Automation Update Issue 61

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The complete solution from a single source The complete solution from a single source WWW.AUTOMATION-UPDATE.CO.UK

Issue 61

HARTING Ha-VIS RFID The complete solution from a single source

Improving productivity in challenging environments Improving productivity in challenging environments ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Fast real-time data Fast real-time data Suitable for use in multiple industrial applications Suitable for use in multiple industrial applications Designed to work on metal surfaces for maximum performance Designed to work on metal surfaces for maximum performance Extended temperature range from -25°C to +85°C and compliant with GS1 EPC ALE 1.1 Extended temperature range from -25°C to +85°C and compliant with GS1 EPC ALE 1.1 Long read range capabilities with 50G shock resistance Long read range capabilities with 50G shock resistance

Improving productivity in challenging environments

For more information call 01604 827500 or e-mail For more information call 01604 827500 or e-mail ■ Fast real-time data ■ Suitable for use in multiple industrial applications ■ Designed to work on metal surfaces for maximum performance









+44 (0) 1844 204420 Email us at

Ecopac (UK) Power Ltd, Unit 4, Ridgeway, Crendon Industrial Area, Long Crendon, Bucks, HP18 9BF

AUTOMATION UPDATE Editorial Assistant Laura Sharpe 01843 580 460 Publishing Director Jodie Little 01843 580 460 Sales Director Tim Johnston 01843 448 443 Advertising Exec Jamie Simmons 01843 580 460

Automation Update is an engaging, editorially led publication & directory giving the reader news and updates on new products and services to our ever Progressing industry.

Publishing House Jet Digital Media Ltd The Forge, Spratling Court Offices, Manston, Kent CT12 5AN


GUARDING WAS NEVER THIS GOOD. SAFETY LASER SCANNER RSL 400 With two autonomous protective functions, an operating range of 8.25 m and a scanning angle of 270°, the RSL 400 sets new standards in safety sensor technology.

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Phone 01480 408 500 –

Automation Update - 3

Take a Different View of Vision See 4Sight in Action at one of our Technology Days

AutoCoding Systems and SICK UK are holding two one day events where they’ll be demonstrating their new innovation in vision, the 4Sight automatic print inspection solution. If you sometimes have problems with partially printed, poor quality or missing codes on your products, you’ll be interested in seeing how 4Sight can resolve these issues. The free one-day events are being held at AutoCoding’s demonstration suite in Runcorn on Tuesday 11th February and at SICK UK’s offices in St Albans on Thursday 13th February. Visitors are being invited to see at first-hand how the 4Sight solution can check for presence, legibility and location of print, as well as deal with varying qualities of print. The 4Sight software is powered by SICK AppSpace and uses the InspectorP range of 2D cameras to create a camera-based solution for multiple inspection methods. The software is resident on the SICK camera, communicating directly with any brand of printer, with no requirement to “teach” the camera what to look for; the software understands the intended message for printing. 4Sight’s automatic set-up means there is no requirement for operators to configure features or regions of interest; the camera automatically adjusts, coping easily with variations in artwork, background and text location. A unique feature of 4Sight is “Inspection Depth”. By offering users different levels of inspection, they can decide what level of inspection they need. 4Sight can be used to confirm presence, legibility and location of printed code, but the standard product can also be configured to OCR thereby checking the accuracy of the printed code. Users can also

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4Sight works seamlessly with AutoCoding, but can also be connected directly to any brand of printer or used in standalone mode

determine acceptable print quality tolerances and define what is considered a good read, bad read or poor read on a per product basis.

line stops. 4Sight uses new and innovative methods for print inspection, simplifying the process and making vision accessible to all budgets.”

The versatility of 4Sight means that as well as operating seamlessly with A uto Co ding , or other co de deployment software, the application can be used as a standalone solution or directly connected to a printer.

Each Technology Day will start at 9.30am and finish no later than 4.00pm. Registration is required by completing the form on either the AutoCoding website, or the SICK UK website .

Managing Director, Mike Hughes, commented, “Inspecting printed codes, particularly at continuous inkjet speed, has always been fraught with challenges, making living with a print vision system quite difficult in terms of nuisance stops or false rejections, causing unnecessary

Who should attend? Anyone involved with the automated printing and marking of products or packaging who needs to ensure that the marking is verified, correct and legible will be interested in this event.



