Engineering Update - June 2019 by Jet Digital Media Ltd

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June 2019

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June 2019



ENGINEERING UPDATE

Ensuring Low Turbidity Drinking Water Supply Amazon Filters has published an application study that describes how two major municipal water suppliers are using their SupaSpun II R31 filtration cartridges to mitigate the risk of their boreholes delivering drinking water with high turbidity. One of a municipal water suppliers’ primary jobs is controlling turbidity. Turbidity is caused by particulates in the water and is synonymous with cloudiness. The consequences to a water company of producing water with high turbidity can be severe. Not only is there a genuine risk to health if the water reaches households but there are also significant financial consequences and the subsequent public relations challenges that will inevitably damage company reputation, value, trust and credibility. Consequently today - turbidity is one of the critical measures of water quality and is used by both water supply companies and industry regulators to ensure the water clarity is acceptable to the consumers.

European Water Quality Directives, the World Health Organisation and the UK Drinking Water Inspectorate specify what is required to ensure the water supplied is ‘wholesome’ and turbidity limits are typically set at <1 NTU (Nephelometric Turbidity Units) and often set at <0.5NTU. As one of Europe’s leading manufacturers of process filtration systems - Amazon Filters has an excellent track record of supplying static and mobile skid mounted filtration systems to ensure low turbidity water supply. Typically, these bespoke water turbidity control systems are based on Amazon Filters SupaSpun II R31 filtration technology. Available in absolute ratings from 0.3 to 180µm, the unique construction of

SupaSpun II R31 filters provides long trouble-free operational life and consistent reliable performance. These highperformance depth cartridge filters have a precision graded porosity that provides absolute ratings, unmatched dirt holding capacity and excellent flow rates. SupaSpun II R31 cartridge filters are proven to comply with a range of potable water regulations. To read the application study in full please visit www.amazonfilters.com/ spotlight-on-supaspun-ii/. For further information on regulatory compliant filtration systems to ensure your water supply clarify please contact Amazon Filters on +44-1276-670600 / sales@amazonfilters.co.uk.

Taking the Difficulty Out of API Process Filtration Amazon Filters reports on strong customer interest at the recent Making Pharmaceuticals** Exhibition & Conference 2019 to showcase its latest filter housings and microfiltration filter cartridges which are used in the manufacture of Active Pharmaceutical Ingredients (API), which are the essential components when creating pharmaceutical products. It is critical that APIs have been manufactured to the highest possible quality in order to make sure that the final product meets specification. Amazon Filters is highly experienced in supplying productive solutions for the different parts

of the API production process, whether it is the initial filtration of raw chemicals and solvents, the purification of the compound with the use of carbon or the fine quality control of the finished product. A typical API manufacturing process involves use of highly corrosive chemicals such as concentrated acids which places considerable demands on both the filter housing and the filter cartridges used. Traditionally specialised filter housings such as those produced with an internal coating or made from exotic nickel alloys have been recommended for API manufacturing. However, neither of these options is ideal. Coatings are prone to mechanical damage and nickel alloys have limited resistance to corrosion by certain acids and some other chemicals. To solve this challenge, Amazon Filters has developed two proprietary filter housings that can cope with these difficult applications. One of the filter housings uses Tantalum metal deposition and the second has been manufactured with an all PTFE construction. Both of these specialist

filtration housings have demonstrated in multiple API manufacturing process applications a significant resistance to corrosive chemical damage. For more aggressive API manufacturing processes that involve concentrated acids or a high temperature, the Amazon Filter range of SupaPore microfiltration cartridges can be supplied in either Halar or PTFE materials. These filters are available with ratings as fine as 0.1 µm and up to over 100 µm, so are suitable for all particle control applications. Amazon Filters are fully conversant with the US FDA and European regulatory requirements for the design and use of filtration products in key pharmaceutical production areas including API manufacturing, sterile products, support utilities as well as the manufacture of creams and ointments. For further information on effective solutions for API process filtration please contact Amazon Filters on +44-1276-670600 / sales@amazonfilters.co.uk.

