August 2025 Electrical Apparatus - Innovation!

More than Motors

Electrical Apparatus Innovation:

Additive manufacturing, autonomous robots, EV recharging, AI chatbots

An energy round-up

CWIEME and Coiltech

Medium-voltage switchgear

Innovations in pumps

Business insurance

Electrical Manager

14 Chatterboxes

AI chatbots are suddenly everywhere. How best to tame and use them?

By Bill O’Leary, EA Contributing Writer Electric Avenue

18 Dealer’s choice

Having EV chargers on site at auto dealerships demonstrates that the dealers stand behind the EVs they sell

By Maura Keller, EA Contributing Writer Energy

21 Energy round-up

What’s new in the energy industry as summer draws to a close

By Charlie Barks, EA Managing Editor

Conventions & Trade Shows

22 A North American debut

Coiltech North America’s premiere performance offered a glimpse of electrification’s future

By Charlie Barks, EA Managing Editor

26 Transformative talks

Presentations on transformers and motors figured prominently at CWIEME Berlin June 3-5

By Kevin Jones, EA Senior Editor

EA Reader Profile

29 En garde, prêts, allez . . . ‘Ready, set, go!’ is fencer Anthony Cuschieri’s approach to running his polyester film company

By Colin Gregory-Moores, EA Contributing Writer

Training & Education

31 Amazon U.

Bakersfield College is partnering with Amazon for educational programs that offer employees a plethora of opportunities

By Avery Heeringa, EA Contributing Writer

Manufacturing

33 3D printing comes of age

How 3D printing — once a novel manufacturing technology — has become firmly established in the industrial workplace

By Bill O’Leary, EA Contributing Writer

Power Transmission & Distribution

39 Breaker breakout

Given the proliferation of massive data centers, demand for medium-voltage breaker switchgear appears boundless

By David Bredhold, EA Contributing Writer

Finance & The Workplace

44 ‘Insuring’ your business continues Covering both property and people can be well worth the cost

By William H. Wiersema, EA Finance Editor

Pump It Up

48 Innovations in pump design and application

Improvements in materials and design are helping to push the limits of performance

By Kevin Jones, EA Senior Editor

word search puzzle based on this month’s “Finance” article

COVER PHOTOS: By (clockwise from upper left) BotPenguin, Robotnik

AG.

At Toshiba, we don’t test one motor per batch—we test every low voltage motor we manufacture. Whether it’s 0.5 HP or 500 HP, each motor undergoes full testing before it leaves our facility. Because when performance powers critical operations, only proven reliability will do. Built with integrity. Tested for trust.

The Editor’s Comment

What’s new in innovation

Innovation is so common in technological applications, it’s become difficult to distinguish the useful from the unnecessary. Claims of innovation are around every corner, every year, as we’ve covered at length in this publication both in general and in the issues with this theme over the years. We’ve even covered failed innovations and aimed to identify which advancements and new products are truly most applicable to the readers in the many industries we cover.

Look no further than this issue of EA to witness that breadth of variety, starting with this month’s cover story by Bill O’Leary, which covers additive manufacturing (page 33).

Additive manufacturing, which in its early stages was usually referred to as “3D printing,” has come a long way in its 40 years of existence. Bill’s research brought up an intriguing range of questions related to innovation, with 3D printing as a prime example:

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FINANCE EDITOR

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CONTRIBUTING WRITERS

David Bredhold, Chase Fell, Colin Gregory-Moores, Avery Heeringa, Maura Keller, John Malinowski, Michael Mitten, Bill O’Leary, Kristine Weller

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Barbara Goetz Barks

CARTOONS AND PUZZLES

John D’Acunto, Myles Mellor, Tim Oliphant

Coming next month in Electrical

Apparatus:

Sidewinders LLC of Magna, Utah; EASA Show report; Battery Show preview; Testing electrical steel for lamination performance; The new tax law.

“What makes an innovative technology sustainable? How does the new become old but not forgotten? The realm of innovative technology is riddled with one-hit wonders — something that was supposed to revolutionize some industry or task but quickly went the way of the dinosaur. Smart glasses, e-ink color tablets, soft exoskeletons for industrial use, hydrogen internal-combustion engines. But the jury is still out on a host of other technological innovations. One gleaming example: the 3D printer.”

Elsewhere in this edition of EA are reports from one realm where innovation is seemingly always visible: the trade show. We have two trade show reports in this issue: CWIEME Berlin 2025 (page 26) and Coiltech North America 2025 (page 22). Both shows featured tons of new ideas and companies putting their stamp on innovative advancements.

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The CWIEME show, which EA has attended multiple times in the past both in America and abroad, is well-established as a haven for the latest lines of thinking in the coil and transformer industries. Meanwhile, Coiltech was debuting its first North American edition, and the early feedback indicates a successful venture that focused on cross-industry networking.

To round out the issue, we have a technical article from David Bredhold on medium-voltage breaker switchgear (page 39), an accounting piece from Bill Wiersema entitled “‘Insuring’ your business continues” (page 44), and the interesting consideration of adding EV chargers to auto dealerships in Maura Keller’s “Electric Avenue” column (page 18).

As always, thanks to our advertisers, readers, and contributors for a great issue!

Electrical Apparatus (ISSN 0190-1370), Vol. 78, No. 8, is published monthly by Barks Publications, Inc., 17 N. State St., Suite 435, Chicago, Ill. 60602-3598; (312) 321-9440; fax (866) 228-7274. www.barks.com. Periodicals postage paid at Chicago, Ill., and at additional mailing offices. Postmaster: Send address changes to Electrical Apparatus, c/o Barks Publications, Inc., 17 N. State St., Suite 435, Chicago, Ill. 60602-3598. PM #40830553

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A note from the publisher

An item in our July EASA Convention exhibitors’ section misstated the ownership of the Marathon brand of electric motors. The Marathon motor brand was acquired by WEG S.A. from Regal Rexnord Corp. in September 2023. Electrical Apparatus regrets the error.

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Let’s Solve Your Problem

Have you been stumped recently by an electromechanical application or repair problem? Send your question to this department, at editor@barks.com, and we’ll see if we can give you an answer.

Can we maintain this commutator in the field?

We use d-c motors for variable-speed and reversing processes in our mill. The operator’s manual for these motors recommends turning and undercutting of the commutator. Can we do this in the plant? If so, what are the steps involved in this service?

The commutator is the copper segmented cylindrical component that serves to connect the armature winding to the d-c power supply through your carbon brushes. The brush contact surface of the commutator should be smooth and clean with runout at 0.003-inch or lower. The insulating mica between the segments should always be approximately 1/16 inch below the bar contact surface.

After finishing the commutator surface and cutting the mica, all slots should be thoroughly re-cleaned and bar edges beveled. A final polish should be performed after the cleaning and beveling. Unless you have access to very special knowledge and equipment, this work should be done in a shop by qualified technicians.

Squirrel-cage a-c motor as a generator?

I have a standard NEMA-frame a-c four-pole 10 hp motor. Can I make this motor run as a generator by rotating the shaft by way of an external source?

Well, maybe. A standard three-phase squirrel-cage induction motor can be used as a generator, but with some important caveats. When you spin the shaft of an

induction motor faster than its synchronous speed, it begins acting as an induction generator. The rotor cuts through the stator’s rotating magnetic field in reverse. This induces current.

However, unlike synchronous generators, an induction generator needs an existing magnetic field to operate. It cannot self-excite unless specific conditions are met. The most common excitation method involves connecting the motor to a live three-phase grid. Once the motor is connected to the grid, spin the motor shaft at a speed faster than synchronous speed. The grid provides magnetizing current (reactive power), and the motor feeds real power back into the grid.

A less common excitation option is the off-grid self-excited induction generator. This is possible if you connect capacitors across the stator terminals to supply the necessary reactive power to generate.

The capacitor solution is more complex and harder to regulate when compared to the grid. Frequency and voltage regulation may be a problem. And you will need switchgear and circuit protection, of course.

Resistance imbalance: What is acceptable?

I measured a 3% resistance imbalance between the three phases of a 100 hp, 480 V electric motor winding in our container board plant.

Is this acceptable? What could cause this imbalance? If it is not acceptable, what should it be, and what is the recommended fix?

A resistance imbalance of 3% in a threephase a-c winding is generally considered too high, according to standards like IEEE 112 or NEMA MG-1, which recommend a resistance imbalance not exceeding 1%. Causes of such imbalance may include

Synchronous Motor Rotating Rectifier Assemblies

•Reverse

•Parts

•Testing

•Repair

uneven wear or damage to the winding insulation, loose or corroded connections, or manufacturing defects.

To resolve this issue, inspect and tighten all connections, ensure there is no corrosion or contamination, and test the winding insulation for damage. If the imbalance persists, consider reconditioning the motor or replacing the affected windings to restore proper operation. If the winding has a shorted turn, it won’t likely run very long.

Running a d-c motor with armature circuit grounded

I’ve been told that it’s possible to run a d-c motor with the armature circuit grounded. Is this true?

Yes, it’s technically possible, but only under specific conditions. It depends on the motor design and the wiring scheme. When people say the armature is grounded, they typically mean that one side of the armature winding is connected to chassis ground. In some older systems, especially vehicle or industrial applications, this is intentional. But it can also be undesirable if it’s an accidental ground fault.

In older automotive or railway d-c systems, it was common to ground one side of the power supply, and sometimes the armature return path was through the chassis. In this case, grounding one side of the armature was by design.

In some cases, one terminal of the motor (either armature or field) is grounded intentionally as part of the control strategy. This is safe, as the power supply return is referenced to ground at the same point and no potential difference builds up. That could cause circulating currents. If a normally isolated armature winding becomes grounded due to insulation failure - this is a fault. It may run for a while, but it’s not right. — Edited by the EA staff EA

Update your calendar with these upcoming trade shows, conferences, and other events. Do you know of an event that you think we should bring to the attention of Electrical Apparatus readers? E-mail us about it at edi tor@barks.com.

• August 6-8, 2025 — NSPECon, InterContinental Kansas City at The Plaza, Kansas City, Mo. National Society of Professional Engineers, www.nspecon.org.

• September 4, 2025 — Golf Day 2025, Belton Woods Golf & Spa Resort, Lincolnshire, U.K. British Pump Manufacturers’ Association, www.bpma.org.uk/ news-article/67ec00e3dc878/BPMAGolf Day2025.

• September 8-11, 2025 — Fabtech 2025, McCormick Place, Chicago, Ill. Fabtech Event Partners, www.fabtechexpo.com.

• September 12-15, 2025 — NECA 2025 Convention and Trade Show, McCormick Place, Chicago, Ill. National Electrical Contractors Association, http:// bit.ly/4f9BWoN.

• September 17-19, 2025 — AEE World Energy Conference & Expo, Georgia World Congress Center, Atlanta, Ga. Association of Energy Engineers, https:// aeeworld.org/conference.

• September 18, 2025 — AEMT 80th Anniversary Conference, British Motor Museum, Gaydon, Warwickshire, U.K. Association of Electrical and Mechanical Trades, www.theaemt.com/ems-event-cal endar/aemt-conference.html.

• September 29-October 2, 2025 — Canadian Manufacturing Technology Show, Toronto Congress Centre, Toronto, Ontario, Canada. Society of Manufacturing Engineers, www.cmts.ca.

Upcoming events

• October 5-7, 2025 — EGSA Fall Conference, Royal Pacific Resort, Orlando, Fla. Electrical Generating Systems Association, https://egsa.org/Events/Fall-2025-Confer ence.

• October 13-16, 2025 — Hydraulic Institute Fall Conference, Kansas City Marriott Country Club Plaza, Kansas City, Mo. Hydraulic Institute, www.pumps.org/ event/2025-fall-conference.

• October 23, 2025 — The 2025 U.S. Celebration of World Standards Day, Bethesda North Marriott Hotel and Conference Center, Rockville, Md. American National Standards Institute, www.ansi.org/events/ standards-events/world-standards-day.

• November 16-20, 2025 — International Mechanical Engineering Congress & Exposition, Renasant Convention Center, Memphis, Tenn. American Society of Mechanical Engineers, https://event.asme. org/IMECE.

• January 31-February 4, 2026 — 2026 ASHRAE Winter Conference, Caesars Palace, Las Vegas, Nev. American Society of Heating, Refrigerating, and AirConditioning Engineers, www.ashrae.org/ conferences/2026-winter-conference.

• February 2-4, 2026 — AHR Expo 2026, Las Vegas Convention Center, Las

Vegas, Nev. The Air-Conditioning, Heating, and Refrigeration Institute, www.ahrexpo. com/sales-floor-plan-2026.

• February 8-11, 2026 — NEMRA 2026: Power Tomorrow, Today, Orlando World Center Marriott, Orlando, Fla. National Electrical Manufacturers Representatives Association, www.nemra.org/save-the-datenemra26-returns-to-the-sunshine-state.

• February 22-26, 2026 — Hydraulic Institute 2026 Annual Conference, Sawgrass Marriott Golf Resort & Spa, Ponte Vedra Beach, Fla. Hydraulic Institute, www. pumps.org/event/2026-annual-conference.

• March 2-6, 2026 — PowerTest 2026, Gaylord Opryland Resort & Convention Center, Nashville, Tenn. InterNational Electrical Testing Association, https://bit.ly/ 4cMrfZ5.

• June 1-4, 2026 — CleanPower 2026, George R. Brown Convention Center, Houston, Tex. American Clean Power Association, https://cleanpower.org/expo.

• June 13-16, 2026 — Electrical Apparatus Service Association Solutions Expo, Rosen Shingle Creek, Orlando, Fla. Electrical Apparatus Service Association, https://easa. com/convention/future-easa-conventions.

• September 14-19, 2026 — International Manufacturing Technology Show, McCormick Place, Chicago. Association for Manufacturing Technology, www.imts.com/ index.cfm.

• June 11-14, 2027 — Electrical Apparatus Service Association Solutions Expo, Ernest N. Morial Convention Center & Hilton Riverside, New Orleans, La. Electrical Apparatus Service Association, https://easa. com/convention/future-easa-conventions. Edited by Kevin Jones EA

Plant Happenings

Limbo number five

Production was suspended last spring at the Denka Performance Elastomer plant in St. John the Baptist Parish, Louisiana. The inde nite suspension of Denka’s synthetic rubber production comes after disappointing nancial results were reported by the company. Rising costs, declining production volumes, and expensive anti-

emissions technology were cited by the company as contributing factors.

Going on the rails

A new advanced manufacturing plant is opening in Hornell, N.Y., as an expansion of the current Alstom production, bringing 258 new jobs and re-

duce stainless-steel rail car body shells, according to the company.

Sausage plant closed suddenly

jobs. The facility, named Plant 4, will pro-

The Industry’s

Quietest Bearings

Utilizing our precision manufacturing process to create improved raceway finishes and tighter dimensional tolerances, NTN pairs high-quality components and a special polyureabased grease designed for the electric motor industry to provide the needed quietness and a high-temperature performance you expect in your applications.

The small Illinois community of Momence was rocked by the sudden closure of the Momence Packing Co. plant, owned since 1995 by Johnsonville Foods. The facility has employed local residents since its opening in 1962, but the June closure displaces 274 employees. Production will be picked up by three plants in Wisconsin and Kansas.

New meaning for new Coke

While New Coke did not garner much support in the 1980s, a new Coke plant has found favorable opinions in Olathe, Kan. The recently opened Heartland Coca-Cola bottling plant is a 700,000-squarefoot facility that includes four production lines, two for aluminum cans and two for PET bottles. Heartland Coca-Cola was founded in 2017 and is an anchor bottler serving the Midwest.

DOE orders change of plans

A soon-to-close power plant outside of Philadelphia had a reversal of fortune U.S. Dept. of Energy ordered the plant’s owner to ensure operations continue through Aug. 28.

Eddystone Generating Station’s owner had planned to retire the plant in May, but forecasts for increased energy demand related to large data centers and transportation electri cation caused the change in plans.

Chips fall where they may

PepsiCo recently announced the closure of its Frito-Lay manufacturing plant in Rancho Cucamonga, Calif., due to decreasing snack sales. The number of employees a ected was not released by PepsiCo. Some of the facility’s employees will remain, as the distribution, warehouse, and transportation divisions will not close. — Kristine Weller EA

Leading the way in energy efficiency yet again, ABB Baldor-Reliance SP4 motors give you a shortcut in energy savings, lower operating costs and total cost of ownership. SP4 motors achieve NEMA Super Premium efficiency across-the-line, independently of a drive. Whether DOL or inverter duty, these motors run cooler, longer and quieter – now with a 48-month warranty. new.abb.com/motors-generators/sp4

IE6 motors and the path to further e ciency gains

It wasn’t long ago that IE4 and then IE5 motors were pushing what seemed the practical limits of e ciency. Now, for the past year, even though the International Electrotechnical Commission has yet to codify IE6 as a motor classi cation, several manufacturers have been marketing motors promoted as such.

The manufacturers o ering IE6 motors include ABB, Lafert, WEG, and Innomotics. Price lists for these motors are typically not available publicly, as these are high-performance, often customized industrial machines whose prices vary based on horsepower, RPM, voltage, features, and application requirements. It’s a virtual given, though, that the up-front cost of an IE6 motor will be notably higher than the price of a motor with a lower e ciency rating.

Does the greater e ciency justify the higher price? Manufacturers can be counted on to assure customers that it often does — that the increased expense is more than covered by the substantial energy savings and rapid return on investment such motors are promised to yield. To the purely economic rationale for buying an IE6 motor can be added the purported environmental bene ts of doing so — at least in those jurisdictions where e orts to cap emissions of carbon dioxide are still enthusiastically embraced. (In the U.S., federal support of energy-e ciency e orts seems to be fading by the day.)