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Connecting a Raspberry Pi to Industrial Sensors

Sensors and actuators are essential elements of industrial systems, instrumental to any application that requires automated control. Raspberry Pi provides general purpose header pins that can be connected to sensors, making the low-cost board a popular choice for engineering prototypes. Pi’s GPIO pins are designed for driving low current devices such as LEDs however, so is it possible to connect to the I/O necessary for industrial environments? Industrial sensors typically require 12-24V power and signal changes using the same voltage. Raspberry Pi’s GPIO input circuitry can be driven to either 3.3V or 0V. This means that whilst a 12V water flow sensor might initially work hooked up straight to a Raspberry Pi, in long-term projects the incompatibility of the currents will almost certainly cause problems. Does this mean your Pi can’t be connected to industrial sensors beyond a prototype? Connecting a sensor to Raspberry Pi directly often means stripping wiring and soldering the cable to the correct GPIO pin. The 12 or 24V of an industrial sensor will then be driven straight to the Pi with nothing in the way to protect Pi internal circuitry including the processor. By adding extra circuitry as a buffer between the input pin and the Pi, it is possible to extend the processor’s source/ sink current capabilities, and prevent excessive power dissipation in the chip.

Brainboxes BB-400 is a smart controller based around an industrial Raspberry Pi and allows prototypes to be deployed straight into factory environments. Sensors and actuators are not wired directly to the Pi, rather electronics between the input pin and the chip do the work which prevents

industrial voltages damaging the Pi. As the BB-400 has removable terminal blocks the module can be taken out without affecting any of the pre-wired terminals. As a single misplaced component leg can cause the whole circuit to malfunction, another useful feature of the terminal blocks is their numbering; it’s a lot easier to find correct connections when you don’t have to count down a row of tiny header pins. The BB-400 has 8 digital I/O connections, making it usable straight out of the box without the need for any add-on units, although there are a variety available if you do find you need more inputs and outputs. As it is packaged in a DIN rail enclosure, it’s the perfect solution for deploying a Raspberry Pi prototype straight onto the factory floor. To find out more contact:

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ut V he IS & 11t rn IT E Fa h – 1 lect Ma US rn 3t ro nu AT bo h ni fa c r F c ST oug ebru s 20 tur AN h, ar 2 ing D GU y 2 0 L1 14 0 35 6 20 TQ

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Replacing Legacy Coders for Reliability, Uptime and Flexibility Boost Lincoln & York Ltd is one of the UK’s largest coffee roasting companies producing enough coffee to make 1,500,000 cups worldwide. The Need As a result of rapid growth and the nature of the business, Lincoln & York was looking to replace its ageing coding equipment with a more reliable and flexible solution capable of increasing uptime and delivering higher quality prints.

The Solution Clearmark identified that by replacing all existing equipment from another supplier across 12 lines with ICE Zodiac thermal transfer overprinters, would allow codes to be printed more efficiently across a range of flexible substrates in a variety of colours at the various throughputs required.

The Benefits The ICE Zodiac thermal transfer printers provide a considerable improvement over the legacy equipment, which was beginning to have a considerable impact on uptime. The Clearmark solution installed on-site has been specifically designed to ensure that the factory is able to meet current and future supplier demand without any risk to reliability or print quality. The ICE coders are also flexible enough to print dates in any format or size, and in any Windows true type font. Their class-leading ribbon capacity means less downtime for ribbon changeovers, reducing waste and increasing production efficiency by up to 25%. “It is essential that we are able to change our label designs as quickly as possible to meet growing supplier requirements, the ICE Zodiacs allow us to do this efficiently without having any impact on production.” – Marc Rockall, Engineering Manager at Lincoln & York.

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The Future As a result of the responsive support provided and ongoing efficiency, compatibility and reliability of existing ICE equipment, Lincoln & York will look to expand its range of ICE technology as they continue to grow. For a bespoke and flexible solution designed for your factory visit or get in touch 01159 640 144

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Compact distance sensors provide millimetre precision Precise distance measurement to the nearest millimetre is essential in many control and automation applications and the latest OGD precision laser distance sensors from ifm electronic provide important features and benefits for the most demanding applications.