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June 2019



ENGINEERING UPDATE

Data Embedded Barcodes

Raising the Bar to Reduce Food Waste With the demand for a reduction in food waste increasing, major retailers are now taking steps to improve their supply chain and help reduce food wastage with one initiative being the use of data embedded barcodes on some of their shorter shelf life products.

So how can a barcode help in the drive to reduce food waste? Currently in the distribution chain before delivery to store, the barcoded information already on the pallets, cases and trays provides visibility and accurate knowledge about where products are, and what shelf life they possess. However, once they are in store the retailer loses that visibility. A new type of barcode (the Data Embedded Barcode or DEB) has been introduced which is printed onto the item of sale. In addition to identifying the product, as the existing barcode does, it also contains the expiry date and possibly batch identification data. By scanning this barcode in store when stocking the shelf as well as at the checkout, the retailer acquires real time information about what stock is on the shelf and how much life it has left. Intelligent use of this information creates the opportunity to make better decisions to reduce food waste, including • Smarter rotation of stock in store, ensuring shortest life product is sold first • Smarter management of price reductions to sell expiring product efficiently • Prevention of out of date product being sold at the checkout • Smarter forecasting of demand to drive more efficient ordering to re-stock the store, taking into account the life left on the existing stock

Along with the benefits, there are a number of challenges associated with the use of data embedded barcodes. Because they have to be read by point of sale scanners at check-outs, a high quality of print is imperative to ensure every product is successfully scanned first time; “no reads” would be unacceptable, both to retailers and customers. At the time of writing, the only coding technologies capable of printing data embedded barcodes at a high enough quality are laser, thermal inkjet and thermal transfer printers. In-line scanning on the production line to validate every pack can be scanned is a key requirement of this initiative and a core part of the AutoCoding solution. Scanning of the larger codes poses no problem for the AutoCoding solution. All products can be scanned in the same way using an inline barcode scanner, with all the information held in the DEB checked on a per product basis against the details in the AutoCoding database. If any details are incorrect or missing, the packaging line will be stopped ensuring problems can be rectified prior to product leaving the factory. autocodingsystems.com

June 2019

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ENGINEERING UPDATE

Think you’re safe? Remove doubt by using Wolf Safety’s new voltage alert technology a clear warning that action is needed to ensure that work can continue safely in the hazardous area. However, it is more likely that issues will arise at the lower end of the voltage range. For example, if too many 24-volt lights are strung together and the transformer is overloaded, voltage could drop below the optimal level and light output will reduce incrementally as the input voltage falls. If this does occur, SOVI™ ensures the light will pulse bright, indicating that the lamp is not within its certified voltage range, though the light itself is still safe as it is certified down to zero volts. This differs from other ATEX lights, where a reduced voltage supply can lead to the light operating outside the certified voltage range.

Working in potentially explosive atmospheres is hazardous enough without having concerns that the voltage being supplied to temporary lighting is no longer within certified limits. How can anyone be absolutely sure what voltage is being supplied, especially in a typical, long cable FPSO situation? Could it be one volt more or less than the certified safe range? Reassurance is now available from Wolf Safety Lighting, whose latest technology gives an immediate warning when voltage either slips below or exceeds certified limits, even by just one volt. Their SOVI™ technology - it stands for Safe Optimal Voltage Indicator – removes all doubt, giving operators the confidence that temporary lighting is operating safely, effectively and at the optimal voltage. Unique to Wolf Safety products, the groundbreaking technology is now incorporated into its ATEX and IECEx certified Hazardous Area Temporary Lighting range, further enhancing safety in potentially explosive atmospheres. It also ensures that a lighting solution is operating effectively and at the optimal voltage. SOVI™ is already incorporated into the LINKEX™ LED TEMPORARY LUMINAIRE LX-400 range as well as the recently updated, market leading LINKEX™ WF-300XL LED FLOODLITE range. New for 2019 is the LINKEX™ LED ATEX EMERGENCY TEMPORARY LUMINAIRE, which features the unique technology. In the unlikely event that a light is operating at a voltage above the maximum certified limit, the beam will pulse from bright to dim, giving