The W23 Sync+Ultra motor from WEG is among motors being marketed these days as IE6. Motors with this classification — which hasn’t yet been codified by the International Electrotechnical Commission with o cial benchmark standards — generally deliver 20% greater e ciency than IE5 motors. — WEG photo

A white paper released in June by ABB, titled “Achieving the COP28 UAE Consensus,” details what ABB characterizes as the vital role high-e ciency motors and drives are playing in meeting global energy objectives. It argues that investing in these technologies o ers rapid and substantial nancial returns for businesses.

Please turn to page 12

Global energy demand is increasing rapidly, the paper points out, with worldwide energy demand in 2024 growing by 2.2%, a rate exceeding the average of the previous decade. Electricity use, driven by factors such as electrification, record temperatures, and increasing digitalization, rose by nearly 1,000 terawatt-hours in 2024.

The financial benefits of improved energy efficiency are considerable, according to ABB. Investment in this area has grown by almost 50% since 2019. Variable-speed drives and high-efficiency motors sometimes pay for themselves within months rather than over several years.

A 2023 report from the Swiss Energy Efficiency Movement Association titled “The Case for Industrial Energy Efficiency” outlines 10 actions that could help bring about significant carbon reductions and financial benefits. According to the report, four of these actions alone could prevent the release of 2.53 gigatonnes of carbon dioxide emissions annually by 2030, which is equivalent to the output of about 600 coal-fired power plants. These actions are also financially attractive, with potential gross financial benefits for industry estimated at $4.1 trillion in savings by 2030.

Energy efficiency offers several benefits for customers, including energy and material savings, enhanced reliability, optimal equipment lifetime, and reduced emissions. For example, ABB’s joint research with the European Laboratory for Particle Physics between 2022 and 2023 identified a 17.4% energy-saving opportunity in cooling and ventilation motors. This represents potential annual savings of 31 gigawatt-hours.

Governments are playing a pivotal role in all of this by setting ambitious standards, providing incentives such as subsidies and tax breaks, and prioritizing energy efficiency in public procurement. India, for example, has included industrial energy efficiency as an eligible offset in its new carbon market guidance. In China, ABB’s installed base of more than 11 million high-efficiency motors and drives has resulted in energy savings estimated to have exceeded 510 billion kilowatt-hours.

A considerable challenge, according to the ABB white paper, is that many motors currently in operation do not meet modern efficiency standards. Straightforward steps, such as correctly sizing industrial electric motors for their applications, can go a long way toward compensating for this shortcoming.

The paper also describes the value of energy audits, which can help identify and quantify potential energysaving opportunities. Digitalization and connectivity are fundamental tools in the quest for greater efficiency because, as the paper says, “You can’t manage what you can’t measure.”

Digital tools provide the basis for the energy monitoring and controls necessary for improving energy efficiency. ABB’s Top Industrial Efficiency Initiative, for instance, can help businesses exceed existing efficiency standards by collaboratively developing and deploying innovative systems, from pilot projects to widespread implementation of power systems.

The technology required for significantly improving energy efficiency, ABB’s white paper concludes, is both proven and readily available. Accelerating the adoption of high-efficiency motors and drives could substantially contribute to global energy savings and economic growth. Doubling the current annual rate of energy efficiency improvements from 2% to 4% until 2030 could avoid a third of the total emissions reductions required to achieve net zero.

And that slick new IE6 motor — the one that hasn’t yet been blessed with official IEC recognition — could play a significant role in making it all happen. — Kevin Jones EA

Chatterboxes

AI chatbots are suddenly everywhere. How best to tame and use them?

By Bill O’Leary, EA Contributing Writer

Sure, everybody is talking about ChatGPT, but have you heard about Eddy? Because Eddy wants to talk to you.

Chatbots have become a mainstay on many business and trade association websites, and the Electrical Apparatus Service Association is no different. Eddy, its artificial-intelligence-powered “assistant,” fields questions and helps members navigate not only the association’s website (www.easa.com) but also the various technical resources, articles, convention papers, and industry reports that fill its vast database.

Eddy is a large language model (LLM) machine, a type of artificial intelligence program that harnesses machine learning to process, understand, and deliver text. LLMs are trained on colossal data sets, allowing them to learn patterns and relationships in language.

They are also trained to sound like humans, producing an experience more akin to a conversation with a knowledgeable friend than combing through an encyclopedia.

Hence, Eddy - and Alexa and Siri before him. This personalization also serves another function. Eddy gets his name from “eddy” currents, which are electric current loops created within conductors by a shifting magnetic field. The currents are common in electric motors and transformers.

Visitors to Eddy’s home, www.easa.com/eddy, are offered a prompt box into which they can type queries, and a couple of preset questions to get a user started, with industry-specific asks such as “What is the EASA ERT Certificate Program all about and how much does it cost?” or relevant technical questions like “What is the minimum insulation resistance of a random wound stator?”

And it’s this level of targeted specificity that conceivably sets Eddy apart from other LLMs. ChatGPT and its digital ilk comb the internet writ large to construct their responses. You’re getting everything, but packaged and ultimately curated based on algorithmic thought and patterns.

That can often lead to irrelevant information or “hallucinations,” which are completely inaccurate responses delivered as fact.

With Eddy, you know what you’re getting, and it’s coming from EASA. The model has been trained on just some of the following:

> The EASA Technical Manual.

> EASA’s AR200-2021: Guide for the Repair of Dry-Type Transformers.

> EASA’s seminar manuals, such as Principles of Medium & Large A-C Motors (NEMA & IEC) and Mechanical Repair Fundamentals of Electric Motors.

> All issues of its newsletter EASA Currents, dating back to September 1998.

> EASA’s website content and resource library, which includes articles on technical subjects, management, sales and marketing.

> Convention papers authored by EASA staff, dating back to 2006.

Swimming in a smaller pond of relevant and authoritative content should help provide a level of validity to Eddy that isn’t often apparent in other chatbots.

There are a variety of business benefits for using website chatbots, which is why they have been digital mainstays for many years, with the recent evolutions in artificial intelligence only further fueling their strength.

Of course, these resources operate around the clock and can accommodate audiences from any time zone. You don’t need to wait for the technician expert or subject matter expert to e-mail you. Their intimidating processing power allows them to handle unlimited conversations at the same time, which reduces wait times and allows human agents to devote their time to more complex issues.

Chatbots also can be used to reduce the need for a larger contact support staff or expensive infrastructure. Whether that should be tagged as a “benefit” is debatable for many, but what is not debatable is that these large language models allow companies to scale customer support strength without a commensurate scale in head count.

Like Eddy, modern chatbots are multilingual, supporting multiple languages using language translation models. This expands customer service to a wide array of new audiences and increases accessibility for non-English speakers. It also cuts down any misunderstandings that are commonplace in verbal communication.

There are dual benefits and drawbacks as well, which shows the risks that confront managers and other business leaders when they implement this technology. Chatbots are designed to give immediate, detailed responses, which reduces the risk of human error or “emotionally heightened exchanges.” Eddy ain’t gonna hang up on you.

But it also ultimately lacks that human touch that some are actively seeking in their interactions. Static, uniform, and scripted responses may be relevant vessels for high-volume info dumps, but what about nuanced, personal discussions that evolve and grow off of subsequent responses? Can artificial intelligence ever capture that level of complexity, that level of specificity, that sheer level of uniqueness that defines the human experience?

There are other challenges that chatbots face. They can become confused by complex, ambiguous, or multi-part questions, which is why prompt generation has become one of the most indemand new skills today. Prompt generation is the process of writing instructions that you provide to the generative AI model to get a desired output. It requires using speci c words, crafting speci c sentences, and communicating speci c contexts to guide the AI.

Good prompts lead to better results and prompt generation is both art and science.

EASA provides a number of prompting tips to best utilize Eddy, such as clearly de ning what you want, including necessary background information, and avoiding complex language or jargon. Simple, direct language is best.

Other tips include the type and amount of questions. One question per prompt helps Eddy focus and provide a more precise response. Have more than one question? Fire it o in the next response. Follow-up questions actually help the large language model better understand the intent of the user since they have more information to go on.

EASA also recommends asking Eddy direct questions, and users can also customize responses by requesting equally direct answers or responses that are more detailed or in a bulleted format. Many a time, while using LLMs, I’ll type a follow-up prompt that says “more detail.” A prompt isn’t a one-anddone a air. Creating a back and forth allows for the model to better isolate the most relevant data, leading to a more pruned and targeted response.

Large language models require sizable processing power and complex setups that I won’t get into here, but the technical demands can lead to delays and crashes on your system. They are also sensitive to data security and privacy, speci cally if they are

built on third-party platforms without a robust security apparatus.

With that said, AI chatbots dominate business websites across all industries, and there doesn’t appear to be an end or even a peak in sight. A recent study by search engine optimization (SEO) analytics company Local Falcon analyzed 60,000 search results over 4,400 businesses in 20 countries and found that AI chatbots typically bypass traditional SEO metrics like page ranking or link volume. They instead rely on authority, prominence, and relevance.

What that essentially means is the old SEO trick of keyword and link stu ng for tra c is ceding ground to what is called “citable evidence of expertise,” which includes data, FAQs, testimonials, and other meatier resources.

Good news for Eddy, who is packed to the brim with industry-relevant data. Warts and all, chatbots are just another way of delivering information with the hope of providing that important answer at the exact time it’s needed. Is a digital assistant the better option? A good old-fashioned human? Well, it really depends on the situation and the preference.

You have a choice, even if you have to dig a little harder for the human option these days. (We’ve all been stuck in the automated message labyrinth constantly saying “speak to a person,” haven’t we?) But whether it’s Eddie at the motor shop in Spokane, Wash., or Eddy from EASA.com, an answer is waiting for you.

Variety. It’s supposed to be the spice of life.

Right? Huh. Just found my next prompt.

— Irina Strelnikova / Shutterstock image

Know Your Industry

Advancing materials and industry at the same time

Society for Advanced Material and Process Engineering

Founded: 1944

Headquarters: 21680 Gateway Center Dr., Suite 300, Diamond Bar, Calif. 91765

Annual Dues: Varies by membership tier Website: www.sampe.org

How often does one stop to consider the materials used in aircraft parts? What about marine and automotive applications?

The average Joe may not consider whether these parts are made from composite materials, but the Society for Advanced Material and Process Engineering, or SAMPE, sure does.

Across aerospace, transportation and construction industries, composite materials are being implemented to improve function and e ciency. SAMPE is the global organization that’s been enabling growth and innovation for these industries for 81 years and aims to “educate and connect the global community of engineers and scientists working in advanced materials and manufacturing, fostering

innovation and knowledge exchange that drives the industry forward,” according to the organization.

Advanced composite materials, which are an integral aspect of the organization’s focus, are the fusion of two or more materials that, when combined, can replace traditional ones like metal and wood to improve a product or part’s durability and application. Composite materials vary in form and can be used in cases like vehicle parts, utility poles, and aircraft parts. Even things as common as tennis rac-

quets, hockey sticks, and bicycle parts can use composite materials. The bene ts of using these materials are often increased durability, reduced weight, and less maintenance.

With the increased popularity of these materials over the years, and as industries continue to evolve toward e ciency and innovation, SAMPE is the bridge that joins engineering professionals across industries together. There are three types of membership tiers with the organization, which include professional, student, and retired. With membership, one gains access to the bi-monthly SAMPE Journal — the “industry’s only technical journal dedicated to advanced materials and processes,” according to the organization — which includes both technical and feature articles and also accepts article submissions from members. In addition to accessing the SAMPE Journal, members obtain entry to thousands of digitized technical papers in the organization’s digital library, as well as an industry resource guide.

One of the main objectives of SAMPE is to connect members across elds, which is facilitated by over 20 North American chapters and more than 60 student chapters at colleges across the country. Abroad, SAMPE o ers a large number of international chapters — from Australia to Beijing, France to Shanghai. At these chapters, whether local, international, or student, networking opportunities and professional connections are facilitated. According to the organization, chapters host meetings and o er tours and workshops among other events. These chapters are governed by elected o cials, and many professional chapters work closely with student chapters.

Dr. German Reyes-Villanueva, who has served as SAMPE’s president for the last year, says, “We have a nice membership

Event attendees huddle together to take in a presentation on hybrid composites.

of people associated with academia, with the industry, with government. We provide networking opportunities, we have technical committees, [and] we produce things like the State of Technology Industry report.”

Dr. Reyes-Villanueva’s involvement with the organization goes back more than two decades, to when he rst joined the Great Lakes chapter as a member in 2004. He worked his way through the organization, going from secretary to treasurer and beyond, ultimately leading to his current role as president. “It’s not just a society for composites or aerospace but actually involves advanced materials and process engineering for all the di erent industries,” he says.

Across the globe, SAMPE has more than 12,000 members, and Dr. Reyes-Villanueva oversees all operations for the North American region — which includes the U.S., Canada, and Mexico chapters — and manages the activities for professional committees, student programs, and more.

“When we work with advanced materials, we can look into di erent types of composites, multifunctional materials that involve not just the basic development of the materials, but also processing [on an] industrial scale, trying to make sure that the process follows all the requirements,” he says of the organization’s work. “It’s not just controlling the process parameters but controlling how the process parameters a ect the behavior of the materials, to ensure that they have the right performance.”

Members not only gain access to information on these process parameters and insider information, but they also earn access to the SAMPE career center and discounts on conferences, workshops, and seminars. “You get to know a lot of people — not just professionals. You get to go [further] than just a simple opportunity or experience, you get to know the individuals and get to help students and see students grow in their professional career,” Dr. Reyes-Villanueva says. “We also launched MentorMatch, which allows our new young professionals to connect with mentors in the industry, academia and government, to help them grow.”

A year since he stepped into the role of President, Dr. Reyes-Villanueva is condent that the best is yet to come for the organization. “SAMPE’s experiencing an exciting period of growth and innovation,” he says. “This has been a very productive year, and it’s not related to one person. It’s the whole team that is working hard to make sure that SAMPE is at the forefront of the industry.” — Avery Heeringa

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Dealer’s choice

Having EV chargers on site at auto dealerships demonstrates that the dealers stand behind the EVs they sell

By Maura Keller, EA Contributing Writer

As electric vehicles make up an increasingly larger segment of sales for auto dealers, it makes business sense for dealers to have EV chargers on site. Not only does it allow them to keep their on-lot EVs always charged, but it provides an opportunity to attract new customers and retain existing ones by offering free (or paid) charging.

David Kubick, vice president of business development at Maverick Corp., says installing EV chargers at auto dealerships is quickly shifting from a value-add to a necessity. For dealers, it’s all about future readiness. With automakers rapidly expanding their EV lineups, having the right charging infrastructure in place is essential for compliance, service, and customer satisfaction — whether they are “prospective” customers or “existing” customers.

ting to utility upgrades and final commissioning.

“What made this project successful was our ability to coordinate with the utility early and tailor the installation to meet both operational needs and branding standards,” Kubick says. “Now, Jack Madden Ford is fully equipped to support their growing EV lineup, and they’re better positioned to serve both sales and service customers in the EV space.”

“On-premise EV chargers allow dealerships to prep vehicles for test drives, deliveries, and inventory maintenance,” Kubick says. “They also enhance the customer experience by offering on-site charging during service appointments, which adds a layer of convenience and loyalty. From the driver’s perspective, visible EV charging infrastructure at a dealership builds confidence. It sends a strong message that the dealer is committed to supporting EVs long after the sale, which matters to today’s increasingly environmentally conscious buyer.”

Jason Powers, vice president, North America, ADSTEC Energy, says many dealers offer free charging to customers, so the on-site chargers make it attractive for buyers to return to the dealership, again and again, once they’ve purchased their vehicle. “And some dealers even make their on-site chargers available for public use,” Powers says.

Maverick Corp. worked with Jack Madden Ford, partnering with them to install EV chargers across multiple dealership locations. The project included both Level 2 and d-c fast chargers, and Maverick Corp. managed everything from design and permit-

According to Olga Haygood, CEO of S44 Energy, an EV charging software company that powers some of the country’s largest EV charging networks, for auto dealers, onsite EV chargers support key business functions: They enable test drives, pre-delivery inspections, and service operations for EVs.

“Chargers can also be used to attract public drivers or offer paid charging, creating potential new revenue streams,” Haygood says. “Strategically, it signals a dealership’s readiness for the EV transition and helps them meet manufacturer requirements.” For consumers, it’s about confidence and convenience.

“Chargers at the dealership demonstrate that the store is equipped to support EV ownership, from education and purchase through ongoing service,” Haygood says. “This can ease range anxiety and help build trust, particularly for first-time EV buyers.”

Embracing challenges

Vehicle manufacturers are making a push to an all-electric future, and dealerships continue to play a critical role in their delivery and service model. Auto dealerships are on the front line of electrification as they work directly with customers to find the best model and charging solutions for their needs. Most vehicle manufacturers have established strategies to ensure charging is available at their dealerships. As a result, many auto dealers are required to install charging infrastructure in order to receive their electric vehicle allotment from the manufacturer.

According to Michael Bresnahan, director of development at Chateau Energy Solutions in Atlanta, the challenge for these dealerships is that EV manufacturers are requiring a specified number of Level 2 and Level 3 EV chargers to be installed at the dealership by a specific year. However, these dealerships are owned by an individual or owner group and the manufacturers do not provide financial support to the dealers to deploy EV charging infrastructure and have charging capability.

Recently, Hendrick Automotive Group selected Chateau Energy Solutions for deployment of the dealership’s EV charging infrastructure – specifically, a total of nine chargers were installed across Hendrick Automotive Group’s three dealership locations. Gwinnett Place Honda

David Kubick, vice president of business development at Maverick Corp.

was equipped with two d-c fast chargers and one Level 2 charger, as well as the capacity for two more d-c fast chargers. Newnan Honda received one d-c fast charger and two Level 2 chargers, while Mazda Mall received two Level 2 chargers and one dual-port Level 2 charger. Chateau Energy was responsible for the design, engineering, construction, procurement of electrical equipment, and commissioning of the project.

