending on cast, batch or storage condition, which is also reflected in different chip formation. This means that in practice, the stock removal situation of the pre-machining is often changed. While blades or entire tools sometimes have to be replaced with a drilling tool, the stock

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removal with a milling cutter can easily be reduced or increased via the driven tracks.

Milling brings flexibility The milling strategy also demonstrates its flexibility when bores with different diameters are required. A single milling cutter can be used for this. For larger bores, it eliminates the need to replace one or even two drills for pre-machining. MAPAL favours using the milling cutter for the materials in question since it is possible to save time, particularly during pre-machining, which outweighs the initial performance disadvantages compared to drilling. For certain workpieces, the milling cutter is superior from the outset, for example, when there is a risk of deformation due to drilling thin walls of structural parts or when bores with a very specific roughness are required in chassis technology.

Combination tools further reduce the cycle time, as Leander continued: “If the milling

operation sits at the front of the tool and the fine machining behind it, the bore can be created completely in one pass.”

With various geometries to choose from, the tools are adapted to the respective machining operation. MAPAL offers SPM milling cutters (Structural Part Machining) with polycrystalline diamond (PCD) cutting edges for machining aluminium. These very sturdily designed high-volume milling cutters were originally developed for the aerospace industry to machine material from solid.

MAPAL has successfully tested the ‘milling instead of drilling’ process with several customers and has changed machining operations thanks to the positive results. “We have to break up old patterns of thinking and dare to do something new,” said Leander, who is working to convince people of the same. mapal.com

MATERIALS HANDLING

Pallet system for round battery cells Aluminium profiles and conveyors specialist mk Profile Systems explains how it was able to create a pallet circulation system for a manufacturer of batteries for electric vehicles.

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manufacturer of batteries for electric vehicles joins together individual round cells to make battery modules.

The manufacturer wanted these round cells to be inspected fully automatically in the goods receipt area.

To this end, it required a pallet circulation system with different interfaces. A robot takes several individual round cells as a set from the packaging and places them on the conveyor system. The cells first need to be separated in order to ionise them against an electrostatic charge. They are then placed in individual compartments of a tray. The individual cells are subjected to different tests along the cycle. The trays must be stopped and positioned at the stations so that the tests can be carried out automatically. The circulation system also needs a mechanism by which to separate defective parts. A tray holds 14 cells and must complete the entire cycle within 15 seconds. On account of the many test and robot stations along the system, the space available on site is very limited.

Solution from mk An mk ZRF-P 2040 timing belt conveyor was used to implement this pallet circulation system. Index stations allow the trays to be positioned within an accuracy of +/- 0.2 mm.

This ensures that the automated checks can be performed reliably. A ramp serves as an infeed into the conveyor system. A robot places the cells onto this ramp. They are separated and then slide into the individual compartments of the tray. Due to the short cycle times and the limited installation space, a shuttle was constructed to transfer the trays to the workpiece carrier return line. The conveyor technology transports the trays into the shuttle, where they are then quickly transported to the parallel conveyor system for the return journey using a linear unit. At

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the end of the line, the cells are removed from the trays so that the trays are available for loading again. mk was able to provide a solution which was a bespoke design configured from its

standard construction kit. The solution has given the customer short cycle times for high output quantities. www.mkprofiles.co.uk

MATERIALS HANDLING

Keeping wind turbine blades moving During the last week of September, Combilift welcomed several hundred visitors to its HQ and manufacturing facility in Monaghan to celebrate the company’s 25th anniversary. Events included factory tours, demos of new products and the opportunity to get an insight into Combilift’s global success with a Q&A with Combilift’s CEO and co-founder Martin McVicar, plus the launch of an exciting new product for the offshore wind sector.

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t the well-attended anniversary event, Combilift announced its move into the offshore wind sector with the launch of a new product designed to meet the loadhandling demands of large-scale offshore wind manufacturers. As the green energy sector sees a surge in larger wind turbine components, including towers and blades, Combilift’s collaboration with industry leaders has resulted in the safe, stable and efficient lifting and storage of these extreme loads.

Combilift worked with Siemens Gamesa, one of the world’s largest offshore wind suppliers, to design the Combi-LC Load Carrier. This enables the movement of wind turbine blades and towers – some as long as 115m and weighing in at around 70t, through production stages and on to storage locations – which can sometimes be as far as 5km apart. The concept is based on two fully customisable remote-control units with low-level chassis beds that can work in tandem master and slave operation, with dimensions and wheel configurations that vary according to load type and weight.

Combilift is in active discussions with other offshore wind companies with similar demands and expects to generate over €50m in revenue per year in this market segment by 2026.

The Combi-LC carrier unit boasts a unique attachment designed to securely grip the substantial cylindrical end of the blade, firmly affixed to the generator hub.