Wolf Safety’s clear, visual warning system and ‘plug in and play’ format means there is no safety risk in connecting too many lights together. Says Michael Morley, Wolf Safety’s Technical Director: “Even if operators are working some distance from the lamp they are alerted by SOVI™ about a power supply issue and made aware that something needs to be done. This avoids an operator having to check the voltage is correct and safe while continuing to work in the hazardous area.” Details of Wolf Safety temporary lighting incorporating SOVI™ can be found at: www.wolfsafety.com/temporary-lighting

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June 2019

ď&#x201A;?

ENGINEERING UPDATE

Automation, CNC, Motion Control, Bakery Automation and general Control system Solutions TRM Electronics Ltd has been designing and manufacturing controls systems since 1994. The company specialises in controllers for machine control, instrumentation, factory automation and bakery control. Machine manufactures can benefit from having their custom designed controllers tailored to suit their machine and budget. Many good quality machines become virtually scrap when their obsolete controller fail, TRM controllers can be used to replace many of these obsolete controllers and bring new life to old machines. TRM offers a milling machine upgrade kit for many milling machines, we can retrofit or upgrade many machine tools including guillotines, routers, plasma cutters, lathes etc.

Our MAP programming language is one of the easiest programming languages to learn, it can be used for applications from CNC using â&#x20AC;&#x153;G Codeâ&#x20AC;? through to PLC and scientific applications, making MAP very flexible. MAP can be programmed off line and there are no expensive compilers to buy, all the software tools are free.

TRM has a range of controllers to suit most applications and budgets. The PMC4, for example, has a built in screen, keypad, motion control, Inputs, Outputs, USB and is housed in a rugged aluminium enclosure. For the less demanding application there are cost effective controllers with smaller displays, touch screens or simple keypads. These controllers are excellent for use in many applications like machine control, scientific applications, medical devices, process control and instrumentation applications. TRM also manufactures a range of other products including PWM to analogue converters, IO Expanders, Signal converters, IR transmitter/detector modules, mains filters, power supplies, encoders and cables. Our custom controller service is available for most equipment manufactures. This could be as simple as changing the colours on the front to suit the company style or complete custom keypads, touch screens, IO, enclosure and of course programming. Whatever your application please get in contact with us. trm-electronics.co

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Monitoring the world

June 2019



ENGINEERING UPDATE

Using Non-Sparking tools?

Here’s some safety advice from Bahco Bahco Non-Sparking (NS) tools are designed for use in potentially explosive environments, where conventional steel tools might create sparks in the presence of combustible or easily ignitable vapours, liquids and dust. Because NS tools can’t achieve the hardness of conventional tools special care is needed when using them. Tony Hudson, an industrial tools specialist at Bahco, offers these safety recommendations to users of NS tools: • Avoid tools over heating; make frequent visual checks of each NS tool during use; • Don’t use both a steel tool and an NS tool at the same time; • Don’t use high copper content tools, such as Al-Br and CuBe tools, in direct contact with acetylene; • Always take considerable care when reworking copper-beryllium (Cu-Be) tools as beryllium (Be) dust or vapour is toxic; • Cu-Be tools should be ground only when wet; • Do not inhale any dust and be sure to wear a face mask; • Make sure all NS tools are kept clean and free from ferrous or

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other contaminants which may hamper the properties of a nonsparking tool; • The tool’s surface temperature must not be higher than the present gases temperature; • Ensure that no objects which could cause a spark fall or are dropped within the working environment. Reducing risk: Non-ferrous, softer materials such as brass, bronze, copper-aluminum alloys (aluminum bronze), or copper-beryllium alloys (beryllium bronze) greatly reduce the risk of producing ignitable sparks. Bahco NS tools are manufactured in aluminum-bronze (Al-Br) or copperberyllium (Cu-Be), making them both safe and suitable for use in hazardous environments. Tools used for striking applications, like slogging wrenches and hammers, are manufactured in aluminumbronze (Al-Br), while tools which require a higher torque and precision performance, such as pliers, screwdrivers and adjustable wrenches,