The small, compact design of the OGD 592 / 593 distance sensors from ifm utilise the innovative on-chip, time-of-flight principle with PMD (photonic mixed device) technology which is vastly superior to conventional diffuse reflection used in laser sensors. This ensures outstanding precision to the nearest millimetre helping to determine the presence of parts and their correct installation, for example an O-ring. In addition, excellent reflection resistance and background suppression together with high excess gain, ensure reliable operation for the most demanding applications.

10 - Automation Update

The OGD precision is available with an extremely small light spot at a 300mm range enabling detection of very small parts. The switch point can be easily set to the nearest millimetre via the three operating buttons, or alternatively via IO-Link, which allows read-out of the current distance value. ENDS. Further details available at: gb/en/shared/product-news/2018/hmi/millimetreperfect-the-new-ogd-precision-from-the-pmdline


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Stay Safe With ATEX Approved Drive Couplings From Reich Safety is always a key consideration in any environment where manufacturing processes or machinery are involved. This topic is even more critical within industries such as petrochemical, refining and mining, where there may be potentially explosive atmospheres. In these critical areas a single spark may be all that is needed to trigger a potentially catastrophic series of events. The European Union’s Atmosphere Explosibles (ATEX) Directives, introduced in 2003 are intended to reduce the hazards created by potentially explosive atmospheres. In this informative article, David Proud – General Manager of Reich Drive Systems UK explains why the company’s ATEX certified MULTI MONT SELLA and ARCUSAFLEX range of drive couplings not only meet these stringent requirements, but also offer enhanced fail-safe characteristics. There are two distinct directives: the first ATEX 95, applies to the design, manufacture and in-service use of equipment within potentially explosive atmospheres. The second directive ATEX 137, sets out the minimum requirements to improve safety and protect workers from explosions. This places specific requirements on employers for risk assessment and implementation of measures to reduce explosion hazards. As a key component in any drive train being used with a hazardous environment, drive couplings must adhere to the ATEX 95 directive. Reich’s MULTI MONT SELLA range not only meets the directive requirements and is certified, but the design of these drive couplings incorporates features which further enhance the fail-safe characteristics of the coupling.

David Proud explains: “In addition to compensating for axial, radial and angular misalignments, shocks and vibrations, these couplings are designed with individual rubber compound saddles. This means that even if one or more of the saddles begins to deteriorate in service, the unit will still operate safely, minimizing the risk of metal-to-metal contact and any subsequent sparks. Although the coupling may exhibit signs of reduced performance, giving maintenance engineers the time to plan remedial work, the coupling will still operate safely.” A further benefit of the MULTI MONT SELLA range is that the rubber saddles can be replaced radially with the coupling in situ, by simply sliding back the retaining cap, saving significant amounts of time by eliminating the need to decouple equipment. This concept is shown in a video which can be viewed HERE.

12 - Automation Update

Also certified for use within hazardous environments is the ARCUSAFLEX range of couplings. These also comply to explosion protection directive ATEX 95, and are suitable for use within hazardous location categories M2 and 2 which require high levels of protection, and 3 which requires normal levels of protection. David Proud continues: “The ARCUSAFLEX coupling is a highly flexible flywheel coupling with an axial plug-in facility. It provides a torsionally soft connection between the prime mover and the driven machine. The highly flexible torque transmission characteristic of the coupling is achieved by a disc-shaped rubber element that is subjected to a torsional load and enables both, the absorption of high torsional vibrations and the compensation of major misalignments. The toothed design of the rubber element is instrumental in maintaining safe operation within hazardous environments.” With a history spanning over 70 years, REICH-KUPPLUNGEN has built up unrivalled expertise in the design and manufacture of drive couplings for use across a wide range of industries and applications, including those within hazardous environments.