This robust machine, powered by a 75t capacity diesel engine and equipped with 12 wheels, offers versatile multidirectional steering with six wheels. What sets it apart is its ‘tip side’ carrier unit, which smoothly

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manoeuvres beneath the blade, supporting it via a hydraulic tilting table-mounted clamp toward its narrower tip. These units often operate in demanding environments with less-than-ideal ground conditions, making their robust design and adaptability all the more essential.

Josh Moffett, Heavy Equipment Manager at Combilift, said: “We believe the Combi-LC will act as a gateway for us to further progress within our venture into the wind energy sector.

The scale of offshore wind projects around the world leads to a unique set of challenges, one of which is the ability to transport the very large components that make up a wind turbine.

The product is specifically made to order and

therefore can be uniquely customised to fit specific applications.”

Martin McVicar, CEO and co-founder of Combilift, added: “We have a track record of innovation at Combilift. We invest 7% of our revenue annually in R&D, and we are delighted to be continuing this tradition of innovation 25 years on. We now employ over 800 people in Monaghan and 200 people in other locations across the world, and the success of Combilift is a testament to our people, our customers, and our supporting global dealers. We are looking forward to the next 25 years at Combilift.” bit.ly/combi-LC

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MATERIALS HANDLING

Charge ahead with lithium-ion While traditional ICE forklifts may still be the best fit for some jobs, more applications than ever are suitable candidates for electrification, which could help operations overcome common productivity challenges, as Robert O’Donoghue, VP of Marketing and Solutions, EMEA at Hyster, explains.

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ithium-ion batteries are gaining traction. These power sources are now available in more lift truck product classes and capacities than ever before, capable of delivering the long-lasting, high performance that intensive applications require.

Here are three ways that your industrial manufacturing operations could charge ahead with lithium-ion-powered equipment.

Maximise operator comfort With an integrated lithium-ion battery, the Hyster J2.5-3.0XNL series lift trucks deliver easy access to the spacious operator compartment. Greater headroom, more space for the operator to move their feet, and a choice of seat options all help to maximise operator comfort. This, in turn, can help support productivity.

These Hyster forklifts, which can lift up to 3 tonnes, also have a reduced weight. This leads to improved acceleration and reduced energy consumption. A repositioned centre of gravity in the design also enhances drive quality and handling, especially when cornering.

As the lithium-ion battery can be opportunity charged during operator breaks, the J2.5-3.0XNL electric lift trucks are well suited to manufacturing operations that require fast and flexible charging, with the added benefit of a maintenance-free battery (compared to a lead acid alternative).

and fuel consumption, and helping lower maintenance costs. With the benefits of lithium-ion battery power, these lift trucks offer exceptional traction power, acceleration, and visibility that will make operators feel like they’re driving a diesel truck.

For lifts up to 18 tonnes, the lithium-ion forklifts are designed to boost performance and efficiency in intensive applications. As well as powering tough indoor and outdoor handling, the integrated lithium-ion batteries also help produce higher performance throughout the charge cycle and have a longer life cycle, helping to reduce your total cost of ownership. With zero maintenance and fast charging times, this also contributes to big operational savings and more uptime.

Heavy loads and harsh conditions

Improve efficiency in the stores

Lithium-ion batteries started small, powering pallet trucks moving loads of consumer goods in and out of trailers and retail stores.

Now, lithium-ion-powered forklifts, like the Hyster J10-18XD, may offer some tough industry application benefits over ICE and lead-acid battery-powered models.

The Hyster J10-18XD series can power your possibilities by reducing emissions

Demanding applications need equipment that can help maximise productivity. Here, the Hyster PC1.5 can help. In industrial manufacturers’ warehouses, it provides an alternative to hand pallet trucks that uses lithium-ion battery power to deliver three times the efficiency.

Lithium-ion-powered travelling, lifting, and lowering not only improves efficiency

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but also reduces strain on operators in tough, busy storage operations. With a durable steel frame design and protective cover, the ultra-compact pallet trucks stand up to operational challenges and harsh environments.

To keep critical operations moving, a recharge alert flags when it is time to plug in the PC1.5 pallet truck. For more intensive operations, a large battery option with a fast charger is also available. The maintenancefree lithium-ion battery also helps to optimise uptime.

Evaluating your power options A well-matched power source can have a significant impact on many aspects of operations, including higher productivity and lower operating costs. That is why businesses should take the time to reevaluate today’s available power options to ensure they are getting the most from their fleet.

Hyster has developed trucks that leverage lithium-ion power to bring benefits to tough trucks for a range of manufacturing industry operations. www.hyster.com

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MATERIALS HANDLING

The future of robotic warehousing solutions In today’s fast-paced world, the logistics and warehousing industry faces increasing demands for efficiency, accuracy, and cost-effectiveness. To meet these challenges, companies like Logistex have been at the forefront of innovation, developing robotics solutions that are shaping the future of warehousing.