are manufactured in copper-beryllium (Cu-Be). Bahco take safety so seriously that they have their NS range certified by the independent German Federal Institute for Materials Research and Testing. The Bahco range of NS tools includes hammers, pliers, screwdrivers, wrenches, as well as other striking and construction tools. Its non-sparking adjustable wrenches, manufactured in copper beryllium, are die-forged, anti-magnetic and offer high resistance to corrosion. NS screwdrivers for use with slotted head, Phillips® or Posidriv® screws have been developed by Bahco using its scientific ERGO® process. Made from copper beryllium they are cold rolled, anti-magnetic and corrosion resistant. The range also includes NS pliers in several types, including combination, diagonal cutting, long nose and slip joint. To see the full range of Bahco nonsparking tools visit: www.bahco.com

June 2019

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June 2019

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ENGINEERING UPDATE

Thermal Imaging Camera Applications in Business Focused Maintenance Today the modern built environment faces many challenges with organisations expecting the reliability of services to continuously improve with cost savings being made due to reducing maintenance regimes. Down-time can be extremely costly to a business in lost income, therefore mission critical services must not be disrupted by failure. Historically businesses have used generic planned preventative maintenance schedules, maintaining plant in the same way regardless of its level of use and value to the business.

dentifying that there was clearly a smarter risk-based approach to maintenance BSRIA published its Business Focused Maintenance (BFM) methodology back in 2004, this was updated in 2016 with the BFM Guide (BG53/2016) which is available from the BSRIA bookshop. BFM provides engineers with a methodology for utilising maintenance budgets more effectively. Assets critical to the business are maintained, while other less critical assets are managed as well as possible within the available budget. By assessing and prioritising plant maintenance needs for risks and criticality to the business, engineers and managers can ensure their maintenance effort is focused, cost-effective and increase their resilience to engineering risk. BFM plant maintenance requirements will require instrumentational monitoring and one of the most widely used monitoring methods is thermal imaging. This has many applications including

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showing faults in thermal insulation, electrical installations and mechanical plant. Thermal imaging cameras are indispensable tools for engineers, they provide a non-invasive, userfriendly and cost-effective solution to maintenance testing. “with the user-friendliness and wealth of applications for modern thermal imaging cameras, you don’t need to be an expert, employ a consultant or have large budgets to get the instant images you need. We work closely but independently with a wide range of equipment suppliers which means we can provide solutions to meet our customer’s specific needs. We can supply a wide range of thermal imagers from entry level units up to state-of-the-art professional cameras and all at an affordable price. We recognise our client’s needs are time critical and we have equipment available for hire and sale direct from stock or with short lead times. In processes where plant failure can cause down-time that can potentially

cost millions of pounds in lost income it is imperative that critical building services must never be disrupted by failure. We pride ourselves on providing fit-for-purpose, user friendly and cost-effective equipment”. BSRIA Instrument Solutions is a leading supplier of specialist test and measurement instruments since 1990 and can assist engineers from all industries in selecting instruments that meet and exceed their expectations. It has built its reputation by providing the most reliable and advanced test equipment from leading manufacturers supporting it with a high level of customer service they can offer a choice of thermal imaging solutions with products from the leading instrument manufacturers. For further details of the Instrument Solutions equipment hire, sales and calibration capabilities visit www.bsria.co.uk/instruments or call our team on Freephone 0800 254 5566 (UK) or +44 (0) 1344 459314.

June 2019

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June 2019

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ENGINEERING UPDATE

Ceramic bearings are opening new avenues of research The global ceramic bearings market set to grow at a CAGR of around eleven per cent between 2017 and 2023, with lab equipment representing a key application for this growth. Chris Johnson, managing director of ceramic bearing specialist SMB Bearings, examines the link between ceramic bearings sales and the output of successful scientific research.