“Typically, the project developer buys and installs the equipment on behalf of the dealerships. Chateau Energy serves our customers in this capacity,” Bresnahan says. “We rst collaborate with our dealership customers to de ne their use case, then we set out to design, engineer, permit, procure, and build the EV charging infrastructure that suits their needs. Where utility upgrades are required, we run point on utility engagement. And in every case, we leverage available federal, state, and local incentive programs to reduce our customers’ out-of-pocket cost.”

Automotive dealers ideally need Level 3 (L3) fast chargers to ensure they can serve a steady stream of vehicles. However, installing L3 chargers typically requires extensive site upgrades and permits that can be both cost prohibitive and time consuming. As Powers explains, many dealers — especially those in city centers or remote areas with limited electrical grid access — are making do with slow L2 chargers, as a result.

“Technologies like battery-bu ered ultra-fast chargers provide an easier and less costly way for auto dealers to bring fast charging to their dealerships,” Powers says. “This category of L3 charger includes a built-in battery storage that enables fast charging on existing power-limited grids.”

In the case of ADS-TEC Energy, for example, the dealership will purchase the equipment and then choose a contractor for the infrastructure. Once that is in place, ADS-TEC Energy performs the installation and commissioning.

“Many auto brands provide nancial support for the project, and if the project is also used for public charging,

it may also qualify for utility or state make-ready funding,” Powers says.

Bresnahan says the biggest challenges and obstacles in deploying EV chargers at auto dealerships are cost and power capacity.

“Each dealership manages its own P&L, and the cost of upgrading their facility hits their bottom line. Deployment costs, including hardware, software, and construction, can be signi cant and don’t have a direct correlation to revenue generation,” Bresnahan says. “Where power is limited and utility upgrades are required, project timelines can balloon, further adding to project costs.”

Kubick agrees that one of the biggest challenges dealerships face when trying to install EV chargers is electrical capacity — as many sites simply weren’t built to support the kind of power needed for multiple Level 2 or d-c fast chargers, which can mean costly utility upgrades.

“Space is another issue. Most dealerships already have limited parking, so

placing chargers in a way that supports tra c ow without disrupting operations takes planning,” Kubick says. “On top of that, permitting requirements can vary widely by municipality, and applying for incentive programs can be time-consuming. And of course, we’re still seeing long lead times on some equipment and transformers, so early planning is critical to avoid project delays.”

Considerations to make

Once an on-site location for one or more chargers is determined, the biggest considerations for installing EV charging are electrical infrastructure and installation.

According to Powers, automotive dealers must consider existing electrical capacity, which must be able to handle the increased load of EV chargers. If upgrades are required, these may encompass new dedicated circuits, electricals, or even transformers. In addition, dealers must consider Please turn to next page

EV DEALERSHIP CHARGERS continued from previous page

installation costs, location, and proximity to power sources and permitting and compliance.

“A major consideration — which is often overlooked — are operating costs, especially electrical demand charges,” Powers says. “Utility companies often charge businesses based on their peak power demand. A single spike in power usage during a billing cycle — such as high use of an L3 EV charger — can result in high demand charges for the entire month. This is another benefit of battery-buffered EV chargers; the built-in batteries enable auto dealers to avoid exorbitant peak demand charges by allowing them to store power and then output when needed.”

Bresnahan adds that while cost and power capacity are the big considerations of making the decision on EV installation, the construction process is also a key consideration during the installation phase.

“Performing the construction activities while not affecting the dayto-day activities of the dealership, such as power outages to install electrical equipment, not impeding traffic flow while trenching, pouring concrete or installing asphalt, striping the charger area, and working around service mechanics in the service bay are just a few other considerations of the EV charger installation,” Bresnahan says.

State-run initiatives

Many states offer incentive programs for auto dealerships that install EV chargers. Efficiency Vermont has an EV Readiness incentive program that gives car dealerships monetary incentives for setting up equipment, tools, and training to sell and service EVs.

Efficiency Vermont’s EV Dealer program has two pillars: 1) the EV Readiness incentive that offers dealerships up to $25,000 for equipment, tools, and certifications needed to service and sell EVs (both new and used), and 2) the EV dealer sales incentives offering up to $600 per new or used EV sold or leased (up to 50 sales per dealer per year, up to $30,000). The program also includes free training on EVs, Ver-

mont incentives, and EV market trends, as well as dealer advertising support, promotional materials, featured promotion in Efficiency Vermont ad campaigns, and online listing via Efficiency Vermont’s “Find a Pro” tool.

“This program supports businesses selling EVs, giving Vermont car buyers more options for more affordable and lower-emission vehicles,” says Nicole Bourassa, Efficiency Vermont’s EV Dealer program manager. “Dealers are critical partners for the EV transition, and the majority of EVs on Vermont’s roads come through local, community dealerships. Many dealers are small businesses, and supporting new and used car dealers to take on and sell EVs supports these local businesses.”

The incentives of the EV dealer program reach dealers mostly through tools, training, professional certifications, and other support. For example, they can get incentives for installing chargers for EVs that customers are test-driving or that are being serviced. They can also purchase new tools and get additional training needed to service and maintain EVs, including their high-voltage batteries. The EV dealer program is specifically designed to help car dealers service and sell both new and used EVs by helping them get the equipment and training for the vehicles their customers are looking for. As more EVs become available, it’s especially important to support used car dealers to help them get the tools and training they need to sell and service used EVs.

“There are many state, federal and utility funding programs available to organizations transitioning to EV sales or offering public EV charging,” Powers says. “Part of our process in needs analysis for prospective customers is to assist them with navigating what funding options may be available.”

In California, for example, the California Energy Commission and utilities like PG&E provide strong support for EV infrastructure, including dealershipspecific incentives. New York, through NYSERDA, offers funding for charging stations and EV readiness tools. In Massachusetts, the MassEVIP program offers grants that dealerships can sometimes qualify for, especially for Level 2 workplace chargers. Connecticut is also very active — Eversource and United Illuminating have make-ready programs that reduce infrastructure costs. And in Colorado, the state energy office has a comprehensive EV readiness strategy that includes dealerships.

“Vermont’s EV Dealer program is implemented in close coordination with State of Vermont partners and Vermont’s electric utilities, which have direct customer incentives for EVs (including offers like purchase rebates and home charging equipment),” Powers says. “The EV dealer program strengthens the EV supply chain by engaging with vehicle dealers through outreach, trainings, and incentives.” EA

Efficiency Vermont’s Erin Moriarity (left) and Alex Frei (center) stand next to Nicole Bourassa, the EV Dealer program manager (right) in front of an Integra Energy EV charger, one of 15 new chargers installed at a dealership with incentives from Efficiency Vermont’s EV Dealer program. — Efficiency Vermont photo

Energy round-up

What’s new in the energy industry as summer draws to a close

By Charlie Barks, EA Managing Editor

Solar numbers shine

Expounding on one of our “Direct & current” items from the June Electrical Apparatus (“It’s sometimes sunny,” page 64): The latest official numbers for the solar power industry are in. The U.S. solar industry installed nearly 50 GW d-c of capacity in 2024, according to an annual report from the Solar Energy Industries Association. The preeminent solar association in the country called this “remarkable,” as it represents a 21% increase from 2023. For perspective, it’s worth noting that renewable energy numbers tend to have annual increases, since they all began at very low percentages over the past few decades.

The solar industry accounted for 66% of all new generating capacity added to the grid in 2024. All solar segments set annual installation records except for residential solar, which experienced its lowest year of new capacity since 2021.

The factors driving installation growth in 2024 varied for each segment. Commercial solar installed 2,118 MW d-c in 2024, setting an annual record and growing by 8% year over year.

The community solar segment completed its largest-ever quarter in Q4, achieving an annual record of 1,745 MW d-c in 2024. This growth was primarily driven by record-breaking capacity additions in New York, Maine, and Illinois.

For the residential segment, a significant contraction in the California market and the impact of sustained high interest rates nationwide contributed to a 31% year-over-year decline in 2024, with 4.7 GW d-c of installed capacity.

Earth Day energy

Energy comes in many forms. It’s easy to forget the role of producing clean air performed by the very environment we’re trying to protect. And for that, we need plants.

In late April, the San Pedro, Calif.-based Sharefest Community Development and its longtime partner

Valero Energy Corp. came together once again to celebrate Earth Day with a beautification project at Banning High School in Wilmington, Calif. This year’s focus was the revitalization of a neglected on-campus parkette — now transformed into a vibrant outdoor space for studentled gardening and horticulture programs. The newly enhanced area features native shrubs, walking paths, revitalized planter beds, and a small orchard, creating a sustainable, hands-on learning environment for students.

“The 1-5 District spans from Watts to the waterfront, and here in the communities of Wilmington, Harbor City, and San Pedro, Valero has been a strong community partner,” said Los Angeles City Council member Tim McOsker, who spoke at the event about the power of cross-sector collaboration.

Wooden wind towers

The wood technology company Modvion, which designs, supplies, and installs wind turbine towers made of wood, is embarking on a new chapter. Maria-Lina Hedlund, previously chief financial officer at Modvion, will assume the role of CEO, the company said May 7. Succeeding the company’s co-founder Otto Lundman, she’ll focus on “product maturation” and strengthening partnerships.

The company, which built the tallest commercial wooden wind turbine in 2023, recently unveiled its newest model, engineered for the largest onshore wind turbines. The tower has been given third-party approval and will now be adapted for series production. The new tower is designed to support a V162 – 6.4MW turbine from the Vestas Enventus platform with a 35-year lifetime. The tower design has been evaluated by the independent certification body TÜV SÜD and received a design evaluation conformity statement. EA

Students from Phineas Banning High School of Wilmington, Calif., participated in a restoration project with Valero Energy and Sharefest Community Development on Earth Day, April 22.

— Valero Energy Corp. photo

Feature | Conventions & Trade Shows

A North American debut

Coiltech North America’s premiere performance offered a glimpse of electrification’s future

By Charlie Barks, EA Managing Editor

NOVI, MICH. — Coiltech, an international trade show with a growing presence, made its North American debut at the Suburban Collection Showplace in this Detroit suburb June 11-12 as a platform for the electric motor, generator, and transformer industry. The 2025 event’s workshop program also included the co-located Applied Electromagnetics Workshop and World Magnetic Conference.

Coiltech was a convention that involved people who are building the future of electrification. This meant traditional coil applications, like those for industrial electric motors, but also burgeoning areas such as the electric vehicle industry. The show featured a wide range of exhibitors whose products included insulation materials based on polymers, tools for technical maintenance in electrical wiring, and more.

Familiar faces

Electrical Apparatus was delighted to see familiar faces, such as those from Electrom Instruments and Rea Magnet Wire, at this year’s event. We also enjoyed meeting new folks from companies like BARplast and PPM.

At the Electrom booth, Jordan Testillo and Kris Torvik had plenty of takers for the company’s latest salvo: the iTIG IV+ winding analyzer. The new product is visually enhanced, with more screen real estate that workers in many different industries can benefit from.

On this series of machines, winding resistance can be measured down to 100 microohms with a resolution of 1 . IR leakage current

measurement resolution is 10 pA (0.00001 microamps), and measurements can be used for PI tests down to 500 pA. PI tests can be done accurately on motors with very low leakage current. Separate highprecision resistance and megohm meters are not needed when the iTIG is used for other tests such as surge and PD tests. Testillo told EA that the company found a number of great leads over the course of the two-day show.

There was plenty of traffic at the Rea booth nearby, too. Kudos to the Coiltech crew — at times it was “way more than what we thought we were going to get” for Rea’s section of the show, according to Nancy Black Hildebrand, a Rea customer experience representative. The long-respected Indiana magnet wire manufacturer found a payoff from bringing a group of employees to the event. Representatives of fellow Fort Wayne company Alliance Winding Equipment were out in force as well, showcasing the company’s trio-suite of products, which encompasses Alliance winding technology, Joyal fusing technology, and Newtech resin/varnish impregnation technology.

Event organizer QuickFairs focused on making the event optimal for face-to-face networking.

Winding equipment at the DMB Winders booth.

The Milan-based company had success with two earlier Coiltech shows in Europe. The core team of Coiltech North America consists of 31 permanent employees, whose main duties revolve around keeping in contact with the exhibitors.

The result was a trade show featuring the most relevant developments in electric motors, generators, and transformers, both on display and in discussion.

Bringing together people from R&D, production, purchasing, and maintenance, the fair delivered condensed, qualified insights in just two days, all while providing free admission, shuttles, parking, and food in what was an efficient expo.

“At Coiltech, ideas spark in the aisles,” said Sebastian Kuester of Coiltech. “You spot innovations before they become industry standard. You meet the supplier who solves the headache you didn’t know you’d have.”

Innovative products

While there was plenty of noise on the floor, it was apparent that the electric vehicle industry is pushing for less on the road. A Wednesday session at Coiltech, headed up by Enedym, covered switched-reluctance (SRM) motors featuring advanced acoustic noise control. This suggests that Enedym, based in Hamilton, Ontario, is working to mitigate the noise associated with SRMs in its products.

The SRMs at the center of Enedym’s approach can generate significant noise, particularly from radial electromagnetic forces. The company says its technology includes “advanced acoustic noise control” for its SRMs.

Methods for reducing electric motor noise generally involve design optimization, using sound-absorbent materials for enclosures (though this may not be economical and can affect thermal characteristics), and utilizing control strategies. Common sources of electric motor noise include worn bearings, misalignment, and issues with internal components.

Another company showcasing innovative products was Delo, an adhesives manufacturer based in Windach, Germany. Adhesives play an important part in making electric drives smaller and more powerful while increasing their efficiency. For example, the installation space required for traditional production processes can be reduced thanks to narrow bonding gaps. Typical bonding applications for electric motors include the securing of buried or surface magnets, the stacking of segmented magnets, and the bonding of stators and housings.

Adhesives are also used for potting coils or for electrically insulating windings. Delo says suppliers can benefit from its extensive product portfolio. Specially developed for electric motors, the products offer maximum strength; they are temperature- and

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If you wish to continue receiving Electrical Apparatus, don’t forget that you need to renew your subscription periodically.

If renewing online, go to ea-renew.com and choose “Renew Subscription.” Then, fill out the form with your Subscriber ID or your e-mail address. Or, mail or fax your mailing label to . . .

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From left to right: Nancy Black Hildebrand, Cory Firks, Mitchell Steffen, and Mason Werling of Rea Magnet Wire.

media-resistant, gap-filling, impact-resistant, and tension-equalizing. Depending on the production process, curing is possible by heat, under the exclusion of air or, in the case of two-component products, at room temperature. If higher demands are placed on bonding accuracy, or if direct and fast further pro-

cessing is required, such final curing is often preceded by initial light fixation.

Show partners express satisfaction

For partner companies of the event, such as Haefely, Schleich, and Eurotranciatura, the debut American show seems to have made a favorable impression.

Eurotranciatura’s team called Coiltech “a dynamic event that offered quality networking opportunities and an engaging combination of exhibition and high-level conferences.” For Eurotranciatura, it was an important opportunity to strengthen its connection with the U.S. market, reaffirming the group’s longstanding presence in the region through its two strategic production facilities in the U.S. and Mexico and its commitment to working closely with local businesses.

The presence of the entire supply chain — from steel suppliers to OEMs, from component and systems manufacturers to research institutes — and the international representation from across Europe, Asia, Africa, and the Americas, made it a truly unique meeting point.

“We’re proud to have been among the most visited booths at the show, a reflection of the value we bring by combining expertise in e-mobility, industrial and infrastructure solutions, with a local presence and global impact,” said Giulia Polvara of EGLA.

Eurotranciatura also gave special thanks to Coiltech, the International Coil Winding Exhibition & Conference’s team, to Kuester for his contribution, vision, and organizational skills, and to Matteo Vezzini for supporting its overseas exhibition.

The next Coiltech North America is scheduled to be held June 10-11, 2026, again in Novi, Mich. There are two European Coiltechs scheduled as well: Coiltech Italia 2025, to be held Sept. 17-18 in Pordenone, Italy, and Coiltech Deutschland 2026, to be held March 25-26, 2026, in Augsburg, Germany. EA

COILTECH continued from previous page

Jordan Testillo (left) and Kris Torvik of Electrom had the idea of paying tribute to the NBA finals with a jumping photo, but Kris had a trick up his sleeve.

Miteya Rahane (left) of BARplast and John Biesterfeld of Bieglo GmbH displaying high-performance polymers.

— Electrical Apparatus photos by Charlie Barks and Copyright 2025 by Barks Publications, Inc.

Views from the Coiltech trade show floor

The operator’s side of a coil winding machine from Broomfield, of Leominster, Mass. The machine features multi-speed, large-capacity, high-torque winding capabilities.

An array of insulation products on display at the booth of Essex Brownell.

Traffic and conversation outside the Big River Steel and EGLA (Eurotranciatura) booths.

Additive Drives, a company out of Dresden, Germany, with U.S. offices in Lafayette, Colo., builds a series of motors without tooling costs.

| Conventions & Trade Shows

Transformative talks

Presentations on transformers and motors figured prominently at the Coil Winding, Insulation & Electrical Manufacturing Exhibition in Berlin June 3-5

By Kevin Jones, EA Senior Editor

The Berlin Coil Winding, Insulation & Electrical Manufacturing Exhibition — most people call it “Cwymee” — is many things: a marketplace of processes and materials used in electrical manufacturing, discussions about coil winding, tantalizing glimpses of new technology for electric vehicles, and ruminations about “sustainability” and the “energy transition.”

CWIEME Berlin typically pays particular attention to coil winding, electric motors, transformers, electrical conductors, and electrical insulation. The 2025 event, held June 3-5 at Messe Berlin, played true to form, showcasing innovations across the entire supply chain for these electrical manufacturing sectors.