Reich Drive Systems UK Limited Telephone 0161 714 4191

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Track and locate components with RFID solutions from HARTING In order to fully digitise industrial processes, the ability to identify and locate components and tools is incredibly important. For example, it allows production facilities to optimise their processes, railways to speed up their maintenance services and logistics firms to track goods across their facility. HARTING’s range of UHF Radio Frequency Identification (RFID) products are robust, reliable and versatile, meaning they’re suitable for a wide range of industries and working environments. Our portfolio includes special transponders (known as RFID tags) for applications within transportation, on-metal smart labels for use on containers or identifying tools and antennae which can be seamlessly installed on conveyor belts or used to create reading zones for smart shelves in stores, allowing you track spare parts in service centres. An RFID system is also able to cope with harsh, industrial environments, as many HARTING RFID products are IP65/ IP67 rated and can endure wide temperature variations, high humidity and continue to be readable in dirty environments where the tag may become coated in oil and grease. Tags can also be securely encrypted and password protected to protect sensitive data. In addition, RFID hardware is future-proofed through the addition of features like WLAN, Bluetooth Low Energy and GSM. A practical example of RFID being used to speed up processes and save money can be found within train maintenance and servicing. Using the transponders mentioned above, different components of a train are identified and tagged. The RFID reader then automatically identifies the train and its important components, such as the axles and individual

carriages, as it enters the maintenance area. The system then notifies engineers about the condition of components which require maintenance, allowing them to focus on the parts that urgently need attention and servicing. A key benefit of using RFID is that, unlike barcodes, you do not need direct line of sight to read the transponder. It’s also possible to get information and data from multiple tags at once, with the high-speed technology allowing you to read up to 300 tags per second. Another advantage for the rail industry is that tags can be read at a distance of several metres, even when trains are travelling at over 120mph. If you’d like to learn more about HARTING’s range of RFID products, including readers, tags, antennae, complete systems and integration software, please click here to visit our website.

14 - Automation Update

HARTING Ha-VIS RFID The complete solution from a single source

Improving productivity in challenging environments ■ ■ ■ ■ ■

Fast real-time data Suitable for use in multiple industrial applications Designed to work on metal surfaces for maximum performance Extended temperature range from -25°C to +85°C and compliant with GS1 EPC ALE 1.1 Long read range capabilities with 50G shock resistance

For more information call 01604 827500 or e-mail

Fabrication Design Considerations For Low Field Shielding Applications Typically, hydrogen atmospherically controlled heat treatment process called perfection annealing or final annealing is required after stamping, machining, bending, rolling, severe forming or welding, and is crucial in relieving material stress and developing the alloy’s maximum shielding performance. Handle annealed magnetic shields carefully to avoid severe deformation which causes reduced attenuation. The perfection annealed fabricated shields and parts are then tested at our in-house quality control lab to certify that the demanding specifications are met. Perfection Annealing Heat Furnace Chamber

One of the most important design questions is whether the source field is internal or external, and which field is most economical and practical to shield. Internal interference is created by designed-in components located within a circuit, system, enclosure, piece of equipment or room. External interference or the H-field source is created by unwanted nearby fields radiating from power lines, circuits, electrical enclosures, transformers, electro-magnetic machinery and the earth’s magnetism. Secondly, should the source of interference or the sensitive device be shielded? The answer to this question depends on several factors. Shielding the source may involve stronger fields, and therefore thicker materials. All interference sources must be shielded, or the sensitive device will still be affected. The usual approach is to shield the sensitive device. This prevents interference from both present and future sources. A hands-on approach to solving a shielding problem can be accomplished with the use of a lab kit, testing, and prototyping. Material selection will depend on the strength of the unwanted field (Ho) and the amount of field attenuation required. MuMETAL® is the preferred solution because of its reliable performance for reducing low-frequency electromagnetic interference (EMI) between the range of 30 Hz to 300 Hz. Available as stress annealed (partially annealed for ease of machinability) sheet stock, it is used for fabricated shields such as enclosures, cylinders, cans, channels or 3-D boxes. Complex cylindrical shaped shields are the most efficient for redirecting and reducing magnetic fields. Magnetic shielding alloys have sensitivity to mechanical shock - bending, forming, even severe flexing may give some reduction in the alloy's magnetic permeability. But modern, vacuum-refined alloys have a lower sensitivity to shock, and normally withstand regular handling without significant loss of properties. Another consideration is cutting the alloy without affecting the alloy properties and degrading the performance. Cutting by shearing, EDM, waterjet, photo-chemical etching, or blanking dies typically only affects that portion of the alloy immediately adjacent to the edge, and the shield will exhibit normal shielding performance. If the alloy had already received its final magnetic anneal, re-annealing should not be necessary.