Ceramic bearings are in high demand. Scientific and engineering end-users are showing the most interest in using these bearings for lab equipment. But, why ceramic? Full ceramic bearings offer the corrosion resistance and hightemperature endurance that steel bearings cannot match. Made from entirely silicon nitride or zirconia, sometimes with PEEK or PTFE retainers, full ceramic bearings can endure highly corrosive environments at extreme temperatures.

scientific research that is boosting demand for ceramic bearings is cryogenics, the study of materials at extremely low temperatures. For bearings, extreme low temperatures have detrimental effects on the viscosity of the lubrication and the brittleness of the steel. Ceramic bearings are often used without lubrication in cryogenic pumps, enabling researchers to evade the issues of viscosity. Magnetic resonance imaging

Cryogenic research

Typically associated with hospital MRI scanners, this technology is also used in scientific research by using a strong magnetic field to generate two and three-dimensional images of any living subject.

As well as corrosive resistance, ceramic bearings also cope well with very high and low temperatures. One area of

Equipment used in these scanners must be non-magnetic, which instantly renders steel bearings unsuitable.

Here are three of many examples of scientific research that are improving due to the availability of high-quality ceramic bearings.

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Non-magnetic ceramic bearings can be used inside the MRI scanner and in any supporting equipment. Cleanroom studies While everyone entering a cleanroom must wear protective clothing, ceramic bearings must offer similar levels of protection to lab equipment. Steel bearings contain lubrication that can disperse into the environment, often referred to as â&#x20AC;&#x153;outgassingâ&#x20AC;?. Full ceramic bearings, however, can run without lubrication as they do not suffer heat build-up within the bearing. Running the bearings dry completely eradicates concerns over outgassing. The global ceramic bearing market size represents something much bigger than increased bearing sales, but the ability to bolster the output of new scientific devices, without the fear of bearing corrosion or failure.

ď&#x201A;?

ENGINEERING UPDATE

June 2019

UPGRADED ROTARY TABLE IS STRONGER AND MORE COMPACT The Japanese manufacturer Kitagawa, represented in Britain and Ireland by sole sales agent 1st Machine Tool Accessories, has introduced the first in a new MK-series of general purpose rotary tables.

he MK200, which has a 200 mm diameter faceplate, features increased holding torque compared with the MR-series table that has been superseded. The result is faster, heavier duty, more productive machining of a clamped workpiece. As the unit is also more compact, loss of table area and working volume in a machining centre is minimised. The manufacturer has stronger and more compact rotary tables of similar capacity in its product range, for example the GT200 and CK200 respectively, but the MK200 is designed to meet 90 per cent of all customer requirements. It provides a rigid 4th CNC axis and reflects Kitagawa's focus on constantly improving the standard of its tables in three main areas: enhanced performance, improved mounting, and breadth of rotary joint availability. Enhanced Performance Clamping torque of the MK200 is 40 per cent higher at 570 Nm than that of the MR200. As with all Kitagawa tables, this maximum holding torque is determined by the point at which the force on the worm wheel causes it to displace by 30 microns. In contrast, other manufacturers use the slipping torque figure as a maximum, which Kitagawa regards as likely to cause inaccuracy at best and catastrophic failure at worst. Additionally, drive torque is highest in class at 270 Nm and the spindle through-hole

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diameter has gone up from 45 to 70 mm. The type of the faceplate is specified by the customer, either with T-slots or pre-drilled holes. The advantage is that a chuck, trunnion or other workholding device can be mounted directly onto the rotary table's spindle, reducing the distance from the spindle bearing. Such compact assembly lessens the load on the bearing, increasing rigidity and longevity. Improved mounting

Above: The new Kitagawa MK200 rotary table from 1st MTA Below: As the worm screw on the MK200 drives a worm wheel of large diameter, greater torque is generated.