This year, about 7,000 attendees gathered to explore new technologies, hobnob with industry professionals, and gain insights into global market trends. The exhibition featured about 750 manufacturers and suppliers from more than 85 countries. The conference program brought together more than 90 speakers.

The conference side of the event is so wide-ranging that one could hardly do it justice in just two pages. To narrow things down: This year’s edition of CWIEME Berlin contained enough about motors and transformers to give visitors a glimpse of where the industry’s priorities lie these days, at least on the European side of the Atlantic.

The latest in electric motors

The discussions about electric motors tended to consider motors in the context of “e-mobility,” but the principles under consideration could generally be applied to industrial motors as well. Ideas entertained by designers of motors for electric vehicles sometimes catch on with designers of industrial motors; see the way in which “power density,” once the purview solely of engineers in the e-mobility game, is now sometimes touted as a relevant characteristic of motors designed for manufacturing plants.

One session worth noting was an exploration of PMG technologies for e-motors, with a special focus on soft magnetic composite (SMC) components and e-axle secondary systems. This presentation delved into the ways in which SMC components can

CWIEME Berlin 2025 brought together some 7,000 attendees, 750 exhibitors, and 90 speakers. The state-owned Messe Berlin conceives, markets, and organizes hundreds of events each year.

enhance motor performance by reducing energy losses and improving magnetic properties. The speaker, Diego Castro Menéndez-Castañedo, director of engineering and R&D at PMG, explained how these technologies are helping to fulfill the growing demand for efficient motors, particularly in automotives.

Improving the performance of electric machines through additive manufacturing was the focus of a presentation by Drs. Anna Ermakova of the University of Bristol and Richard Pollock of Technelec Ltd. Their presentation showed how metal additive manufacturing can offer freedom for designers of electrical conductors, enabling new approaches to reduce a-c loss, improve thermal management, and provide alternative electrical insulation options.

“The Global Evolution of the Electric Motor Supply Chain and Technology Development: Evolving Landscape” was the title of a timely presentation by Michael Southcott of S&P Global Mobility. He explored the dynamic environment of the electric motor supply chain, looking particularly at the supply chain’s rapid growth and at technological advancements within the automotive industry.

The “circularity” of electric machine manufacturing came under scrutiny by Dr. Adriana Encinas-Oropesa of Cranfield University and Matthew Lamb of Turntide Technologies. Their presentation, titled “Circularity of Electrical Machines: A Case Study from the Automotive Industry,” was intended to show manufacturers of electric motors the way toward improved “circularity” practices. (The idea of circularity, in the sense in which European industrialists are fond of using the word, is to keep products, components, and materials in use for as long as possible, extracting their maximum value while in use, and then

— CWIEME photo

recovering and regenerating products and materials at the end of their service lives.)

Continuous flow winding, or CFW, a manufacturing approach for electric motor stators, was described by Daniele Nocciolini of IMA Automation and Davide Bettoni of MAVEL. The technology behind CFW, the speakers explained, combines hairpin precision with inserted winding simplicity to enhance electric motor performance. In short, the purpose of CFW is to reduce rotor losses and provide superior thermal management through direct oil cooling within stator slots. Because it optimizes current density and streamlines the production of coils, this innovation, according to Nocciolini and Bettoni, can offer a compact, cost-effective, and scalable approach to designing and manufacturing motors.

The benefits of using composite materials in the manufacture of sleeved interior permanent magnet, or IPM, motors were outlined by Dr. David Hind of Drive System Design. (IPM motors are a type of permanent-magnet synchronous machine whose permanent magnets are embedded within the rotor core.) Hind explored the merits of using composite sleeves in IPM machines compared with conventional designs. Comparisons with a standard automotive traction market machine, he said, have shown that the optimized composite-sleeved motor design achieved a 0.6% increase in drive cycle efficiency alongside a 23% reduction in cost.

Carrying out the maintenance, repair, and end-of-life phases of electric motors — all with a view toward “sustainability” — was taken up by a trio of presenters from the International Copper Association Europe: Fernando Nuño, Tomas Jezdinsky, and Bruno de Wachter. Their discussion explored methods of extending motor life through innovative maintenance and repair strategies. They also examined current practices and potential improvements across various motor classes and sizes.

Transformer transformations

Transformers took center stage in several sessions, with sustainability, not surprisingly, a recurring theme.

Kirsi Seppäläinen, vice president of commercial planning and product management at Stora Enso Biomaterials, delivered a talk about building sustainable transformers. Her presentation covered innovations in materials and manufacturing processes that reduce environmental impact while maintaining performance. Seppäläinen emphasized the need for transformers that can handle the demands of modern power grids, which — as we have observed numerous times in Electrical Apparatus — are increasingly drawing on renewable energy sources.

In another session, Dr. Pawel Rozga of Lodz University of Technology discussed recent advances in transformer insulation, addressing nonstandard lightning impulse testing of dielectric liquids used in power transformers. His presentation detailed findings from experimental studies that tested the lightning performance of various dielectric liquids. Rozga highlighted new testing approaches aimed at verifying the dielectric properties of these insulating liquids, which are critical for transformer operation and safety.

A session titled “Supply-Demand Dynamics in the Transformer Market: Trends, Challenges, and Opportunities,” presented by Hassan Zaheer of PTR, Inc., explored the evolving supply-demand landscape of the transformer market. Subjects covered by Zaheer included global transformer market growth drivers, regional demand shifts, the impact

of supply chain disruptions and raw material shortages on transformer production, and technological innovations influencing transformer design and efficiency.

In a session with the provocative title “The Inconvenient Truth about Transformer Fires: Risks, Realities, and the Path to Safer Solutions,” Javiera McGuiggan of Cargill BioIndustrial addressed the often-overlooked risks of transformer fires. She confronted the frequency, impact, and data gaps surrounding such incidents and urged making fire safety a higher priority. McGuiggan’s discussion covered the operational, financial, and environmental consequences of transformer fires, and she presented several solutions — such as the use of FR3 natural ester fluid — as steps toward mitigating firerelated risks.

Mario Viarengo of Shell Lubricant Solutions, in a session titled “Energizing the Future: Sustainable Power for a Growing World,” spoke of the increasing demand for reliable, efficient, and sustainable energy. He explored the intersection of environmental regulations, renewable energy, and innovative technologies, emphasizing the impact these factors have on energy infrastructure.

Martin Stössl of Siemens Energy Austria GmbH and Sebastian Rehkopf of Maschinenfabrik Reinhausen GmbH, meanwhile, collaborated to present “Empowering the Energy Transition: The Role of OnLoad Tap-Changer-Equipped Transformers in Grid Sustainability.” The two spoke of the importance of decarbonizing the energy sector to meet climate targets, noting the contribution of renewable sources such as wind toward meeting this objective.

A session titled “Collaborative Decarbonization: Establishing Green Lead Markets for CO2-Reduced Electrical Steel in Energy Grids,” presented by Marcel Hilgers of thyssenkrupp Electrical Steel, examined collaborative efforts, particularly among producers of CO2-reduced steel, transformer manufacturers, and grid operators, to meet climate goals. (“CO2-reduced steel” refers to steel manufactured with processes that produce less carbon dioxide than conventional methods.) Hilgers also outlined strategies for maintaining the resilience of supply chains for grain-oriented electrical steel.

For people with an appetite for electric machines, materials, and electrical manufacturing methodologies, CWIEME is a movable feast. Those who missed the Berlin event — provided they could swing the time and the travel expenses — would have been able to catch CWIEME Shanghai at the Shanghai World Expo Exhibition & Convention Center June 25-27. The next CWIEME Berlin is scheduled to be held May 19-21, 2026. There used to be an annual CWIEME North America in Rosemont, Ill., but the most recent of those was held in 2019.

Associations

An association lays out an innovative energy plan

A March 10 call for opinions by the U.S. House of Representatives’ AI and Energy Working Group drew a response from the National Association of Manufacturers that lays out a plan for responding to increasing electricity demand. The response was signed by Charles Crain, the National Association of Manufacturers’ managing vice president of policy.

The Congressional working group, created and headed by Rep. Julie Fedorchak of North Dakota, had invited energy industry stakeholders to “examine how best to harness domestic energy resources, secure critical infrastructure, and tailor policies that not only meet today’s needs but also position the United States to outpace global competitors, particularly China, in the AI era.”

In its response, the National Association of Manufacturers, or NAM — which represents nearly 13 million workers, contributes some $2.94 trillion annually to the U.S. economy, and is a strong advocate for free markets — emphasizes the importance of cooperation among manufacturers, energy producers, and regulators in meeting the nation’s future energy needs.

As manufacturing becomes increasingly digitized, advanced data centers are placing unprecedented strain on the nation’s energy grid, NAM explains. These data centers, along with manufacturing facilities, rely on such things as cooling systems, electrical equipment, and semiconductors, all of which require robust and reliable sources of energy.

The surge in energy demand presents a significant challenge to the U.S. energy grid. According to the research and consulting group Wood Mackenzie, U.S. power demand could increase 15% by 2030, with data centers alone projected to use upwards of 9% of the nation’s electricity resources by that year. A U.S. Dept. of Energy study from August 2024 suggests that electricity generation must double to meet this demand.

To quench this thirst for more electric power, NAM recommends an energy strategy that would leverage natural gas, oil, nuclear, geothermal, solar, wind, thermal, battery storage, and emerging technologies such as hydrogen and advanced nuclear reactors. “As demand grows and supply remains relatively static,” NAM says, “there is a pressing need to use all policy levers available to ensure sufficient, reliable, resilient, and affordable energy for all users.”

A reform of the permitting process, according to NAM, is one key to unlocking energy innovation. In its letter, NAM speaks of the need to streamline processes to expedite the development of energy generation, transmission, and distribution. Current permitting requirements, NAM says, hinder the deployment of baseload and renewable energy sources as well as the energy storage systems that are critical to the grid’s stability.

Reforms proposed by NAM include accelerating judicial reviews, establishing enforceable deadlines, increasing the use of categorical exclusions under the National Environmental Policy Act, and streamlining the Clean Water Act. Unblocking access to domestic

sources of critical minerals and reducing regulatory barriers would also help, because weaknesses in these areas can cause delays that undermine the global competitiveness of U.S. manufacturers.

Grid reliability and resilience are also critical, says NAM, which notes the rising risks of service disruptions due to aging infrastructure, severe weather, and the retirement of traditional power-generating units. Existing nuclear reactors, despite the economic and permitting difficulties associated with them, remain a vital source of baseload power.

Then there’s the matter of renewable energy. Sources such as wind, solar, and battery storage are expanding, but they currently lack the capacity to provide consistent baseload power, NAM notes. Natural gas, therefore, remains a critical complement to renewables, which are intermittent in their delivery of electricity. Investments in transmission and distribution infrastructure would be essential in supporting the grid’s capacity to handle the growing energy needs, NAM says.

Data privacy and semiconductor manufacturing are two other areas in which policy can help boost innovation, according to NAM, which is calling for comprehensive national legislation to replace the patchwork of state laws that currently exists. In semiconductor manufacturing, timely implementation of funding agreements by the U.S. Dept. of Commerce and renewal of the Advanced Manufacturing Investment Credit would be critical to boosting domestic production of AI chips.

Similarly, preserving the Advanced Manufacturing Production Credit would support the production of critical minerals and grid components. NAM also recommends tax incentives for research and development. Helpful reforms in this area would include immediate expensing of R&D costs and full expensing of capital investments to encourage private-sector investment in AI infrastructure.

As it happens, NAM’s recommendations align with broader national goals of maintaining U.S. leadership in AI and energy. A Presidential executive order issued last Jan. 23 emphasizes removing barriers to AI leadership to promote economic competitiveness and national security. The Administration has also spoken of a need for a balanced regulatory approach that would avoid excessive caution while maximizing AI’s transformative potential.

As NAM sees it, by helping to develop a policy environment that supports energy innovation, grid reliability, and AI development, the U.S. can secure its supply chains, enhance national security, and drive economic growth in a manner beneficial to all. The association’s proposals, if followed through on, would go far toward creating an environment in which innovation in AI and energy would mutually reinforce each other — which in turn would help U.S. industry compete globally while meeting its domestic energy needs. — Kevin Jones EA

— Electrical Apparatus photo by Kevin Jones

En garde, prêts, allez . . .

‘Ready, set, go!’ is fencer Anthony Cuschieri’s approach to running his polyester film company

By Colin Gregory-Moores, EA Contributing Writer

In 1991, Anthony Cuschieri started International Packaging Film (IPF) as a sole proprietorship to source international suppliers of 12-micron polyester and polypropylene film mainly for thermal laminating companies and the snack packaging industry in the U.S.

As Anthony laconically and knowingly adds, “In the course of 34 years, a lot of things can transpire.” Specializing now in polyester film with thicknesses of 125, 190, and 250 to 350 microns, IPF sources it globally for U.S. companies for a wide range of applications, including electrical and industrial insulation. The company, with annual sales of $8 million, is situated in Norwood, N.J.

Anthony was born in Sampson County, N.C., in 1953 to a mother of English, Scottish, and Irish origin, whose family had been in the U.S. since the early 1700s, and to a father who was a recent immigrant from Malta. Since Moses Cuschieri could neither read nor write, he enlisted in the U.S. Army in March 1941 for 12 months in order to become a U.S. citizen. However, following the Japa-

nese attack on Pearl Harbor on Dec. 7, he was called back from furlough to active duty in April 1942. Stationed at Fort Bragg as a cook, he met his wife, Maggie, a bomber mechanic. With his innate New York wit, Anthony comments, “If that doesn’t screw you up a little bit, I don’t know what will.” In 1955, the family settled in East New York, a neighborhood of Brooklyn, N.Y.

Growing up in East New York, Brooklyn

The parents and five kids were very poor. Fortuitously, Anthony’s mother registered him with The Fresh Air Fund, a New York organization founded in 1877 to take inner-city kids and connect them with families outside the city. At the age of six, he spent two summer weeks in the affluent town of Upper Saddle River, N.J., at the home of Mr. Meyer Blom, a Dutchman, his wife Betty, and their only son Allan, who was Anthony’s age. “It was a life-changing experience,” he marvels. He had never eaten in a restaurant, never driven in a car, or even been allowed to ride a bicycle before. “It was just a whole new world,” Anthony gesticulates and laughs. From then on, he went there every summer and later for Christmases too. He now lives in New Jersey with his own family.

Of East New York, he says, “One of the beauties of growing up in Brooklyn is the diversity of cultures that you are confronted with. My world wasn’t the best, but there was always something to extract out of it.” Amidst all the destruction and violence, he recalls this beautiful garden his parents cultivated. It was 100 by 50 feet, with roses everywhere. His mother planted vegetables, and his father planted tomatoes. When the women would come out of church on Sundays, they would see the vegetables and say, “I wish I could have some of them.” Overhearing the women, his father replied, “Well, if you’d like to buy some, I’d be more than happy to sell you some.” Anthony bursts into laughter, deftly imitating the cadences and accents of the women and his father.

Growing up in a family in which everyone worked, he started his own newspaper collection business at about the age of 10. Once a week, he would go around to all his neighbors’ houses and collect their used newspapers. When he had about 400 lbs., he would take them to the local junk shop to be paid half a penny a pound.

All for one, and one for all

Wanting to be part of a group at high school, he unsuccessfully tried out for the track and gymnastics teams before giving fencing a try. Fencing

A 1972 production titled “Et Tu Brutus,” enacted by (from left to right) Harry Malave, Neil Sol, Anthony Cuschieri, and Doug Arena. — Anthony Cuschieri photo

Anthony Cuschieri, trader and entrepreneur. — Anthony Cuschieri photo

did not require any prior experience or skills. Being tall, skinny, fast, and analytical, he was a natural. Unfortunately, none of the coaches in high school really knew anything about fencing, except to say, “Be fast like a snake,” Anthony laughs.

Like his friends, Anthony couldn’t afford any private lessons. So, on Saturday afternoons, they would go by the famous Giorgio Santelli’s fencing school in Greenwich Village to watch the master give lessons and fence with some of the older men. At Brooklyn College (1971-75), Anthony became a member of the varsity team, coached by Michel Sebastiani. Both Santelli and Sebastiani were inducted into the USA Fencing Hall of Fame.

Trading

Having an illiterate father who could never live out his full potential, going to college was important for Anthony: “I knew that was going to grease the rails of my life.” He studied psychology, convinced that it was something that he really wanted to do, influenced by the introspection of the 60s, Vietnam War protests, and the counterculture of Woodstock.

After graduating, he worked for Bendix International Marketing Operations, Inc., for three years before quickly transitioning from spare parts and customer service into high-level international trading at General Electric Co., where he stayed for nine years. When he was 30, he was awarded a $2,000 prize. Bemused and frustrated by the slow processing of export documentation, he submitted a suggestion to expedite the processing of documents. This led to faster invoicing and substantial savings for GE.

From 1984-87, he was responsible for negotiating the purchase and sale of steel products to liquidate GE’s countertrade and barter obligations. At one point, there was so much Turkish pipe coming into

the U.S. that the American pipe producers filed an anti-dumping lawsuit. Since he could no longer import Turkish pipe, his boss told him to go to the plastics section. “Plastics?! What the hell do I know about plastics?!” Anthony retorted.

The petrochemicals and plastics division was headed by Mustafa Say, an MBA graduate from Columbia University. He and Anthony became a team. Anthony was sent to Turkey to get a quick introduction from Polinas about the production of biaxially oriented polypropylene film for import into the U.S. Anthony recalls the questions of U.S. food-packaging companies, “How do they keep the bugs out of the film when they’re making it in Turkey?” With spunk he would fire back, “How do you keep the bugs out of it when you’re making it in Alabama?” Polinas is now a well-established company selling all over the world.