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ogistex is recognised for being a leading systems integrator in warehouse automation and logistics solutions within its class. With a rich history spanning over three decades, the company has continually adapted and evolved to meet the changing needs of customers.

The company’s commitment to innovation has led to the development of a wide range of automation and robotics solutions that optimise warehouse operations, enhance productivity, and reduce operational costs.

Evolution Logistex has been a pioneer in introducing robotics solutions that integrate seamlessly into the warehouse environment. Its robotics solutions have evolved from basic automation systems to sophisticated, AI-driven machines capable of performing complex tasks. These robots have proven invaluable in streamlining various aspects of warehousing, including: Order picking: Robotic systems can autonomously navigate through warehouse aisles, identify and retrieve items, and assemble customer orders with remarkable precision. This reduces human labour requirements, minimises error, and enables employees to focus on other areas of the business.

Inventory management: Advanced robotics integrated by Logistex can efficiently conduct inventory audits, ensuring stock accuracy and reducing the need for manual stock-taking.

Material handling: Material handling robots can transport goods within the warehouse, optimising the flow of products and minimising bottlenecks.

Collaborative robotics: Logistex has also ventured into collaborative robotics, where robots work alongside human employees to enhance efficiency and safety in the warehouse.

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The future As we look ahead, the future of robotics solutions integrated by Logistex appears incredibly promising. Here are some key trends and developments to watch for: Increased customisation: Joining partnerships with robotic companies such as Hai Robotics, Logistex may offer more customisable robotics solutions, allowing businesses to tailor automation to their specific needs. This flexibility will make robotics accessible to a broader range of industries and warehouse sizes.

Sustainability initiatives: Logistex is likely to focus on sustainability by developing eco-friendly robotics solutions that reduce energy consumption and minimise the environmental impact of warehousing operations.

Enhanced collaboration: Collaborative robotics will become more advanced, ensuring that humans and robots can work harmoniously together, enhancing productivity and safety. In some cases, they can be used on a temporary basis, such as during peak times, e.g. Black Friday sales, saving additional costs for seasonal staff.

Pick and place robot technologies: One of the more recent advancements in warehouse robotics is the effectiveness of robot arms for picking, placing and inventory manipulation tasks. Driven by improved camera capabilities and AI, which enables these robots to identify the handling characteristics of a high range of SKUs, complex packaging and fragile items, Logistex believes they will be increasingly used in warehouse operations. They will deliver increased throughput, a reduction in

labour, and faster and more accurate order processing.

Software platform (WES): Logistex continues to develop its world-class Warehouse Execution Platform (WES), which not only integrates the various forms of warehouse automation, including robots, but optimises the picking of orders across a DC. Using real-time information on the current status of warehouse tasks, it will orchestrate orders to ensure that they are picked by the most appropriate form of automation considering congestion, order characteristics and other constraints. This leads to improved efficiencies and faster and lower cost order fulfilment rates. Logistex WES will also enable fast adoption of new technologies whilst reducing complexity by simplifying the IT landscape required to operate a multi-agent DC. In conclusion, Logistex has demonstrated a remarkable commitment to shaping the future of warehousing through its robotics solutions.

As technology continues to advance, we can expect Logistex to play a pivotal role in transforming logistics, making it more efficient, cost-effective, and sustainable. By embracing automation and robotics, companies can look forward to a brighter future in the world of warehousing. www.logistex.com

PUMPS & PUMPING SYSTEMS

Improving spent grain transfer efficiency As part of an ongoing programme of carbon reduction projects, Tennents Lager has worked with progressive cavity pump specialist, SEEPEX, to improve energy efficiency in its spent grain transfer process.

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ennent’s Wellpark Brewery is Scotland’s oldest brewery, tracing its roots back to the 1500s. Since its establishment in 1885, it has consistently produced award-winning brews. The brewery’s fascinating story revolves around Hugh Tennent, who defied sceptics in 1885 to create Tennent’s Lager, initially dubbed a ‘madman’s dream’ by newspapers. Today, Tennent’s Lager dominates the Scottish market, accounting for every second pint of lager consumed in the country.

Enhanced efficiency As part of the brewery’s process, spent grain is transferred from two mash filters that drain the spent grain to 24%DS. Originally, the spent grain fell from the mash filters into an expeller unit from where it was conveyed over 64m with a 20m elevation to the silo. With the expeller, the grain transfer took ~90 minutes after each brew and used 1,125Nm³ of air.