At only 155 mm from front to back, the depth of the new table is 10 per cent less than that of the former MR version. Together with recessed bolt mounting, it has allowed the footprint of the MK200 to be reduced by 40 per cent. Moreover, if a riser block is needed to raise the table's centreline, the same small footprint of 407 cm2 is preserved. The design also reduces accumulation of chips around the base of the rotary table, reducing cleaning time and ensuring the absence of interference to the workholding system an important consideration in automated production cells. Wide selection of rotary joints The MK200 accommodates built-in 6 +1 port rotary joints, compared to only 4 +1 for its predecessor. If, for example, a trunnion arrangement is in use with one end powered by the rotary table, greater flexibility of hydraulic or pneumatic workholding actuation is provided via the rotary joint housed within the large spindle

bore. This avoids wear and interference due to the presence of tubing if workholding actuation is brought forward of the faceplate. The 6+1 rotary joint includes a 12.5 mm diameter, multi-purpose hole through the centre for additional air or hydraulic services. The hole can also be used as a duct for cables feeding signals back from fixture sensors confirming correct workpiece seating. The design of the workholding configuration can thus be improved and its capabilities enhanced. 1st MTA is able to provide a high pressure 25 MPa, 4-port or 6-port rotary joint instead of the standard 7 MPa variety, enabling a further reduction in fixtures sizes as well as improved clamping speeds. A video summarising the benefits of the MK200 may be viewed here

www.1mta.com

June 2019

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June 2019

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ENGINEERING UPDATE

Nexen ring drive for precision rotary motion control in measuring system Compact ring drive systems from Nexen are used in industrial rotary applications where high positional accuracy and dynamic performance are required.

Custom solution from Mahr for measuring an engine component with CRD350 Compact Ring Drive from Nexen

The custom rotary indexer CRD350 was developed jointly with the metrology specialist Mahr for a French automotive manufacturer.

eadquartered in Germany, Mahr GmbH is a global manufacturer of production measuring technology and is active all over the world. From the simple caliper gauge to precision optical measuring systems, Mahr is a key supplier in a wide range of industries including the automotive industry, medical technology, aviation, optics and renewable energies. In many sectors where precision is an essential production factor, equipment from Mahr is at work, delivering supreme accuracy in measuring dimensions, contours and surfaces with the smallest possible tolerances.

"The rotary table includes the Nexen rollerpinion system with a special ring gear and high-performance cross roller bearings for outstanding load capacity and rigidity. The system is mounted on a cast part. The central passthrough of the annular design allows the essential access to the middle of the table, which is extremely convenient for routing electrical wires or inserting other machine components", explains Alain Fourcroy, sales engineer for Unicum. "The application meets the expectations of the end customer in every detail. By combining the expertise of our two companies, we have completed a project unlike any other with complete success."

Mahr received the order to develop a customer-specific system for measuring the roughness of a key engine component for a French car maker. To complete the order, Mahr entered into partnership with Unicum Transmission de Puissance, Nexen's sales and marketing partner in France. After a preliminary study which they completed jointly, Mahr and Unicum together developed an innovative solution, the only one of its kind in Europe: the Nexen CRD350 rotary indexer. It is capable of very high positioning accuracy during rotation and remarkable dynamic output.

"Demand and need are at above average levels at the moment", says Jacques Loiseau, special developments manager at Mahr. "For further developments, we want the rotary table to be able to deliver the same accuracy with eccentric loading as well. At the moment, the overhung load is about 250 kg with an eccentricity of 200 mm. Despite the challenges, we were able to satisfy this requirement with complete success: the ability to handle heavy loads with zero backlash." Its low structural height and generally compact design make the ring drive system extremely versatile. Apart from this customer-specific development for Mahr, Nexen CRD ring drive systems are used in a wide range of applications including cutting and gantry systems, medical devices, robots, machine tools, semiconductor production, materials handling and aerospace.

The rotary table is based on a rollerpinion system. It enables both dynamic movements and an exceptional level of positional accuracy. The performance parameters of the rotary table are impressive: Accurate to 35 arc seconds, maximum speed 94 rpm, maximum torque 564 Nm. Besides these advantages, the Nexen CRD350 is an exceptionally compact drive solution without backlash, requiring no maintenance or lubrication.