16 - Automation Update

Magnetic shielding applications may occur at a high vacuum. Co-NETIC® AA alloy is specifically formulated for maximum magnetic shielding properties and has some physical properties similar to stainless steel. Out-gassing is minimal and cleaning for high vacuum applications can follow the same procedures used for stainless steel. Co-NETIC® and NETIC® magnetic shielding alloys have a positive coefficient of permeability with respect to temperature. This is a quick way of saying that the permeability increases as temperature increases. The Curie temperatures are between 850°F (454°C) and 840°F (449°C) for Co-NETIC®, NETIC® and MuMETAL®. At operating temperatures above the Curie temperature, the shield will not provide any attenuation of the magnetic field. Roll-off of permeability begins as operating temperature nears (within 25°F) the Curie temperature listed, so a safety factor for allowable operating temperature should be used. Temporary temperature excursions above curie temperature do not degrade the alloys. Shielding function is restored when the temperature again falls below Curie point. High permeability MuMETAL® and Co-NETIC® alloys have an optimal temperature range in which the permeability peaks. Permeability starts to drop below -40°C, making it unsuitable in low temperature applications. Cryo-NETIC® sheet, our proprietary cryogenic nickel-iron soft magnetic alloy is ideal for shielding magnetic fields at extremely low temperatures down to 4 Kelvin (liquid helium). Located in the USA Chicago metro area, Magnetic Shield Corporation has been leader in the custom shielding fabrication market, manufacturer, and supplier for over 75 years; providing expertise and engineering consulting on thousands of projects, applications and shielding designs. For more information regarding our proprietary shielding alloys and forms available, wiring and cable shielding, Zero Gauss Chambers, and modular MuROOM® view our websites here, or


The demand for stainless steel clamps is especially high for the bottling, packaging and

Reich Drive Couplings

processing technology as well as for outdoor

appliances and equipment bearing thermal loads.

Keeping Industry Moving

We work constantly and with great dedication on innovative products and solutions for our customers.

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Power Generation Applications

Mobile Applications

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Industrial Applications

Marine Engineering

Buckinghamshire HP19 8RY 01296 611660

Unit 4 Bankside Business Park Coronation Street Stockport SK5 7PG T: Office + 00 44 161 714 4191 |


Automation Update - 17

Rittal Supplies Bespoke Panels for Critical Controls The East Midlands Instrumentation Company Ltd (EMI), an electrical, instrumentation and control installation contractor for the power generation, power transmission, rail and industrial markets based in Gainsborough, had a complex specification from a client.

The client needed specially designed panels to protect critical equipment that controlled a remote pumping station and dam.  A complex control and distribution system with Rittal's Ri4Power system allowed segregation of the busbars from the controls. This meant three panels were needed for power and motor control, automation and control, and monitoring/ communications. The monitoring equipment needed to be installed within an area at risk of flooding, so it was decided to place the panel on a metre-tall frame to reduce the chances of the equipment being damaged by floodwater inundation. To overcome this, Rittal’s engineers designed a custom-sized Ri4Power panel to sit comfortably on the frame. All three panels had to withstand internal fires and each compartment was fitted with a special fire resistant lining to stop fire spreading from one to another, and a smoke/fire rated venting system. In addition, special filters were installed for ventilation, which included a gel that expanded if heat was detected and closed any air gaps. The power and motor control panel was specially designed in an L-shape to fit neatly within its allocated space. The Rittal team also developed a busbar that was designed to accept a mains supply, but which could also accept a temporary generator supply, if needed, for essential loads. Further information at and or on twitter @rittal_ltd.





VX25. SYSTEM PERFECTION. More options, more efficiency, less effort: This is thanks in particular to a frame profile with a 25 mm pitch pattern that is symmetrical across all levels. The VX25 is also infinitely extendable and accessible from all sides – even from the outside.




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