Tennent’s Lager, part of leading drinks manufacturer and distributor C&C Group, is committed to a robust sustainability strategy, exemplified by ambitious carbon reduction targets. These targets aim to achieve a 35% reduction in scope 1 & 2 emissions by 2030 and have been validated by the Science Based Target initiative.

In recent years, Tennent’s has made significant investments in various carbon reduction projects, including carbon capture and anaerobic digestion plants. Additionally, Tennent’s has partnered with SEEPEX to improve energy efficiency in its spent grain transfer process, which is the most air intensive process on site.

Together with SEEPEX, Tennent’s explored the benefits of SEEPEX’s cutting-edge Smart Air Injection (SAI) technology. This groundbreaking solution combines an open hopper progressive cavity pump and pneumatic

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Tennent’s brewery achieves 56% air savings with SEEPEX’s SAI technology.

dense-phase conveying to efficiently transfer 15-40%DS spent grains, draff, and hops in plugs. Controlled air pulses enable seamless conveying over long distances.

SEEPEX established the optimum operation point with minimum air consumption to reduce the original air consumption and carbon footprint, and also assessed the energy efficiency in comparison with the initial system. SEEPEX was able to calculate all the consumptions, eliminating the need to carry out a trial.

A path to sustainability The demonstrated energy efficiency from SEEPEX Smart Air Injection (SAI) enabled Tennent’s to access the Scottish Industrial Energy Transformation Fund (SIETF), designed to support the development and deployment of technologies that enable businesses with high energy use to transition to a low carbon future. Through this, the government funded 30% of the project.

Air consumption has decreased by an impressive 56%, dropping from ~1,125Nm³ to 500-700Nm³ per brew. Furthermore,

there is a decrease in spent grain transfer time associated with the SAI system. The reduction in air use contributes to Tennent’s carbon reduction plan by reducing electricity use within the site.

Seamless maintenance As Tennent’s embraces the future of brewing, it benefits from SEEPEX’s plannedCARE package. This comprehensive service ensures proactive, on-time planned pump maintenance, guaranteeing uninterrupted operation. This includes diagnostics to identify potential issues, enabling planned, proactive maintenance for increased uptime and lower total cost of ownership.

Tennent’s commitment to innovation, efficiency, and sustainability shines through its partnership with SEEPEX. With enhanced efficiency, substantial energy savings, and a focus on seamless maintenance, Tennent’s continues to set the benchmark for excellence in the brewing industry. www.seepex.com

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HVAC

Fan selection in fume extraction systems Industrial air movement and fan integration specialists, Axair Fans, has published a comprehensive free-to-download specifier white paper, ‘The Ultimate Guide to Fan Selection in Fume Extraction Systems’, designed to help readers master the process of fan selection in complicated fume extraction systems.

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ith laboratory set-up, operational maintenance and the intricacies of daily running, ensuring worker safety, regulatory compliance, and operational efficiency in labs is paramount.

To a new contractor, specification consultant or in young building services roles, this can be a daunting task as you don’t initially specialise in a particular niche. Containment of chemical substances is one of the key activities in laboratories and process systems, and at the core of these systems, when maintaining the required pressure and airflow to extract fumes effectively, the responsibility rests with the industrial fan. This makes correct fan selection one of the most important system specifications.

Free to download from the Axair Fans website by scanning the QR code shown or visiting the link, the comprehensive ‘Ultimate Guide to Fan Selection in Fume Extraction Systems’, written by the experts in fume fans and air movement for chemical applications, is a roadmap to mastering the process of fan selection in complicated fume extraction systems, ensuring a healthier, safer, and more productive workspace.

Navigating the array of fan options can be overwhelming, especially when faced with the challenging task of managing hazardous fumes and airborne contaminants. That’s where Axair’s guide comes in. With over

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30 years of fan selection expertise, the company has condensed the complexities of fan selection into an accessible and easy-to-understand document that equips readers with the knowledge needed to make informed decisions. Covering a wide range of topics, from supplier choice, understanding the questions being asked to ensure system compliance, and understanding airflow requirements and system compatibility to deciphering the nuances of corrosion

resistance and material durability, understanding what polypropylene is, and if it is a more practical material than stainless steel or GRP, the practical toolkit can guide readers through the selection process.

Where static discharge can be a concern in certain environments such as chemical laboratories, the paper explores the role of carbon-loaded ATEX fans that effectively dissipate accumulated static discharge, and helps readers understand ATEX zones, categories, and temperature classes, while also giving a deeper understanding of the relationship between fan specifications, ductwork design, and safe fume extraction.

The guide also explains the importance of EN14986, known as ‘The design of fans working in potentially explosive atmospheres’, and how products must be constructed in compliance with directives to ensure fan components do not act as a source of ignition, alongside looking at permissible pairings, clearance of rotating parts and what Ex h means in ATEX labelling.