Lessons learned

At one point, Mustafa started thinking that they could make more money if they worked for themselves. He launched his own company, and Anthony started IPF in 1991 after working as a trader at Vinmar, Inc., Houston for two years. Although all the contacts and the relationships he had made started coming into play, he admits that if he had had a family in the first three years, they would have starved to death. Since he had always been a big saver, he financed himself pretty much on his own. “When you first start out, I think, a lot of people are afraid to give you a chance. But if you can hold on long enough, then people go, ‘Maybe he’s for real.’”

When you have been doing something long enough, eventually it’s no longer an option. Fortunately, Anthony’s proverbial sheepdog, as he calls it, has always nuzzled him to where it wants him to be in the face of various market changes. Currently, he is exporting out of India, Bahrain, and Dubai.

Doing right by his clients, tenacity, reliability, honesty, and his word are his trademark. He has always been in the business for the long haul. Comparing it to fencing, he says: “You’re fighting to get the order, you’re fighting to establish yourself in a company and be respected, you know. And once you get those things, you can’t just frivolously let them, you know, go away. I’d rather do this than anything.”

The Brooklyn College Fencing Team 1972: Michel Sebastiani (middle row, first from left), Anthony Cuschieri (back row, second from right). — Anthony Cuschieri photo

View of the Cuschieri family’s garden in East New York, Brooklyn, 1964/65.

— Anthony Cuschieri photo

Feature | Training & Education

Amazon U.

Bakersfield College is partnering with Amazon for educational programs that offer employees a plethora of career-advancement opportunities

By Avery Heeringa, EA Contributing Writer

What’s better than getting assistance to cover the cost of college? Tuition assistance programs, increasingly popular within the last few years, offer employees the chance to pursue degrees alongside their work. Starbucks has its College Achievement Plan, McDonald’s has Archways to Opportunity, and Amazon offers Career Choice, which strives “to meet individual learners where they are on their educational journey through a variety of education and skills training opportunities,” according to the company.

As part of the company’s lofty goal to become “Earth’s best employer,” Amazon Career Choice is motivated to assist its employees with its highereducation goals. The program has served hundreds of thousands of global participants and partners with more than 600 schools across 14 countries, including the U.S., Costa Rica, France, and South Africa, to name a few. One of these schools is Bakersfield College, a community college on the West Coast that has partnered with Amazon for several education programs.

The Amazon Career Choice program, for example, has four key areas: college, pathways, foundations, and coaching. The first of these offers prepaid tuition for higher education. The second offers industry certifications for in-demand professions like the HVAC/R industry, for example. The foundations area offers high school completion, GED, and English language education services. The last category, coaching, aids employees in reaching their career goals through advising and other services.

According to Amazon, “Students are able to attend their classes at one of more than 400 education partners around the world, including community colleges, local and national colleges, HBCUs [historically Black colleges and universities], and other skills training providers.” The program offers flexible scheduling, access to mental health services, financial counseling, and mentorship groups.

The Bakersfield College Foundation has committed $1.37 million to grow local industrial sectors through their workforce training partnership with Amazon, according to the college’s website. Beyond the Career Choice program, the more specialized Mechatronic Robotic Apprenticeship (MRA) pro-

gram offers participants industry certifications and clear pathways to industrial opportunities. Bakersfield College is one of five colleges nationwide to offer the Mechatronic Robotic Apprenticeship program as well as the Reliability and Maintenance Engineering program, which provides education in industrial maintenance.

Both programs began in July with an initial cohort of 20 apprentices, according to Cheryl Scott, executive director of the Bakersfield College Foundation. Three cohorts will be trained from now until the end of the year, with the goal of training 200 apprentices next year. “Students completing the program are typically hired into financially rewarding positions by the time they graduate,” Scott says. “Employers in the energy, food processing, and the supply chain and transportation industries are especially interested in our graduates.”

Another one of Bakersfield College’s offerings is a four-year Baccalaureate degree in Industrial Automation. Scott says the program “prepares students for careers at Amazon and other local employers,” many of which are involved in robotics and automation, instrumentation and process control, and electronics and electrical systems.

Of all the programs the school offers, Scott says that the college is especially looking forward to tracking the successes of the employeestudents from Amazon. “The partnership with Amazon is evidence of Bakersfield College’s commitment to local industry and employers,” she says. “We are proud of our workforce development initiatives because they set our students on a path to success.”

Equipment inside the labs for the training programs, the first project of this magnitude at Bakersfield College. — Cheryl Scott photo

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Names & Faces

The Association of Electrical and Mechanical Trades recently announced the appointment of Mark Brady as its new honorary president. He takes over the position from outgoing president James Stevens, the CEO of Preformed Windings. Brady, managing director at electromechanical maintenance specialist Hayley 247 DEXIS, assumed the president’s position after serving as vice president.

Commenting on his appointment, Brady said, “I want to express my heartfelt thanks to our outgoing president, James Stevens, whose leadership over the past term has been nothing short of exemplary. James has steered the AEMT through a period of growth, innovation, and renewed purpose with a steady hand, strategic vision, and unwavering commitment to our members, leaving a lasting legacy.”

Randy Walter was recently named CEO of Timberline Manufacturing in Marion, Iowa. A U.S. Army veteran and former chief financial officer, Walter brings decades of senior leadership experience in manufacturing and distribution. The company conducted an extensive search after Tom Pientok announced his plans to retire.

Timberline employs about 220 people and has more than 30 years of experience in electrical contract manufacturing. The company specializes in wire harness assembly, control panels, electronics, and electromechanical assembly.

New Hampshire construction materials company W.R. Meadows has promoted Frank Bifero to vice president of manufacturing. Since joining the company in 2022, “Frank has demonstrated a deep commitment to operational excellence, quality, and innovation, earning recognition throughout the organization for his leadership and results-driven approach,” the company said in a statement.

Bifero began his tenure at W.R. Meadows as a plant manager before being promoted to director of manufacturing. He also established a new engineering department that supports operations across the company’s 11 manufacturing plants and warehouses in North America. As vice president of manufacturing, Bifero will oversee operational strategy across all plants.

Hitachi Energy has appointed Wolf Mueller executive vice president and business unit managing director for service, while Luis Ramos has been appointed executive vice president and chief communications and government relations officer. Mueller joined Hitachi Energy’s predecessor in 2018, serving as senior vice president of the service function for its Grid Integration business unit. Ramos joins Hitachi Energy from HH2E, a green energy startup in Germany, where he developed and led communications from the company’s inception to its sale.

— Charlie Barks EA

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Wolf Mueller and Luis Ramos

Mark Brady

3D printing comes of age

How 3D printing — once a novel manufacturing technology — has become firmly established in the industrial workplace

By Bill O’Leary, EA Contributing Writer

What makes an innovative technology sustainable? How does the new become old but not forgotten? The realm of innovative technology is riddled with one-hit wonders — things that were supposed to revolutionize some industry or task but quickly went the way of the dinosaur. Smart glasses, e-ink color tablets, soft exoskeletons for industrial use, hydrogen internal-combustion engines. The only guarantees are death, taxes, and that more will be added to that list.

But the jury is still out on a host of other technological innovations. One gleaming example: the 3D printer. Also known as additive manufacturing, simply put 3D printing is the process where physical objects are created through multiple layers from a digital design. These objects are composed of a variety of materials, including metals through direct metal printing where a wire or metallic powder is melted by an electron beam or laser to deposit it layer by layer.

3D printing also harvests plastics through fused filament fabrication, where plastic filaments are heated and extruded through a nozzle. Resins, selective laser sintering powders and even food can also provide the manufacturing ingredients.

A mix of benefits

3D printing grabbed headlines and made the manufacturing world take notice due to a mix of unique benefits. It can create intricate and interlinked shapes that would otherwise be difficult to produce with traditional methods. Lattice structures, organic forms, internal channels, and other complex geometries can be produced with 3D printing. Also, 3D printing can use lighter material for parts of a reduced weight without compromising strength, which allows for easy use in aerospace and other industries.

The CAD spine of the entire process that creates a design that feeds into the machine provides for rapid prototyping and modeling. It also allows for objects to be designed and printed on demand, which allows for a high level of customized products. The short development cycle

Please turn to next page

Close-up view of a stepper motor and timing belt on a RepRap Mendel90 3D printer. RepRap, short for “replicating rapid prototyper,” is an opensource project intended to support development of low-cost 3D printers.

— Dennis van Zuijlekom / Creative Commons photo

The 3D printer market

can be anywhere from hours to a few days, increasing speed to market. And that speed means fast iteration as well, where users can test and revise designs quickly without making costly tooling changes and catch design flaws before executing on higher volume and expensive production.

The production process is also much cheaper, as larger pieces and materials from traditional manufacturing such as jigs, molds, and dies are not required. This drastically minimizes set-up costs for one-offs or small batches. It also enables on-demand manufacturing, which reduces waste and excess inventory. Manufacturers can move faster to create exact quantities with pinpoint precision.

This also means that spare parts and repairs are strong output candidates. As long as a design or schematic is available, you can reverse-engineer and print once-obsolete components for outdated motors, gears, impellers, and enclosures. Hybrid additive manufacturing systems can be used to repair damaged parts in remote and hard-to-reach areas such as motor shafts and turbine blades. The decentralized production that is borne from the relatively small and remote device means parts can be printed at the point of need.

There are a number of sustainable advantages to additive manufacturing as well. Its near-net shape manufacturing capabilities mean minimal waste compared to computer numerical control (CNC) or casting. This is particularly important for expensive materials such titanium and rare-earth alloys.

Plenty of benefits here could mean that 3D printing is here to stay, but do numbers support it? Let’s temperature-check the 3D printing market today.

The global market for 3D printers was valued at $19.3 billion in 2024, with some projections saying it could reach $23.4 billion by 2025 and $101.7 billion by 2032. That is a compound annual growth rate of 23.4%. Alternative forecasts are more generous, projecting as much as $150 billion by 2032.

For context, a CAGR of 18%-24% is considered very strong, particularly for the manufacturing sector. Less than 5% is a slow, declining sector, while 10%-20% is strong, sustainable growth that is attractive for industrial technology. Anything greater than 20% . . . well, now you’re cooking with gas, as this indicates exceptional growth and the likely interest of investors and other capital sources, potentially prolonging the innovation and adoption.

Let’s compare these numbers to its building brethren. A variety of projections peg the CAGR for injection molding anywhere from 4%-6%, CNC machining around 5%, and industrial robotics from Please turn to page 36

3D PRINTING continued from previous page

A 3D rendering of an electric motor can help designers envision the placement and proportions of motor components — some of which might be manufactured with 3D printing. — stefanphotozemun / Shutterstock image

An assortment of plastic PVC machine parts as they might be produced with 3D printing.

— Deyan Georgiev / Shutterstock photo

10%-14%. Comparatively, the market for 3D printing should expand rapidly, driven by increased adoption in a variety of industries such as aerospace, energy, defense, automotive, healthcare, and — you guessed it — electromechanics.

Use of the technology is spreading across the supply chain from prototyping to end-use production, and it would not be inconceivable to think that because of all of this, venture capital and industrial research and development dollars will continue to flow into additive manufacturing technologies and startups.

Further breakdowns, provided from a market report by global market research company IMARC Group, bolster the strength of 3D manufacturing today. North America leads global adoption with 41% of market share, while Asia-Pacific is the fastest growing region, with a 22%-23% compound annual growth rate and growing industry adoption.

By application, prototyping is the dominant-use case at 55%, but functional part manufacturing is rising. The ability of 3D printers to quickly create detailed and precise prototypes, enabling engineers, manufacturers, and designers to double-check, update, and evolve their concepts, is fueling this dominance.

By segment, industrial accounts for the majority of the market share over consumer products, aerospace, defense, automotive, healthcare, and education and research. The industrial sub-segments included aerospace, automotive, healthcare, and manufacturing. Additional evidence for the durable abilities of 3D printing for industrial uses can

3D printing: What’s in it for repair companies?

With 3D printers, repair companies can recreate discontinued or obsolete components for motors, control panels, and generators, to name a few items that would otherwise be too expensive or too scarce to replace. The following are common, relevant outputs from 3D printing:

> Housings

> Casings

> Stator frames

> Stator supports

> Rotor cages

> End bells

> Brackets

> Cooling channels

> Heat exchangers

> Wiring guides

> Insulation fixtures

And that’s just for the electric motors. For generators, 3D printers can produce:

> Cooling ducts

> Fans

> Mounting structures

> Terminal blocks

> Enclosures

> Brush holders

Let’s round out our list with printable components for control panels and electrical cabinets:

> Cable clamps

> Bushings

> Mounting brackets

> Rails

> Switch panel bezels

> Switch panel covers

> Conduits

> Junction boxes

> Knobs

> Selectors

> Button covers

> Insulators

It’s clear from this list that additive manufacturing is making an impact in electromechanics. The industry is run by machines that are composed of incredibly detailed, customized, and interconnected parts. And that benefit of precision is baked into the upstream attributes of the product, as damaged parts can be 3D-scanned and modeled with the printer’s CAD software. Then, a new, non-damaged piece can be reprinted in durable metal, flexible plastic, or fine resin. — BO’L

be seen in the material breakdown, where metal accounts for 54% of the related market while polymers and ceramics constitute the rest.

Industrial-scale additive manufacturers’ providers also dominate the market. Stratasys, an early entrant and pioneer in fused deposition modeling, sits at the top of the heap with a market capitalization of $1.5 billion and annual revenue of $650 million in 2024. Fused deposition modeling is a type of additive manufacturing where a thermoplastic filament like ABS or nylon is heated to a semi-liquid state and extruded through a nozzle to create a layer-by-layer build platform. The layers cool and fuse together to solidify the 3D object layer cake for the industrial world — although it won’t taste nearly as good as what you’ll find in a bakery.

3D Systems, a manufacturer of stereolithography printers, software, and on-demand services had revenue of $440.1 million in 2024, earning the silver medal. However, this was approximately a 10% decline from $488.1 million in 2023. Stereolithography uses ultraviolet light to cure liquid photopolymer resin into solid plastic. The UV projector or laser traces a cross-section of the object into a vat of liquid resin. The resin then hardens when exposed to the light. The build platform lowers and a new layer of resin cures on top of the previous one - a process that repeats until the full object is built.

A who’s who of big-name players in other industries are also jockeying for position in this fledgling industry, hoping to utilize their vast capital and infrastructural resources to lap the first movers. They include GE Additive, which uses advanced metals, direct-metal laser melting, and electron beam melting to produce vital parts in the aerospace and medical sectors. Direct-metal laser is the stuff of James Bond, harnessing a high-powered laser to melt metal powder particles in a tightly controlled environment. The fiber or diode laser has a heat source of anywhere from 200-1000 W.

Electron beam melting is somewhat similar but utilizes the very building blocks of life by producing a targeted beam of electrons to melt metal powder inside a vacuum chamber. It produces coarser layers than direct metal lasers but has lower residual stress due to preheating.

As you can see, additive manufacturing has expanded to multiple industries, multiple use cases, and multiple production types. That fragmentation is often a telltale sign of an innovative technology that is growing up. More players are finding more reasons to use 3D printing for more specific needs, which bodes well for its longevity.

And one such player is the electromechanical industry. Additive manufacturing has seen increased use in electromechanical repair due to

precision in creation of intricate parts, customization that arises from digital prototyping, and the quick turnaround time in production and implementation.

3D printing parts and tools

The sidebar on the facing page lists some of the many motor, control panel, and generator components a 3D printer can produce. But the advantages of additive manufacturing go beyond the guts of the motor. Users can expeditiously fabricate alignment tools, jigs, and fixtures that are implemented to align or repair important components for movement, such as motor windings and stators. That increased precision of producing a custom part that fits nice and snug in a custom machine as part of a custom process reduces downtime across a number of dimensions.

Managers no longer have to scour the internet to find that exact replacement part, which as mentioned earlier could be obsolete, or twiddle their thumbs as that rare piece travels through a long and arduous delivery supply chain.

Let’s advance further outward. Additive manufacturing can also be used in the creation of electrical

and thermal insulation components. Using non-conductive, heatresistant polymers as material, users can build custom phase barriers in three-phase motors that are designed to isolate the A, B, and C phases to reduce electromagnetic interference and prevent short circuits.

Printed coil formers are also a possibility. These are insulating components that function as a structural base for winding coils in stators and armatures, holding the wire in place during and after winding. They also isolate the coil from the motor’s magnetic core of conductive frame, and they deliver exact, consistent wire placement during coil manufacturing.

The ability to print coil formers is a near game-changer as they serve essential functions across multiple motor types. Coil formers guide field and armature windings for small, brushed d-c motors. For brushless a-c and d-c motors, they are used for modular stator coils. For stepper motors, printed plastic formers serve as winding support. And last but certainly not least, they hold concentrated field windings in universal motors that can operate on either a-c or d-c power, commonly seen in portable tools and household appliances that deliver high torque and speed in compact spaces.

3D printers can also be used to produce spacers, which are insulating, mechanical components used to maintain exacting separation between parts. Spacers, if implemented, offer a variety of foundational benefits, including alignment, mechanical support, insulation, and heat dissipation.

Please turn to next page

In 2019, the University of Maine Advanced Structures and Composites Center unveiled this, what it said at the time was the world’s largest 3D printer. — ChristelmPeters / Creative Commons photo

They are most often composed of materials that flow through today’s 3D printing machines such as plastics like nylon, PTFE, and polycarbonate for electrical and light-duty mechanical separation. But they can also be composed of metals like aluminum and steel for structural spacing in mechanical assemblies and ceramics for high-voltage and high-temperature applications.

In many cases, additive manufacturing can produce customer motor spacers faster and cheaper than conventional machining. Motor designers and engineers can rapidly prototype or manufacture spacers that are precision-fit, thermally optimized and electrically insulated which are on-target for motors, control systems, and generators. Stator and rotor spacers, with separate windings to improve insulation and reduce eddy current losses, can be printed with high-temperature, flame-retardant plastics such as PEEK and PA6.

Bearing spacers that prevent preload damage are 3D-printed with nylon and other reinforced composites to deliver on dimensional stability. For coil and winding head spacers, 3D printers can produce custom forms to route and secure end turns and preformed coils. Finally, busbar and terminal insulation spacers can be printed using flame-retardant-rated resins or glass-filled nylon. This allows for insulated spacers that can maintain strength and separation in highvoltage zones.

And 3D printers are not simple point-and-clicks. There is a level of skill and nuance with proper use leading to stronger outputs. For example, slots and tabs can be designed to ensure alignment with windings and laminations. Ribbing and honeycomb patterns can lead to interlocked added strength without added weight.

And ensure that you are accounting for thermal expansion if the spacer interacts with hot components. Every material expands when heated, so it’s important to account for added space where the spacer

can expand lengthwise without pressing against bearings, housings, or end plates. This is called axial clearance. It is also beneficial to design for radial gaps to ensure the spacer won’t seize or deform under compression, whether that be expanding outward or inward. For every 10°C rise, a 50 mm plastic spacer with a coefficient of thermal expansion (CTE) can grow approximately 0.035 mm. Some 3D design experts recommend accounting for those numbers in the final product, as it can be enough to cause interference in precision fits.

The future of 3D printing

So, from everything gathered above, it seems that 3D printing potential has the staying power needed for an innovation to go from flash-in-pan to fixture of everyday life. Less Google Glass and more glass bottle when it comes to use and ubiquity. But how will it continue to iterate and evolve over time to stay relevant and ahead of the curve?

Volumeric and holographic printing can sculpt complex solid parts at increased speeds. We are talking seconds, with no need for layering or supports. There is also Swarm 3D printing, where a nano-fleet of mobile robots, with print tools in their heads, process different parts of a product in tandem, which leads to faster, scalable manufacturing in open spaces. Then we have advanced multimaterial and multi-color printers that leverage new systems to produce full-color models that are also rigid, flexible, and conductive in a single build while fluidly transitioning between materials.

And we haven’t even touched on AI-driven solutions where machine learning can optimize print settings in real time, predict and prevent errors, and adjust builds for the best strength and weight based on specific applications — where additive manufacturing meets Industry 4.0, another recent innovation that is looking for ways to continue to grow and provide solutions.

Because isn’t that the real reason why innovations avoid being one-hit wonders? If it helps, it stays. And it helps in ways that no other piece of technology can. 3D printers are able to execute on those promises. Can it sustain that beneficial momentum? The future certainly looks bright, but at the end of the day, the only certainty . . . is uncertainty.

Feature | Power Transmission & Distribution

Breaker breakout

Given the proliferation of massive data centers, demand for medium-voltage breaker switchgear appears boundless

By David Bredhold, EA Contributing Writer

Medium-voltage switchgear has many uses. Petroleum refineries, steel and aluminum rolling mills, chemical manufacturing plants, utility generating stations, semiconductor foundries, and many more industries are home to medium-voltage gear.

Given the accelerating demand for massive data centers requiring large quantities of electric power, the opportunities for the use of medium-voltage switchgear are boundless. Some data centers are even demanding nearly the full output from some generating stations.

Ever larger chillers require medium-voltage motor drives. Electrode boilers operate at medium-voltage levels: 4.16 kV, 13.8 kV, and such. Petroleum pipeline pumps are too large to operate at low voltage levels.

Fusible gear is one type of medium-voltage switchgear that is often used to power medium-voltage equipment. It provides acceptable basic protection, disconnection, and lockout protection. Coordination with fuses is readily applied with upstream and downstream equipment.

While fuses provide protection, the equipment is limited in that it cannot easily be opened and closed remotely. Motorized fusible gear is available for remote control, but it is not often employed. Remote tripping can be had, but someone must go to the gear to manually re-close it.

Circuit breakers have a lot going for them over fuses. They can be remotely opened and closed. Coordination is readily accomplished through solid state protection relays. Breakers can be reset after tripping, rather than having to be replaced as with fuses.

Medium-voltage circuit breakers as manufactured today are significantly improved from their forebear: the air circuit breaker. Air circuit breakers were manufactured for many years and proved their worth in their day. Some still remain in operation here and there. When vacuum interrupters were developed, they became the leading technology employed for the manufacture of medium-voltage circuit breakers through at least 38 kV. (See Figure 1.)

Drawout breakers can be racked out of their cubicles to be repaired or replaced quickly and easily. Try that with a medium-voltage, fusible switch! Breaker gear maximizes up-time.

Vacuum breaker features

Let us look at the workings of a vacuum circuit breaker. As mentioned earlier, the essential element in a vacuum breaker is a vacuum interrupter, a bottle containing contacts enclosed in a cell containing a vacuum (Figure 2).

Medium-voltage breakers contain a closing spring to rapidly and solidly close the breaker’s contacts. An opening spring opens the breaker’s contacts rapidly to quickly interrupt current, often in as few as three cycles — especially important when interrupting short-circuit current. The longer contacts require to break current, the longer arcing and consequent damage occurs.

A charging motor charges the opening and closing springs. The opening spring is charged at the same time as the closing spring — very important should the breaker close on a short circuit.

A wide range of operating voltages is available for controlling breakers. A-C voltages are 120 V and 240 VAC. D-C voltages are 48 V, 125 V, and 250 VDC; many facilities employ a station battery to provide control power, especially important should a utility be disrupted. The charging voltage for the motor may differ from the close and/or trip voltages, depending on the control system used. Be sure to determine prior to specifying gear.

Figure 1. A medium-voltage drawout vacuum circuit breaker.

— Square D/Schneider Electric photo

Auxiliary contacts are included to indicate a breaker’s open and closed conditions. An operations counter provides an indication of the number of cycles for the breaker to assist in tracking the life cycle for the breaker’s components. It can be especially useful for predictive maintenance purposes where a breaker is used in an application involving frequent cycling.

Wear indicators are often included on the main contacts for a go/ no-go indication. When the need is indicated, the vacuum interrupter bottles can be replaced and the breaker put back into service. Vacuum bottles and all other components are readily available, providing for a long life for the vacuum breaker.

Applying breakers

Breakers may be used to switch various loads. While some loads will be energized and left to run for long periods of time — an induced draft

fan at a coal burning electric generating station, for example — others, such as a breaker used to switch power factor correction capacitors, may be switched frequently.

Attention must be paid to the switching frequency, which determines the operating life for a breaker. Figure 3 illustrates the switching characteristics for breakers by voltage, ampacity, and short-circuit current rating. Breakers that undergo frequent switching require frequent servicing, as is expected.

Protective relaying

Vacuum circuit breakers do not contain short circuit, over current, ground fault, and other protective features. Instead, they rely on separately mounted protective relays as the example shown in Figure 4. Unlike molded case low-voltage circuit breakers, which may be used for varied purposes, mediumvoltage breakers are typically chosen for specific loads. Protective relays for medium-voltage breakers are built for these specific loads. The relay shown in Figure 4 is intended for use to protect feeder circuits. Relays are available for transformer protection, for motor protection, for differential protection, and for other purposes. Protective relays can be networked to distributed-control and SCADA systems to remotely monitor equipment.

Protective relays must obtain voltage and current inputs from the equipment that the circuit breaker is protecting. To do so, potential transformers (PTs) and current transformers (CTs) are employed. Three of each are required for each circuit breaker. The PTs and CTs are mounted within the compartment containing the breaker, usually in the rear behind the breaker. Also, depending on the type of circuit, additional PTs and CTs may be required (Figure 5).

Complete assemblies

Now that the operating components have been selected, we can turn our attention to assembling them into structures.

First, consider ratings. Maximum voltage ratings run from 4.76 kV to 38 kV. Ampacities run from 1200 A to 4000 A depending on the voltage. All ampacities are not available for all voltages.

Next, consider types of enclosures. Medium-voltage switchgear is available as “metal-enclosed” or as “metal-clad” gear. A structure for metal-enclosed gear is a steel cabinet. The area within the structure is essentially open from top to bottom. Metal-enclosed switchgear is an economical choice for basic equipment.

Metal-clad gear has metal surrounding each circuit breaker in its cubicle; this is known as compartmentalization. Should an eruptive event occur within the cubicle, any material that is ejected as a result will be contained within the cubicle. Adjacent cubicles should not be affected.

Figure 2. Medium-voltage vacuum interrupters.

— Eaton Corp. photo

Figure 3. Breaker operations information.

— Eaton Corp. bulletin

BREAKER BREAKOUT continued from previous page

Metal-clad gear has higher switching duty ratings and higher interrupting ratings. Breakers in metal-clad gear are always drawout devices, where metal-enclosed equipment allows fixed mounted breakers. While metal-clad gear is more expensive than metal-enclosed gear, for some applications it is considered a better choice. The user must make the evaluation.

Finally, consider construction. Medium-voltage switchgear can be constructed as one-high or twohigh equipment. The switchgear shown in Figure 6 has breakers mounted one above the other. Some may be built only one-high, depending on ampacity, voltage, and auxiliary compartments that may be provided above or below a breaker. Note in the figure that the protective relays for each breaker are mounted in the front door, providing easy access for observation, for adjustment, and for resetting after a tripping event.

Insulated vs. uninsulated bus

Bus is always insulated in metal-clad gear, whereas metal-enclosed gear allows the use of uninsulated bus. Whether specifying metal-enclosed or metalclad gear, I always choose insulated bus. Tracking and corona at medium-voltage levels can be a deal killer when a fault occurs. Fluidized bed epoxy is offered for bus insulation by some manufacturers; it offers exceptional track resistance and is flameretardant.

Whether insulated or uninsulated bus is employed, periodic inspection is recommended for medium-voltage switchgear. Damage may occur from tracking or from heating. Quartz windows are available mounted in the outer walls of gear as options when gear is manufactured. The windows

Figure 4. A feeder protective relay. — Schweitzer Engineering Laboratories photo

Figure 5. At left is a penitential transformer, or PT; at right, a current transformer, or CT.

allow infrared scanning while the gear is energized. Many installations have IR scans conducted once or twice annually. The windows and scans are worthwhile investments.

Continuous thermal monitoring is an additional measure that can serve to portend potential heating problems. Thermal monitoring is accomplished through the use of thermal sensors mounted on the bus, with leads run to an appropriate relay.

Bus plating

Switchgear bus is plated to prevent oxidation from heating. Bus is available with tin plating or with silver plating. The choice is left to the specifier. Consideration is worthwhile when operating in adverse atmospheres. Following is an excellent commentary on choosing plating material. It is quoted from Chand Tailor, electrical engineer, at Eaton’s Greenwood, N.C., medium-voltage switchgear plant in a memo to Eaton’s application engineers:

“It is well known that in corrosive environment especially where hydrogen sulfide is present, growth of silver whiskers (filaments) can occur on conductive parts made of copper with silver plating,” Tailor writes. “Also, it has been noted in various studies and literature that higher temperature of the parts (above 140°C) seems to accelerate the growth. Thin metal whiskers growing from electroplated tin have been reported in various papers but has not been found or described in literature on current-carrying parts of large-size distribution equipment with tin plating.

“Tin plating is [a] better choice for electrical conductors exposed to corrosive environment,” Tailor’s memo continues. “But tin is a soft metal and therefore presents [a] different problem if used at [a] sliding joint made of spring-loaded primary disconnect fingers and stationary stab. In MV applications, given the high contact loading force and small contact surface area for each finger, tin will fret and wear out when breakers are inserted and removed.

“A good plating on both sliding surfaces is essential for smooth transfer of current with least resistance,” Tailor writes. “If tin is used and once it wears out, it can create hot spots and thermal failure at the sliding joint. We have been using heavy (extrathick) silver-plating on primary finger clusters and stationary stabs in medium-voltage breakers and switchgear for decades. It provides least resistance to current transfer across the contact surface and helps maintain joint temperature at or below 105°C limit for plated joints (metal-clad standard). There is no other choice for plating for MV breaker/Switchgear sliding joint.”

As Tailor notes, insertion and removal of breakers can create wear on contact fingers. For normal usage, breaker fingers will not likely experience excessive wear. However, for installations where breakers are racked in and out frequently — lockout purposes for equipment maintenance, for example — wear can be an issue. Tailor notes that extra thick plating is used to prevent the condition.

Partial discharge detection

Partial discharge is a condition caused by breakdown of insulation resulting from heat degradation,

Figure 6. Two-high medium-voltage breaker switchgear. — Eaton photo

Figure 7. Metal-clad switchgear

David Bredhold illustration

corona discharge, or internal creepage within the insulation. With time, partial discharge can result in insulation failure. The condition is not usually evidenced in equipment operating at 2400 V. Operating levels of 4160 V and above are another matter.

Partial discharge monitoring is an option and is available from many manufacturers of mediumvoltage switchgear. It is accomplished by employing RFCTs mounted on epoxy bottles on line side bushings or on specially designed bus. The RFCT monitors discharge current on the stress shield ground wire. Sensing leads are run to a special partial discharge monitor. Additionally, be sure to mount sensors on incoming cables as well.

When testing switchgear, safety is important. While configuring gear, a grounding and testing device is a worthwhile option. The grounding and testing device is not mounted permanently in the gear. Instead, it is a separate device that is racked into position to temporarily replace a breaker. The device provides access to the primary bus to temporarily ground the bus while testing and repairing gear, and while protecting personnel.

Structures

In metal-clad switchgear, standard indoor metalclad vacuum breaker switchgear is approximately 96 deep. The gear is accessed from the front and from the rear. Where floor space is not an issue, and rear access can be accommodated, metal-clad switchgear is certainly not a problem. Figure 7 shows a plan view for a basic layout, while Figure 6 shows the actual gear. Sufficient room is provided in the gear for installation of cable and for maintenance purposes.

Metal-enclosed, front-accessible switchgear (Figure 8) can be a workable solution where depth of gear is an issue. Where metal-clad medium-voltage breaker switchgear is a minimum of 96 deep, and requires rear access, metal-enclosed vacuum breaker switchgear is only 61.5 deep, and requires no rear access. Width for a single-high breaker structure is 26; exit for the cable can be from the top of the gear or from the bottom.

Where a two-high breaker structure is needed, an additional auxiliary enclosure is provided for top exit, bottom exit, or top exit for one cable and bottom exit for the other. It is notable also that width for the two structures is only 9 wider than for a metal-clad structure, while saving a great deal of floor space overall.

The trade-off between metal-clad gear and metalenclosed gear is a level of fault tolerance relative to the two types of structures. The equipment’s owner must discern the difference between the two options.

An additional trade-off from metal-clad switchgear: Breakers in metal-clad gear are rated 1200 A,

2000 A, and 3000 A. Breakers in metal-enclosed switchgear are rated 600 A, 1200 A, and 2000 A.

When configuring metal-enclosed gear, consideration can still be given to some precautionary details serving to embellish its fault tolerance. As with metal-clad gear, insulated bus can be specified, helping protect from degradation due to oxidation, corona, and consequent tracking.

Partial discharge detection can be employed also for switchgear operating above 2400 V; it usually isn’t necessary for 2400 V gear. Partial discharge is no more nor less a possibility than with metal-clad gear. Protection from partial discharge is worth the additional cost. We do not want this less expensive gear to be vulnerable to its debilitating effects any more than we do with metal-clad gear.

The addition of infrared inspection windows is worthwhile as well. The same inspection interval — semi-annual or annual — should be observed as with metal-clad gear. And remember to add continuous thermal monitoring. Bus in metal-enclosed gear can overheat as can any other gear.

Still more to learn

Through our tour of medium-voltage vacuum breaker switchgear, we have covered the basics necessary to understand the subject. It is well worth the time to drill deeper into the topic due to the myriad uses for the gear and the numerous iterations possible for operating and protecting equipment, especially considering that the proliferation of large data centers is boosting demand for this switchgear. Learn well and prosper! EA

Who’s who in medium-voltage switchgear

Medium-voltage switchgear has been manufactured for many decades. Names such as Westinghouse, General Electric, and Allis Chalmers are familiar names for the early generations of medium-voltage switchgear. Siemens completed its purchase of the Allis Chalmers electrical operation in 1985. GE sold its medium-voltage switchgear business to Powell Industries in 2006 and is now back in the switchgear business. Westinghouse sold its switchgear business to Eaton in 1993 and has now reentered the switchgear business. Eaton, ABB, Schneider Electric/Square D, GE, Westinghouse, Siemens — all are familiar names of manufacturers of medium-voltage breaker switchgear. — DB

Figure 8. Metal-enclosed vacuum circuit breaker switchgear.

— David Bredhold illustration

Feature | Finance & The Workplace

‘Insuring’ your business continues

Covering both property and people can be well worth the cost

By William H. Wiersema, EA Finance Editor

Unexpected disruptions, such as from natural disasters, cyberattacks, or the death or disability of a key person, can cause a shutdown that threatens a business’s survival. When a business closes, it lacks the income needed to pay vendors, employees, or owners.

Contingency planning entails looking ahead to the best way to respond to a crisis. A key focus is having emergency funding available to address the projected financial impact of potential threats. However, in identifying sources of cash, managers may struggle with maintaining reserves while overlooking the potential of insurance.

Managers often consider only the insurance that is mandated by regulators, lenders, or parties to contracts. Policies like liability, property, auto, workers’ compensation, and medical insurance are often approached simply as negotiations for the best price. Strategies for cost-saving include raising deductibles, self-insuring to a stop loss, reducing claims, joining captives, or implementing beneficial initiatives such as safety or wellness programs.