By the time readers have gone through the pages in the guide, they will be in a stronger position to write specifications to pass to future stakeholders, to talk to suppliers confidently or to troubleshoot poor system performance, armed with the information needed for fast and efficient decisions. bit.ly/AxairFEGuide

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BATTERY TECHNOLOGY

Li-ion battery risks reduced by VOC sensors VOC gas sensor specialist ION Science explains how Photoionisation detection (PID) sensors are able to detect potential problems before they occur in the manufacture and use of lithiumion (Li-ion) batteries, and the enormous variety of devices that use rechargeable batteries.

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he safe utilisation of Li-ion batteries is a key concern for the developers of equipment such as electric vehicles, e-bikes, mobile phones and laptops. The risks posed by Li-ion batteries have been highlighted by a number of high-profile incidents. In 2006 and 2007, for example, millions of laptops and mobile phones were recalled due to safety fears relating to their Li-ion batteries, and in 2013, a Boeing 787 was grounded following electrical issues with the Li-ion battery in the aircraft’s auxiliary power unit.

Famously, in 2016, around 2.5 million mobile phones had to be recalled after complaints of overheating and exploding batteries. Extensive investigations revealed insufficient insulation material within the batteries and a design that did not provide sufficient space to safely accommodate the batteries’ electrodes, resulting in thermal runaway, which occurs when temperatures are raised by thermal or mechanical failure, short-circuiting, or electrical abuse. In more recent news, there has been a 60% increase in e-bike fires in London in 2023 compared to 2022, and this number will continue to rise.

As a result of the magnitude of this problem, and the global publicity which ensues, demand is growing for sensing technology that can detect faulty Li-ion batteries, during both production and operation.

The main safety hazards associated with failing Li-ion batteries are the ignition of the battery cell and/or the emissions of toxic gases. These gases include volatile organic compounds (VOCs), meaning sensitive VOC sensors can be used to check the condition of these batteries – either within portable detectors or in process/plant monitoring equipment.

The anode in rechargeable Li-ion batteries is typically graphite, the cathode is a metal

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oxide, and the electrolyte is usually a lithium salt in a (flammable) organic solvent. This electrolyte includes compounds such as ethyl methyl carbonate (EMC), which is known to be among the gases emitted by a faulty Li-ion battery. Conveniently, EMC can be detected by ION Science’s PID, so the developers of monitoring systems and equipment are able to design technologies that utilise ION’s MiniPID sensors.

Due to their specificity, PID sensors are the most commonly employed technology for the detection of VOCs, and ION’s MiniPID range includes the most sensitive PID sensor

in the world, which makes it ideal for the detection of trace leaks from faulty Li-ion batteries.

Summarising, Peter Morris from ION Science said: “Prospective customers for our PID sensors in Li-ion battery applications include the developers of portable instruments, as well as the designers of monitoring systems for processes within battery manufacturing, as well as in the manufacture of EVs, e-bikes, laptops, tablets, phones and many others.” www.ionscience.com

October 2023 www.mepca-engineering.com

September 2023

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Machine Building Supplement

Euchner EKS – The Key to Secure Automation

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Regular Sections: Food Processing Machine Building Robotics Imaging & Vision Drives Motor & Controls Sensors & Sensing Systems Test & Measurement Additive Manufacturing Pumps & Pumping Systems Packaging & Inspection Manufacturing Software Health & Safety

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EVENT PREVIEW

Experience engineering excellence In a few short months, the world of engineering will gather once again at the Southern Manufacturing & Electronics exhibition. The event, which is already taking shape, will be held at the Farnborough International Exhibition & Conference Centre from 6 to 8 February.

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he annual Southern Manufacturing & Electronics exhibition promises to reach new heights as it welcomes an unprecedented number of international companies, solidifying its position as a global focus for innovation in mechanical, electrical and electronics manufacturing. The 2024 show is well on its way to being a sell-out, prompting the organisers to create extra space to accommodate the demand.

Since its relocation to the Farnborough International Exhibition & Conference Centre in 2008, the show has undergone a remarkable transformation. What began as a modest regional event has blossomed into an internationally acclaimed gathering, attracting visitors and exhibitors from around the world. It will once again co-locate with AutoAero, a specialist theme woven into the main programme concentrating on aerospace and automotive engineering.

Alongside some of the largest manufacturers of machine tools, workholding equipment and other mechanical engineering accessories, almost every element of electronics production and test will be in evidence, together with suppliers of consumables, labelling, storage and handling systems and a plethora of dayto-day essentials that every manufacturing business needs. A comprehensive array of inspection equipment and services will ensure that quality control remains high on the agenda across the board.

One of the show’s distinctive features is its ability to attract both major manufacturers and small to medium-sized engineering enterprises. With a policy of open access that discourages larger firms from monopolising the space, the event nurtures a vibrant atmosphere that fosters collaboration and discovery. Many exhibitors have been

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loyal attendees since the show’s inception in 1997, a testament to its effectiveness as a business forum.

The success of Southern Manufacturing & Electronics lies in its unique composition, with approximately equal representation from the mechanical engineering and electronics sectors.

The exhibitor list for 2024 already includes hundreds of firms from the UK and overseas whose stands will feature cutting-edge machinery, hardware and software, subcontracting services, mechanical, electronic, electromechanical and pneumatic components of all descriptions, consumables, workshop essentials, freighting services, financial consultancy and more. The amalgamation of diverse vendors under one roof makes it an ideal platform for tackling multifaceted sourcing requirements.

Another aspect of the event that sets it apart is its seamless integration. The absence of physical barriers between areas encourages cross-over between the different engineering disciplines, enabling visitors to discover companies they might not otherwise encounter. Technology Trails guide visitors through the showground, grouping firms with expertise in specific areas, facilitating efficient exploration.

The 2024 exhibition will place particular importance on automation, driven in part by the skills shortage in the UK and Europe. Other difficulties with which manufacturing is grappling include postBrexit delays, supply chain disruptions, the

soaring cost of materials and energy, and increased taxation. To alleviate some of these challenges, exhibitors will showcase advances in Industry 4.0, autonomous production technology, collaborative robotics, reshoring of production, green energy, power-saving machinery and additive manufacturing.

Over the three days, visitors will be able to take advantage of an extensive technical seminar program. Covering both mechanical engineering and electrical/electronic engineering, these seminars offer valuable insights into the technical, managerial and environmental challenges facing manufacturers today.

Southern Manufacturing & Electronics 2024 will open its doors from 6 to 8 February and is very accessible. There is ample free car parking, and the site is well served by road and public transport links. A regular, complimentary bus service runs between Farnborough’s Main and North Camp railway stations and the showground. Admission and parking are also free of charge. More information and tickets are available online. www.industrysouth.co.uk

FARNBOROUGH | Hants | GU14 6TQ 6th - 8th February 9.30am - 4.30pm

(3.30pm close Thurs)

Where Industry and Innovation converge

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Incorporating The Subcontract Engineering Exhibition

Over 600 national and international AUTOMATION suppliers come together to exhibit at DEFENCE Farnborough International Exhibition and Conference FOOD & DRINK Centre this February for Southern Manufacturing AUTOMOTIVE / AUTOSPORT and Electronics (inc AutoAero) 2024. Meet the ELECTRONICS power behind UK manufacturing industry and see AEROSPACE live demonstrations and new product launches of TRANSPORTATION machine tools & tooling, electronics, factory & PACKAGING process automation, packaging & handling, ELECTRICAL & MECHANICAL ENGINEERING labelling & marking, 3D print technology, test & measurement, materials, composites & adhesives, ADDITIVE MANUFACTURING LOGISTICS rapid prototyping, ICT, drives & controls, plastics & MARINE polymers and laboratory equipment.

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EVENT PREVIEW

Best practice abounds at this month’s LiftEx 2023 LiftEx 2023 is the global showcase for the lifting industry, the ideal show for anyone who uses lifting and height safety equipment. Taking place at the Exhibition Centre, Liverpool, on 21-22 November 2023, it is the annual flagship event of the Lifting Equipment Engineers Association.

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iftEx 2023 is an essential event for the manufacturing sector.

Plants and factories use a wide variety of cranes, hoists, platforms, cradles and their associated chains, ropes, slings and other tackle to lift goods during production and lineside support.

Reliability leading to minimised downtime is the key to manufacturing efficiency, but it is safety that is paramount in any lifting operation. One of the best ways manufacturing and production operations can mitigate the risk of an inspection by Health and Safety authorities is to ensure that when procuring lifting equipment or supporting services, they look for the LEEA logo. This shows that the equipment or service provider is an Association member and has therefore undergone a rigorous auditing process to uphold LEEA’s ‘gold standard’ and provide customers with the assurance of excellence.

LEEA members are driven by quality and commitment to the highest possible practices.

The Association is established across the globe as the leading representative body for all those involved in the lifting industry worldwide and contributes to the development and dissemination of legislation, regulation and ‘best practice’ guidance.

Finding best practice at LiftEx Celebrating its 18th year in 2023, LiftEx offers the best opportunity to find the LEEA logo on a whole host of lifting equipment, products and services from its member companies. They operate in a forward-looking lifting industry that is always innovating, with constantly developing technologies – including AI, virtual reality simulation, condition and load monitoring, remote control and anti-collision systems – spreading throughout the sector to reduce risk from working at height.