For example, one optional coverage that many businesses do not even realize they have until needed is for employee dishonesty. Managers encounter situations where theft has been committed by skimming cash receipts, forging checks, transferring funds without authorization, creating fake vendors or payroll entries, and so on. Even if only discovered years later, they can claim against the insurance that was in effect at the time. Coverage often includes not only financial losses up to the policy limit but also investigation and documentation. Insurance coverage helps businesses continue. Without proper insurance, a business may never reopen after a disaster. Let’s examine two main types of optional insurance: business interruption and key person life, meant to protect businesses in crisis with emergency funding. In addition to considerations below, potential insurance carriers need to be assessed for prompt response and local presence.

Insure business interruption

Property insurance covers the costs of repairing or replacing damaged buildings, equipment, and inventory. Business interruption insurance (BII)

goes beyond property damage to address indirect losses from closures, which include lost profits and ongoing expenses. Also, a disaster may lead to extra costs, such as overtime pay.

BII provides income replacement and pays for expenses that continue while the business is rebuilt. The company is entitled to the insured amount, even if it opts not to rebuild. The foundation of BII is the net income lost during the interruption period considering expenses. However, since income is typically less than 10% of revenue, insuring it alone is insufficient. Each covered expense is added to the net income calculation, which can include fixed costs, payroll, taxes, and overtime or other out-of-pocket expenses incurred due to the interruption.

For example, a business having $5 million revenue earns a net contribution to its bottom line of $2 million after variable costs such as materials and commissions. To fully cover its fixed continuing costs, that business would pro rate that amount over the desired rebuilding period. For example, six months would indicate $1 million in coverage, which might add $250,000 for extra out-of-pocket expenses. This results in total coverage of $1.25 million.

Since BII is optional, managers can tailor it to their risk appetite. Fortunately, this insurance can be relatively inexpensive and often well worth the cost, offering peace of mind. Pricing varies based on the amount of coverage selected and several other factors. A building’s

— Illustration by Bing generative AI

construction influences BII as well as property insurance. High-risk locations also affect pricing and availability. The coverage period is an important consideration, as most BII policies have a 24- to 72-hour waiting period before commencing. As to damage, BII policies specifying “agreed-upon values” provide the most reliable benefits.

Basic BII is tied to physical damage to property, which means that most policies do not cover pandemic-related business shutdowns. Floods and earthquakes might require separate policies. Expanded coverage may include extended utility outages known as utility service interruption, or restriction on access by government order known as civil authority.

When a disaster affects a neighboring business or an essential customer or supplier, BII can also provide “contingent” protection. Any business can be affected, often significantly, by the shutdown of another. For example, a retail store in a shopping center may suffer if an anchor store tenant closes.

Manufacturers that rely on specialized machinery can add equipment breakdown insurance to the BII to cover repairs or replacements due to mechanical or electrical failures. Specialized insurance is also available to protect against cyberattacks.

Cover your key people

Owners are crucial to middle-market businesses, making the disability or death of an owner or key person devastating. Beyond the financial turmoil is the highly emotional time for both family members and colleagues. Multiple owners add complexity to succession planning.

Key Person Life (KPL) insurance funds cash to the business upon the death of a key individual. In determining the amount of the policy, managers can estimate the monetary impact of the key person’s death or disability. The funding should be enough for the company to recruit replacements, cover lost revenue, and reassure lenders and clients. KPL prevents disruption by enabling the business to continue operating, while also ensuring that beneficiaries preserve value. Additionally, KPL addresses liquidation risk to pay estate taxes that arise upon an owner’s death. In the absence of other estate planning objectives, term life insurance is usually the lowest in cost.

Often, a rule of thumb of five to ten times compensation may be applied in determining the amount of coverage, so that $250,000 in compensation indicates $1.25 to $2.5 million. A more detailed way is to count debt guaranteed by the individual, anticipated lost contracts, recruitment, recovery costs, and estimated lost profits during transition.

Key Person Disability (KPD) insurance offers similar protection if an individual becomes unable to perform their duties. For smaller businesses where an owner is also responsible for day-to-day operations, disability overhead expense insurance can help cover essential costs such as rent, salaries, and other fixed expenses while the owner is incapacitated.

For businesses with multiple owners, a well-structured buy-sell agreement is essential to prevent disputes or forced sales due to an owner’s death or disability. Buy-sell agreements outline the procedures that occur when an owner in a multi-owner business dies or becomes disabled, with KPL funding the buyout of the deceased owner’s interest. The agreements ensure that remaining owners can buy out the deceased owner’s share, providing fair settlements to heirs while maintaining control of the business. KPD buyout insurance may also be beneficial for permanently disabled owners.

Often, a rule of thumb of five to ten times compensation may be applied in determining the amount of

coverage

Key Person Life

KPL can cover the risk of death, ensuring that funds are available when needed, as long as premiums are paid. The coverage is based upon the value of the owner’s interest in the business, to provide for an automatic buyout mechanism. The KPL amount can adjust based on the changing value of the business according to a valuation formula. To control costs effectively, businesses may obtain excess insurance coverage initially to address anticipated growth in their value over several years.

There are two main structures for these agreements: redemption and cross-purchase. In a redemption agreement, the company owns KPL. When an owner dies, their equity is redeemed by the company, keeping the ownership proportions among surviving owners steady. In contrast, a crosspurchase agreement requires each owner to carry KPL on the others, which can lead to more policies but protects against business creditor claims.

These approaches can be combined. Stockholders may have first rights to purchase ownership interests or defer to the corporation, allowing flexibility as circumstances change.

While some owners could hold their own policies, this may cause adverse tax implications. If the deceased owns KPL, proceeds in their estate are subject to estate tax, leading to higher tax burdens for the survivors.

When a buy-sell agreement is triggered by death, KPL proceeds are generally tax-exempt for beneficiaries. To ensure this, corporate beneficiaries must adhere to Section 101(j) of the tax code, requiring notice and consent from the insured. In C corporations, proceeds received through redemption may incur alternative minimum tax.

For cross-purchase agreements, survivors who take over stock obtain a basis step-up, increasing their investment value. However, S corporations must allocate tax-exempt insurance proceeds based on ownership, potentially wasting the estate’s share. In an LLC taxed as a partnership, the LLC can hold KPL policies and distribute proceeds to surviving members, enabling them to purchase the deceased member’s interests while obtaining a stepped-up tax basis. This approach allows for efficient tax-exempt income allocation exclusive to surviving members. EA

Product Showcase

What’s new in automation, robotics, and electric vehicle technology

Smart lead-acid battery tester

Shenzhen Leagend Optoelectronics Co. Ltd. has announced its smart lead-acid battery tester for tackling critical challenges in battery production and service operations. Engineered around high-precision sensors and advanced algorithms to deliver accurate and repeatable (batch) measurements, it supports smart data analytics to facilitate data-driven decision-making and customization of results, as well as remote monitoring and maintenance. The manufacturer says it’s suitable for a wide range of industry applications, including production lines, sales and service networks, evaluation, and maintenance of large battery packs in the eld.

Aluminum welding cobots

Lincoln Electric Automation has introduced the latest upgrade of its Cooper aluminum welding cobots, with the Cooper app for guiding users through standard single-pass linear or structural steel multi-pass welds. The new CRX-25iA cart features a longer torch bundle, relocated AutoDrive SA push feeder, and support post for leveraging the full work envelope of the cobot arm. The CRX-10iA/L comprises a new GEN II Universal Cart design, relocated programming buttons, improved cable management, and linear design within the torch bundle to improve aluminum wire feeding.

Collaborative robots

Universal Robots has introduced UR15, the latest in UR’s high-performance series of cobots, with a payload of 15 kg/17.5 kg and featuring what the company describes as unparalleled motion capability (reach 1300 mm), a maximum TCP speed of 5 m/s while retaining the UR trademark of lightweight design (40.7 kg) and small footprint (Ø 204 mm). Trajectory smoothness and accurate movements are enhanced by UR’s OptiMove. UR15 runs on UR’s software platform PolyScope and can be used with the UR AI Accelerator developed with Nvidia. It is TÜV- and UL 1740-certi ed.

Ethernet converter

Adtek Electronics is presenting its AME RS-485 Ethernet converter, with ARM Cortex M3 microprocessor, for deployment in factory automation, security protection, or any other low-speed data transmission equipment. It uses state allocation to handle TCP/IP protocol stacking and supports TCP, UDP, IP, DHCP client, Modbus/TCP, and HTTP protocols. Parameters can be set with any browser or HyperTerminal in console mode. Reaching communication rates of 115.2 Kbps, it supports four independent client commands corresponding to respective internal data locations and HTTP protocols, with simultaneous execution.

Smart EV charger

Sungrow Charging has introduced the IDC480E-C ultra-fast compact EV charger, featuring Sungrow’s proprietary 40 kW power module and isolated air-cooling technology, anti-corrosion protection, and AI-supported lifecycle management. Its modular scalability, smart charging exibility, e ciency, and low maintenance requirements make it suitable for both compact urban sites and large-scale charging depots, according to Sungrow Charging. Expandable architecture allows for the addition of power modules or increasing dispenser con gurations, supporting total output capacities of 240 kW, 320 kW, 360 kW, 400 kW, and 480 kW. The charger may be integrated seamlessly with Sungrow’s uni ed PV + ESS + EVC system.

Intelligent automation platform

Fathym, Critical Mission Studio, and C Squared Funds have launched OpenIndustrial, a Cloud-native and AI-native automation platform bridging legacy industrial systems with modern Cloud and AI automation infrastructure, comprising autonomous operations, collaborative interfaces, and ownership of Cloud infrastructure. Teams co-create automation logic, schemas, and applications in real time with the AI collaborative agent Azi. Re ex Memory, a persistent, programmable memory layer, captures system states and decision logic, allowing continuous evolution of system re exes. Forkable runtime provisions sandboxed environments for simulation, testing, or parallel work ows. — Colin Gregory-Moores EA

Innovations in pump design and application

Improvements in materials and design are helping to push the limits of performance

By Kevin Jones, EA Senior Editor

What’s new in pumps? Improved efficiency and sustainability remain primary goals in pump design and application. Easing the way toward achieving these twin goals are several elements of pump design, manufacture, and application. These include

Energy-efficient motors

Recent innovations in energy-efficient motors used with industrial pumps have largely focused on integrating advanced control — that, along with smaller footprints and enhanced reliability. A significant development has been the embedding of variablespeed intelligence directly into motors, which allows for precise control over pump speed and flow rates, substantially reducing energy use.

Consider for example ITT’s VIDAR smart motor. This machine integrates advanced variablefrequency technology inside a package that’s 60% smaller than current equivalent products, according to ITT. Field trials have shown that deploying VIDAR on a single pump can cut energy use by more than 50%, which obviously translates into significant cost savings. This feature is a “drop-in” replacement for existing conventional motors; as such, it requires no special wiring or additional enclosures.

Energy efficiency is a top priority among today’s pump manufacturers, which are developing pumps and compressors with variable-speed drives, improved materials, and refined designs to help users reduce operational costs

artificial intelligence, cloud connectivity, advanced materials, “smart” motors, variable-frequency drives, and improved digitalization.

One needn’t look far to see how the addition of these elements to pumping systems is bringing a new dynamism to the marketplace. On this and the facing page are just a few examples of this trend.

Smart pump technology

The industrial smart pump sector has seen a few notable developments over the past year. Manufacturers are continuing to follow the trend of integrating advanced sensors, cloud connectivity, and artificial intelligence into pumping systems to provide real-time data on performance, energy use, and maintenance needs. This trend is easing the way toward more predictive maintenance and allowing for dynamic adjustments to optimize operations based on changing conditions.

One example of innovation in smart pump technology comes from Grundfos, which in February launched MIXIT, a system that appears poised to aid the transformation of energy efficiency in HVAC/R systems. The MIXIT technology integrates multiple components — including actuators, controllers, and sensors — into a single, compact unit. Its “all-in-one” design is said by the manufacturer to simplify installation, reduce commissioning time by up to 50%, and enable precise control over temperature and flow.

Remote Monitoring and Control

Innovations in remote monitoring and control of pumps have largely focused on enhanced digitalization, artificial intelligence, and better connectivity. The integration of smart technology — including the Industrial Internet of Things and advanced sensors — is enabling real-time data collection on such parameters as vibration, temperature, pressure, and flow rates. This data forms the foundation of AI-driven predictive maintenance systems.

Companies like Sensaphone, to take just one example, are introducing new products such as the Sensaphone Sentry system, introduced last January at the AHR Expo in Orlando, that are bringing these innovations to market. While intended primarily for HVAC/R, boiler, and coldstorage applications, the Sensaphone Sentry system embodies a broader trend towards affordable, cellular-based remote monitoring products that track multiple conditions and send alerts via phone, text, or e-mail to the user, making proactive maintenance more accessible. This prioritization of real-time data analysis and AI-powered analysis marks a significant shift towards more efficient and reliable pump operations. The Sensaphone Sentry

Grundfos’s MIXIT smart pumps

ITT’s VIDAR smart motor

Self-priming pumps

Recent innovations in self-priming pumps have brought efficiency, sustainability, and integration of smart technology to the fore. Advanced impeller designs and corrosion-resistant materials, such as high-grade stainless steel, are enhancing the durability and performance of pumps used in harsh environments. IoT-enabled sensors allow real-time monitoring, which optimizes priming and reduces energy use. Energy-efficient motors are consistent with global sustainability goals, meeting such standards as the EU’s Ecodesign Directive. Automation improvements are enabling faster priming cycles, which reduces downtime in applications such as wastewater treatment and agriculture.

Rovatti Pompe’s HA Series self-priming pump

Italian pump manufacturer Rovatti Pompe, for example, last year introduced a product line that exemplifies the latest in self-priming pumps. The company’s HA Series of pumps for hydraulic motors joins the company’s existing HL and HX Series of centrifugal pumps, which are made, respectively, from cast iron and AISI 316 stainless steel. The new HA Series of cast-iron self-priming pumps consists of three models with 2 and 3 suction and delivery ports that are said to be capable of achieving a flow rate of up to 72 m3/h and pressure head of up to 36 m. They’re compactly built, and mounting is versatile, according to the manufacturer.

Noise reduction technologies

In the realm of noise reduction, we’re seeing manufacturers incorporating sound-dampening materials such as composite coatings to reduce vibration noise. Improved impeller and casing designs are minimizing turbulence, which in turn lowers acoustic output. Variable-frequency drives are being used to adjust pump speeds to reduce noise during low-demand periods. And IoT-enabled sensors are monitoring vibration, which makes possible the kind of predictive maintenance that can help prevent the escalation of noise in the first place.

Variable-frequency drives

Manufacturers of variable-frequency drives are concentrating on drives that offer smarter pump system optimization, with built-in lead/ lag and alternation capabilities for multi-pump configurations. This allows VFDs not only to vary motor speed based on demand but also to manage entire pumping operations for maximum efficiency and extended equipment life.

While some innovations involve integrating VFD technology directly into the motor itself, other manufacturers continue to refine standalone VFDs. ABB, for example, showcased just such an innovation at Bauma 2025 in Munich last April. The company’s featured products included the HES580 mobile inverter, which enhances motor efficiency by significantly reducing harmonic losses. This type of advancement — though promoted by ABB in the context of mobile applications — underscores a broader push for VFDs that not only control speed but also actively contribute to overall electrical system health and energy quality.

Magnetic-drive pumps

Magnetic-drive pumps continue to see advances in efficiency, materials, and the integration of “smart” technology. Improved magnetic couplings and corrosion-resistant materials, such as carbon-fiberreinforced ethylene tetrafluoroethylene (ETFE), are enhancing durability and performance in the handling of aggressive chemicals. Modular design of magnetic-drive pumps continues to reduce maintenance time and costs, while IoTenabled monitoring systems are making real-time diagnostics a reality.

One notable new product in this area, introduced earlier this year, is the Italian pump manufacturer CDR Pompe’s DTN line of pumps. This line features an ETFE-lined magnetic-drive pump for chemical and pharmaceutical applications. One advantage of these pumps is a new dynamic shaft design, a configuration that ensures not only greater pump reliability but also less axial thrust along all performance curves, according to CDR Pompe. The manufacturer says the new line offers improved hydraulic efficiency, a dynamic shaft design to reduce axial thrust, and energy-saving features certified under ATEX 100 standards.

Advanced materials

Armstrong Fluid Technology’s Design Envelope end suction pump

One notable product introduced in 2025 that strives for these objectives is Armstrong Fluid Technology’s Design Envelope end suction pump, launched this past spring. This pump incorporates vibration isolation mounts and advanced motor designs to reduce noise levels. The design meets ASHRAE 90.1 noise and vibration control recommendations, isolating transmission of vibration between the piping, pump, and the floor of the building where the pump is deployed. The pump’s smart controls optimize performance, reducing energy use and noise output, according to the manufacturer.

Recent innovations in the materials used in pump manufacture have emphasized durability, efficiency, and sustainability. Corrosion-resistant alloys such as Hastelloy C-276 are being used to extend pump life in harsh chemical environments. Advanced ceramics such as silicon carbide are enhancing wear resistance in abrasive applications. Biocompatible plastics, including polyetheretherketone (PEEK), are improving performance in food and pharmaceutical processing by improving resistance to chemicals and high temperatures.

Illustrative of these trends is Grundfos’s CR 255 pump, which is designed for clean, nonaggressive liquids such as potable water and oils. Stainless steel used for the shaft, sleeve, impeller, and chamber resists corrosion; this can extend a pump’s life in clean, non-aggressive liquids. Silicon carbide and tungsten carbide in seals and bearings offer superior wear resistance, reducing maintenance, according to Grundfos. PEEK neck rings and carbon-graphite-filled Polytetrafluoroethylene bearings minimize friction, improving efficiency.

CR 255 pumps from Grundfos

A CDR Pompe DTN magnetic-drive pump

ABB’s HES580 mobile inverter

Standards

Report finds China taking the lead in standards development

A report published last December by an Australian think tank — and finding particular relevance today — says that China has dramatically increased its participation and leadership in the two largest global standards organizations over the past few decades, making the nominally communist country an emerging leader in international standards.