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The dedicated event addresses many different challenges, solutions, regulations and best practice advice under one roof.

This makes LiftEx the ideal venue for anyone involved with, or responsible for, lifting equipment in the manufacturing sector to join over 1,500 industry professionals in catching up with suppliers and exploring their latest innovations, viewing demonstrations and gaining valuable lifting knowledge across two days.

A show full of lifting innovation The show’s Headline Sponsor, CoreRFID, which provides Lift Inspection Software and RFID technology, will be demonstrating its SaaS solution CheckedOK, which fully automates the user’s governance and compliance workload through cloudbased software.

Also on display will be a broad array of lifting equipment solutions from companies such as Atlas Winch & Hoist Services, Cromax, Delta Hoisting Equipment, Foster Cranes, George Taylor Lifting Gear, Green Pin (Royal Van Beest), Hird, JD Neuhaus, Mipromet, Modulift, Nautilus Hooks, Pinpoint Manufacturing, Rope and Sling Specialists (RSS), TTC Lifting, Tusk Lifting and Worlifts. Visitors interested in

materials handling equipment will find GGR Group, Lift Turn Move, Probst, Prolift Handling and Tracked Carriers.

Chains, ropes and accessories will be featured by companies including Bridon Bekaert, Codipro, European Management & Marine (EMM Corp), Ferryl, Hendrik Veder Group, Latch and Batchelor, Lift Turn Move, Lift-Tex Heavy Lift Slings, RUD Chains, Sahm Splice, Talurit and William Hackett Chains.

There will be slings and rigging from Aberdeen Web, Crosby, Dolezych, Hendrik Veder Group, Petersen Stainless Rigging, PMS Industrie and Suhbo Industrial Co. Exhibitors displaying height safety equipment include Guardian Fall, North Sea Lifting, RidgeGear, SafetyLiftinGear, Safehold, SpanSet, Tiger Lifting, Trans-Web and YOKE Industrial Corp. There will be load monitoring equipment from DLM, Load Monitoring Systems (LMS) and Red Rooster Lifting. A range of IT solutions will also be shown from companies, including CoreRFID, Formability, Onix Work, RiConnect and Tele Radio UK. With approximately 100 exhibitors on the show floor and over 20% appearing at LiftEx for the first time, this year promises to be the best LiftEx yet. bit.ly/Liftex23

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INDUSTRY UPDATES

AMR top module offers roving conveyor solution

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o keep up with the ever-growing demand for autonomous material handling, Interroll has developed an autonomous mobile robot (AMR) Top Module as an expansion of its Light Conveyor Platform (LCP). This roving conveyor solution has been successfully tested with MiR and OMRON, two leading mobile robotics companies that have identified it as a preferred choice.

With the LCP AMR Top Module technology, Interroll is demonstrating its commitment to pushing boundaries and developing new robotics products to further revolutionise the market.

The LCP AMR Top Module conveyor module enables the handling of lightweight goods and offers a seamless interface which guarantees a smooth material flow when an AMR is integrated.

The end-user can trust in a complete solution, the highest level of customer comfort, and an easy integration process.

The Interroll Lifetime Service team will support system integrators and end users with the initial LCP AMR Top Module installation and throughout the solution’s complete lifetime of service.

When it comes to service, Interroll’s expert service technicians are a valuable source of strength, closely supporting customers worldwide. Production of the LCP AMR Top Module will start this year in Europe, with other Interroll regions to follow.

Precision and power

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xperience precision and power with RIFT Actuators. As an industry leader, Rift Actuators offers cutting-edge electric, pneumatic, and smart electric actuators, enhancing performance in fire suppression, water management, and oil & gas. Its range ensures precision, reliability, and efficiency, from water distribution to fire suppression. RIFT SMART Actuators revolutionise control, reshaping industries. Discover the power of precision with Rift Actuators.

www.riftactuators.com

A universal solution for terminal screws

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.K Tools has developed a range of screwdrivers that offers a comprehensive solution for terminal screws during switchgear installations.

Eliminating irritating, time-wasting and costly breakage caused by ill-fitting screwdrivers.

The new expanded Dextro VDE Modulo Slim range covers all screw types commonly used in circuit breakers, contactors, relays, terminal blocks, PCB clamps and electrical boards, as well as those found in RCBOs. Dextro VDE Modulo Ultra Slim screwdrivers build on the wider success of the award-winning Dextro VDE range, which is ergonomically designed to give an extra quarter turn thanks to its superior grip. www.carlkammerling.com

Commercial and industrial LED lighting

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owerLed, a leader in commercial LED lighting and power supplies, provides interior and exterior lighting that delivers reliable, efficient and intelligent solutions suitable for all conditions. The company also supplies over 10,000 MEAN WELL products.

interroll.com

Expertly designed from the LED driver outwards, PowerLed’s products feature premium components and cutting-edge technologies from small applications through to large-scale projects across warehousing, retail, marine, harsh environments and Atex, to name but a few. Intelligence to adapt to daylight and aisle control with high IP and IK ratings, coupled with emergency options, make the PowerLed range the go-to solution for all lighting requirements. www.powerled.uk.com

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www.mepca-engineering.com

BESPOKE AUTOMATION SOLUTIONS Designing, developing and producing innovative special purpose and bespoke automated machinery for manufacturing industries.