In the report, titled “Standards Development Organizations in an Era of Strategic Competition,” Tom Barrett of the University of Sydney’s United States Studies Centre writes, “China is now the most active participant across the two major global SDOs [standards development organizations] and has increased its number of leadership positions between five and 17 times in the technical committees that make up these SDOs, surpassing major Western powers.”

SDOs, which set technical standards for such things as electrical machines, household appliances, telecommunication devices, and the Internet of Things, are increasingly arenas in which nations flex their economic muscle. Barrett argues that the U.S. and its allies must up their game if they’re going to counter China’s growing dominance in these forums, which exercise considerable influence over economic competitiveness and national security.

nology norms, particularly in fields such as 5G telecommunications and artificial intelligence. While there’s no evidence that China is distorting SDO processes in order to embed authoritarian values, the report suggests the potential for such an agenda exists. In contrast, the U.S. and its allies, including Australia, Canada, and the EU, have struggled to keep pace. Their decentralized, industry-driven approach lacks the coordination of China’s state-backed strategy, according to Barrett.

Barrett observes that standards don’t merely affect technical fields; they influence economic and security outcomes as well. He points to ISO/IEC 42001:2023, a 2023 standard for AI system management, as an example. As a framework for overseeing AI systems that enables conformity, potentially building trust throughout international supply chains, this standard shows why an informed approach to standards-setting by government is critical, according to Barrett. The standard has been adopted by Standards Australia and integrated into the U.S. National Institute of Standards and Technology’s AI strategy.

Barrett is calling for increased funding to support U.S. and allied participation in SDOs, as financial barriers often deter experts from attending meetings. He also recommends hybrid meeting formats and translation technologies to make participation more accessible. And he suggests improving data collection for a better understanding of the dynamics of influence within SDOs and establishing domestic forums to coordinate strategies prior to international meetings. These measures, Barrett says, would strengthen Western engagement while preserving the consensus-based model that lies at the heart of SDOs.

— brgfx / Freepik illustration

The report looks specifically at the International Organization for Standardization (ISO) and the International Electrotechnical Commission (IEC), groups that have historically operated on a consensus-driven, industry-led model. China, Barrett says, has shifted this dynamic. Its Standards Administration, a public entity under China’s State Council, has aggressively increased participation through incentives such as tax credits and subsidies for Chinese firms.

China’s steady increase in participation and leadership roles in international standards bodies — which has happened as involvement by the U.S. and its allies has declined — has dramatically altered the composition of these forums, Barrett writes. Since 2004, Chinese experts have surpassed their Western counterparts in important ISO and IEC technical committees, giving China significant influence over standards covering emerging technologies.

China’s 2021 national standards strategy, built on something called the Standards 2035 initiative, seeks to align 85% of the nation’s domestic standards with international ones. Barrett says it’s unclear whether China is trying to adopt global standards or impose its own standards onto the rest of the world.

Whatever China’s ultimate objective, the strategy reflects China’s broader ambition to shape global tech-

The report goes on to frame SDOs within the broader U.S.-China strategic competition, alongside issues such as trade disputes and military tensions. Barrett points to a 2023 Global Policy study by Sebastian Klotz, which examined the International Telecommunications Union’s standards arm. He also cites a 2024 Brookings Institution article by Cameron F. Kerry that advocates cooperation on international standards in order to maintain a “level playing field.”

Barrett’s analysis and his recommendations are pragmatic yet urgent. He acknowledges the complexity of SDOs, in which technical expertise and consensus remain central, but stresses that inaction could cede critical ground to China. Developing a clearer picture of the current system is crucial to informing and refining any potential reform, he writes. Without renewed engagement, the U.S. and its allies risk losing influence over the drafting of standards that shape global technology, from artificial intelligence to the Internet of Things. Influence here has — and is certain to continue to have — a ripple effect on innovation and security around the world.

SDOs play a vital role in encouraging global interoperability and innovation, Barrett writes, but their susceptibility to geopolitical pressures demands action. China’s rise in these forums is in sync with China’s broader technological ambitions; the U.S. and its allies must revitalize their participation to maintain their influence.

Barrett’s recommendations constitute a balanced approach, one that offers practical reforms to support technical experts and ensure that standards remain a tool for global cooperation and don’t become a weapon in a battle for global technological dominance. — Kevin Jones EA

Mobile autonomous robots for safer substation inspections

The growing demand for electricity — driven in large part by the ravenous appetite of data-processing systems for more electrical power — has significantly expanded the need for reliable electrical infrastructure. Meanwhile, we’re seeing an increase in the development and use of renewable energy sources.

With these developments has come an increased need for reliable inspection of electrical substations. Regular equipment checks can identify anomalies among components, such as transformers and circuit breakers, that, if left unaddressed, can lead to failures. And yet these inspections are fraught with risks, such as fires and explosions. So what’s the best tool for conducting inspections?

The answer, according to Energy Robotics GmbH, an automation company headquartered in Darmstadt, Germany, is the mobile autonomous robot, which can perform substation inspection tasks that would pose hazards to us, the robot’s highly intelligent but physically vulnerable carbon-based peers.

An article published by Energy Robotics, titled “The Future of Substation Inspection: Harnessing the Power of Robots and AI,” observes that the U.S. operates about 55,000 substations, while Germany has around 8,000. These facilities, often located in remote areas, pose logistical and financial challenges owing to the complexity and risks that inspections often entail.

Traditional inspection methods, reliant as they are on human personnel, are costly, time-consuming, and hazardous, according to Energy Robotics. Mobile autonomous robots guided by artificial intelligence are the safer, more efficient alternative. Robots can account for risks while adapting to an evolving energy landscape, particularly as renewable energy sources increase the burden on substations.

“Substation inspection is not just a maintenance task; it’s a proactive measure to ensure the continuous supply of electricity to homes and businesses,” Energy Robotics explains. But traditional methods — including visual inspections, thermal imaging, and ultrasonic testing — require inspectors to navigate high-voltage environments and hard-to-reach areas. People who venture into these places face such hazards as electrical arcing, which is potentially fatal and can cause fires as well.

An ABB study cited by Energy Robotics notes: “Most switchgear arcing accidents at substations occurred due to human factors during either installation, maintenance, or inspection.” Human error compounds the limitations of manual inspections — which are also, not incidentally, subject to regulations that vary by jurisdiction, which only compounds the complexity of the challenge.

Mobile autonomous robots equipped with advanced sensors and imaging technologies can address these difficulties by performing thorough inspections without human intervention. Such robots can access difficult areas and collect consistent data without exposing humans to risk.

For example, robots can monitor power couplings to prevent arcing and check transformer oil levels to

mitigate the risk of fires, Energy Robotics notes. And “AI can analyze the vast amounts of data collected during inspections to identify patterns and anomalies.” This combination of monitoring and analysis can improve the accuracy of inspections and reduce downtime. Another attraction of autonomous robots is that robotic inspection is scalable for utilities that manage numerous remote substations.

As noted, safety is one significant reason to adopt robotic inspections. By replacing human inspectors in hazardous environments, robots reduce the risk of accidents, to be sure. But robots also address environmental concerns, particularly leaks of sulfur hexafluoride (SF6), a gas said to have 23,000 times the “global-warming potential” of carbon dioxide. In 2017 alone, according to Energy Robotics, SF6 leaks in the European Union were equivalent to emissions from 1.3 million automobiles.

Robots can also help prevent copper theft, a global scourge that in 2021 caused outages for 2,137 households in Kingston, South Australia, and 2,000 homes in eastern Texas. Equipped with cameras, the ever-vigilant robot can monitor substation perimeters, check fences, ensure that gates are locked, and relay alerts to security teams in real time if a person with possibly bad intentions approaches a substation.

A 2021 pilot project by E.DIS and Energy Robotics demonstrated the potential value of robotic inspections. Using a software platform combining a hardware-independent operating system, Cloud-based fleet management, and AI-driven analytics, the project tested robots’ ability to read analog instruments and monitor security features such as fences and locks, with LiDAR creating 3D substation maps. Similarly, Bayernwerk, Bavaria’s largest distribution operator, has used robots to enhance supply security and safety by shortening inspection intervals and reducing the need for employees to venture out to remote sites.

Despite these advances, there remain challenges, including the high initial costs of robots and the complexity of integrating them with legacy systems. The scalability of robotic inspections, however, allows utilities to cover multiple facilities efficiently, optimizing resources as the energy landscape expands. Regulatory pressures are further encouraging adoption, since utilities must comply with safety and reliability standards to avoid penalties.

A shift to robotic inspection of utility substations will do more than simply reduce risks for maintenance personnel, as praiseworthy an objective as that may be. As robots become more autonomous and AI more sophisticated, inspections are likely to shift from a reactive to a proactive approach, which should help reduce outages and enhance the reliability of the grid.

— Kevin Jones EA

An autonomous robot manufactured by Robotnik Automation of Valencia, Spain, makes the rounds at an electrical substation. — Robotnik Automation image

Classified

RATES AND INFORMATION

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Classified Display adsadvertiser’s own art with no category limitations*: require a one-year, $2400 minimum contract.

For more information, closing dates and requirements, contact Barbara Wachter, Adv. Director E-mail: barbara@barks.com Phone: (312) 626-2316

*subject to Publisher’s acceptance

Business for Sale

FOR SALE IN MONTE VISTA COLORADO

Full service electric motor repair, sales and rewind shop. Established 65 years and growing. Fractional through 1,000 horsepower. Business and property, 395,000.00.

Allan 970-560-0614

Help Wanted

Electric Motor Shop in Wake Forest, NC, is looking for candidates for:

• Field Service Techs

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• Motor Mechanics

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• Switchgear Specialist

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Electric Motor Shop o ers competitive pay and benefits, including 401k. For employment consideration, please contact Kristine Larsen at 919-556-3229 or by email at Kristine.Larsen@emsnc.com

WE ARE HIRING!

ACT, a globally renowned manufacturer of electromechanical components, is actively seeking talented individuals to join our dynamic team. We are currently hiring experienced MAZAK CNC Programmers, skilled machinists, and trainees with technical aptitude.

Our company is in a phase of expansion, and we have openings for both part-time and full-time positions available across all shifts. You’ll have the opportunity to work in a climate-controlled environment while enjoying top wages paid weekly and a comprehensive benefits package.

ACT takes pride in being a Drug-Free Tennessee company and has upheld Equal Opportunity Employment practices since 1993.

If you are interested in joining our dynamic team, please reach out to us at hr@act-inc. com for more information or to submit your application.

Help Wanted

EASA SEEKS MOTOR ENGINEER

Join EASA’s world-renowned technical support team! EASA seeks an engineer with at least 5 years of experience in repair, service, maintenance and/or redesign of ac and dc motors. Must understand motor theory as well as application and be able to communicate e ectively in a fast-paced consulting role. Some travel required. For more info, see easa.com/careers.

Competitive salary; excellent benefits; team environment. Remote work option for the right candidate.

This is an exciting role with variety that impacts the entire indsutry. Send cover note and résumé to Linda Raynes; lraynes@easa.com.

Help Wanted

LOCATED IN JACKSONVILLE FLORIDA

We are seeking qualified candidates for the following positions:

• Electric Motor Mechanics AC/DC

• Electric Motor Winders & Apprentices

• Shop Foreman

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• Pump Mechanics

Competitive pay and benefits package including medical, dental, vision and relocation assistance.

Including Sign-on bonus 5% of base salary.

Please contact Brandie Knight at 904-757-1127 or by email to brandie@westside-electric.com

ELECTRIC MOTOR TECHNICIAN

SUPERVISOR - 2ND SHIFT

10+ years exp w. industrial AC/DC electric motors, generators & electro-mechanical equipment repair. Must have previous supervisory exp. Pay based on exp. Excellent benefit package: 401k, medical, dental, vision, vacation, sick pay, paid holidays.

EEO

Apply at bit.ly/mti_jobs

Motor Technology, Inc.

515 Willow Springs Lane York, PA 17404

The EA word search

A stomach for business

In the grid at left, nd and circle the words listed below, which are taken from this month’s article by Contributing Editor William Wiersema about business insurance. Circle the words, and the remaining letters, arranged in order, will describe something appealing about business interruption insurance. The solution may be found online at http://barks.com/puzzles, or call (312) 321-9440. Happy hunting!

Fear of speaking keeps many people from being

MOTOR SERVICE MANAGER

Toshiba International Corporation based in Houston Texas is looking for an experienced Motor Technician with knowledge In: Sleeve Bearing Motors, Vibration Analysis and Field Applications.

Technicians will be required to provide technical support via phone or email.

Candidate must be able to evaluate Medium and Low Voltage motor failures for warranty consideration.

Position will be 30% Travel and 70% o ce support.

Candidate must be competent in Microsoft o ce suite as computer skills are necessary.  Toshiba o ers competitive wages, 401K (Up to 6% Match), PTO/Holiday pay and Health, Dental and Vision insurance.

For employment consideration, apply through the career website: Careers | Toshiba International Corporation (Ref#: MANAG00124900)

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Bookmark these links to access our flipbooks AUGUST 2025 (this issue)

ELECTRIC MOTOR WINDER

Relocation assistance available for the right candidate. Join Savannah Apparatus Repair, a trusted name for over 45 years, in the heart of Savannah, GA - a historic coastal city known for its charm, a ordability, and high quality of life.

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Requirements: Electrical experience and Baker testing up to 4160V. Must handle Start to finish work from strip and recording data to brazing and soldering.

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EXPERIENCED SHOP FOREMAN

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Classified Display

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ELECTRIC MOTOR WINDER

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ADVERTISING INDEX

9 Advanced Rotors, Inc 10

Akard Commutator of Tennessee 17

BAE Wire & Insulation, Inc 55

Bartlett Bearing Company, Inc 11

Dreisilker Electric Motors, Inc 32 Electric Coil Service, Inc 16

Direct & Current

GRID & BEAR IT. Can’t stand the heat? The electrical grid feels your pain. This June, the U.S. Dept. of Energy issued its latest emergency order to address a heat wave across the Southeast, putting grid capabilities at risk of blackouts, allowing maximum utilization of certain areas’ electric generating units. “We had to issue an emergency order a few days ago just to let utilities in the Southeast run their plants at full capacity so they could keep the lights on,” said Secretary of Energy Chris Wright. The order was in place for only one day, but that was more than enough for persistent concerns about the grid to resurface.

HATS

Learn more about the products and services featured in this issue! Use the QR code or go to https://shout.com/s/YTaJdH3c to request information from advertisers.

OFF TO THE GRADS. Onondaga Community College of Syracuse, N.Y., celebrated the accomplishments of its students enrolled in the Electromechanical Technology program during an event held May 15 on its campus. The program was created in response to Micron Technology’s decision to build a chip fabrication plant in Onondaga County. The college welcomed its first group of electromechanical technology students in the fall 2023 semester.

WHO TOUCHED THE THERMOSTAT? Deep inside the electric motor, where it is too hot, too cramped, or simply impossible, some startup companies are aiming to measure temperature precisely, according to ZF, a German technology company that supplies mobility products and systems for passenger cars, commercial vehicles, and industrial technology. The company says this type of data could allow significantly more power to be extracted from an electric motor, and it works entirely without additional hardware – only through AI. With its AI-based TempAI solution, ZF thinks it may have improved forecast accuracy by more than 15%.

APPLY YOURSELF. GE Appliances, now under the Haier umbrella, has made a $490 million investment in its Louisville, Ky., global headquarters (its largest manufacturing site) to “create its most advanced manufacturing plant for production of clothes washers,” the company announced June 26. The project will bring production of the GE Profile washer/dryer lineup to Kentucky, creating 800 new full-time jobs.

WEB NOBILITY. You probably wouldn’t expect a utilities co-op to have an interest in how its website is presented, but hold your horses, because it’s a web-based world. Nobles Cooperative Electric announced recently that it has received the Gold Spotlight on Excellence Award at the Connect Conference in Kansas City. This prestigious recognition is presented by the Council of Rural Electric Communicators and the National Rural Electric Cooperative Association. — Charlie Barks Have the digital “Direct & Current” delivered each week, at no charge, to your e-mail in-box. Scan the code at right or sign up now at http://eepurl.com/dEkrB9.

A new class of electromechanical students at SUNY-OCC in Syracuse, N.Y. — SUNY-OCC photo

Standard VFD

Enclosed Packages

Pre-configured packaged solutions assembled, tested, and ready to install.

NEMA 12

- Siemens G120X VFD

- 40, 75 125, 200 hp (CT)

- 50, 100, 150, 250 hp (VT)

- Industrial package panel

NEMA 3R

- WDFC Flex Control VFD

Configurable VFD Enclosed Packages

- 40, 60, 100, 150, 250 hp (CT)

- 50, 75, 125, 200, 300 hp (VT)

- Ideal for rugged outdoor applications, such as oilfields, irrigation, aggregate, and more.

Take any standard drive package and configure it to meet your exact application requirements. Standard enclosure features with highquality internal control and power components.

NEMA 3R

- WDFC Flex Control VFD - 0.75-800 hp (VT)

NEMA 12

- Siemens G120X VFD - 1-700 hp (VT)

Soft Starter

Enclosed Packages

Our packages protect against undue load and torque on your motors while giving your operators full control. Many models are instock, ready to ship with either the WorldStart WSIQ or Siemens 3RW Series soft starters.

Standard Duty - 230V 3-Phase 10-150 hp - 460V 3-Phase 20-300 hp

NEMA 4

- WDFC Flex Control VFD - 3-125 hp (VT)

NEMA 4X

Heavy Duty - 230V 3-Phase 10-60 hp - 460V 3-Phase 20-500 hp

Non-Combination

- 230V 3-Phase 10-200 hp

- 460V 3-Phase 20-600 hp

- Siemens G120X VFD

- 40-200 hp (VT)