Committed to learning and at the forefront of technological developments, our team has diverse experience in specialist technologies such as mechatronics, production automation, vision inspection, robotics, control systems engineering, and so much more, including: • Creating more productive and sustainable businesses through green technology solutions.

• Designing manufacturing automation equipment for medical device product assembly and testing.

• Bespoke special purpose-built machinery.

• At the forefront of technology advances with best-in-class performance solutions in laboratory automation.

Our multi-disciplinary team are highly experienced in: • Delivering solutions in regulated industries.

• Mechanical, Software and Electronic Engineering.

• Expertise in a broad range of advanced manufacturing technologies.

+44 1353 667394

info@innomechgroup.co.uk www.innomech.co.uk

CONNECTIONS 3D Print Manufacturing

Machine Safety

Midlands 3D Printing Units 6-7 Emerald Way, Stone Business Park, Stone, Staffordshire, ST15 0SR T: 01785 594389 E: sales@midlands3d.com W: www.midlands3d.com

Anti Vibration Products, Mounts & Bushes

Schmersal UK Ltd Sparrowhawk Close, Malvern, Worcestershire, WR14 1GL T: 01684 571980 E: uksupport@schmersal.com W: www.schmersal.co.uk

Pipework Systems Jacob UK Ltd Laundry Bank, Church Stretton, SY6 6PH T: 01694 722841 E: sales@jacob-uk.com W: www.jacob-group.com/uk

Fibet Rubber Bonding (UK) Ltd Unit 9 Dale Mill, Hallam Road, Nelson, Lancashire, BB9 8AN T: 01282 878200 E: sales@fibet.co.uk W: www.fibet.co.uk

Control Systems

Robotics & Automation KUKA Robotics UK Ltd Great Western Street, Wednesbury, West Midlands, WS10 7LL T: 0121 505 9970 E: sales.uk@kuka.com W: www.kuka.com

Beckhoff Automation Ltd The Boathouse, Station Road Henley-on-Thames, Oxon RG9 1AZ T:+ 44 (0)1491 410539 E: info@beckhoff.co.uk W: www.beckhoff.co.uk

Dust & Fume Solutions

Rotation Monitoring Equipment Rotech Systems Unit 57, Canal Bridge Centre, Ellesmere Port, Cheshire, England, CH65 4EH T: +44 (0)151 356 2322 E: sales@rotechsystems.co.uk W: www.rotechsystems.co.uk

Impact Technical Services 3 Kingsley Street, Leicester, LE2 6DY T: 0116 244 8855 E: enquiries@impactts.co.uk W: www.impacttechnicalservices.co.uk

Flow Meters

Sensors Titan Enterprises Ltd Unit 2, 5A Cold Harbour Business Park, Sherborne, Dorset, DT9 4JW T: +44 (0)1935 812790 E: sales@flowmeters.co.uk W: www.flowmeters.co.uk

High Shear Mixing Equipment Silverson Machines Ltd Waterside, Chesham, Buckinghamshire, HP5 1PQ T: +44 (0)1494 786331 E: sales@silverson.co.uk W: www.silverson.co.uk

Industrial Communications Brainboxes T: + 44 (0) 151 220 2500 E: sales@brainboxes.com W: www.brainboxes.com

Industrial Fans Axair Fans UK Limited Lowfield Drive, Wolstanton, Newcastle-under-Lyme, ST5 0UU T: 01782 349 430 E: aj@axair-fans.co.uk W: www.axair-fans.co.uk

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Carlo Gavazzi UK Ltd 4.4 Frimley Business Park, Frimley, GU16 7SG T: 01276 854110 W: www.carlogavazzi.co.uk IFM Electronic Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD T: 020 8213-0000 E: enquiry.gb@ifm.com W: www.ifm.com PLUS Automation Ltd Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire, WR9 0LG T: 0121 58 222 58 E: Sales@PLUSAutomation.co.uk W: www.PLUSAutomation.co.uk

Test & Inspection Cupio Services Ltd T: 01256 262800 E: info@cupioservices.co.uk W: www.cupioservices.co.uk

A Kawasaki Robot for every application

Kawasaki Robotics Tel:+44-1925-713-000 www.kawasakirobotics.com/uk/