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www.mahr.com

The CRD350 Compact Ring Drive from Nexen in the customer-specific measuring system by Mahr

Details: The CRD350 Compact Ring Drive from Nexen in the customer-specific measuring system by Mahr

The Compact Ring Drive system (CRD) from Nexen with precision grade bearing and drive mechanism in a sealed housing

Besides ring drive systems, Nexen produces roller pinion, linear and rotary drive systems, industrial brakes, clutches,

torque limiters, overload protection devices, and control systems. The company is headquartered in the USA, with their European office based in Wemmel, Belgium. Nexen holds 120 US and international patents. The products are available from over 40 sales offices and more than 1,500 distributor outlets worldwide.

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www.industrialclutch.com

June 2019

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June 2019



ENGINEERING UPDATE

Keyhole surgery using robots The Bristol Robotics Laboratory are incorporating maxon products as part of a project to develop Robot Assisted Minimally Invasive Surgery (RAMIS).

sing robots in keyhole surgery offers many a d v a n t a g e s compared to traditional Minimally Invasive Surgery, including improved vision, precision and dexterity. The SMARTsurg project has been setup to develop an advanced system for performing Robot Assisted MIS. The project involves a team of ten institutions across Europe of highly experienced clinical, academic, and industrial partners. One of the institutions is the Bristol Robotics Laboratory (BRL). maxon have worked with BRL on several projects and were delighted to be asked to assist on RAMIS. The team are using maxon DC motors and controllers to drive and position the 3-finger surgical instrument that goes inside the body. The instrument will be controlled by exoskeletons that fit over the surgeon’s hands. In addition, they will also develop smart glasses to allow the surgeon to have a realistic view of what is taking place inside the body. The team found maxon products were easy to use and offered the precision and high power density necessary for this application.

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BRL used the maxon online Configurator to select and configure the DCX 19 S brushed DC motor, GPX 22 gearbox and ENX 10 encoder. An advantage of using the maxon Configurator are the short lead times. Designing the maxon products online enabled the best fit package in terms of output torque, speed and encoder feedback. Physical dimensions could also be realised, simply and quickly including full technical details of the package published, including 3D CAD model, at the touch of a button. The maxon EPOS2 positioning controller and the CAN communication protocol were used to ensure each axis responds to commands from the master controller in terms of position, speed and torque. Sanja Dogmadzi, Professor in Medical Robotics at BRL explained ‘While the popularity of RAMIS is steadily

increasing, the potential for improving patient outcomes and the potential for other procedures is not fully realised, largely because of serious limitations in the current instrumentation, control and feedback to the surgeon. Specifically, restricted access, lack of force feedback, and use of rigid tools in confined spaces filled with organs pose challenges to full adoption. The development of robotic surgical platforms has introduced 3D vision and significant improvements in the levels of dexterity. Robot Assisted Minimally Invasive Surgery will reduce the demand on the surgeon, shorten training time and deliver accuracy, safety and reduced procedure time.’ Further details could be found on the project website: http://smartsurg-project.eu/ To discuss your application please contact maxon on +44 (0)1189 733 337 or salesuk@maxonmotor.com.

June 2019

ODU-MAC®

THE ALL-ROUND SOLUTION FOR MANUAL MATING AND AUTOMATIC DOCKING Compact modular connector system

The intelligent path to customer-specific connections: ODU-MAC – our versatile modular connector solution enables the transmission of power, high current, high voltage, coax, high-speed data, fiber optics and other media such as air or fluid. For your made-to-measure connection.

COMPLETE SYSTEM SOLUTIONS ODU provides pre-assembled component solutions. Our development and manufacturing expertise, combined with our state-of-the art manufacturing facilities in Europe, China and the USA, enable us to offer our customers outstanding assemblies and a full range of logistics services.

ASSEMBLY

ODU-UK Ltd. Phone: +44 03301509 002 266433 0640 sales@odu-uk.co.uk www.odu-uk.co.uk

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June 2019



ENGINEERING UPDATE

Custom Filters – Made in Britain Croft Filters Ltd, based in Warrington England, have been supplying custom filtration and separation solutions for over 32 years. Throughout this time Croft has developed a reputation for their quality, bespoke service through manufacturing a variety of products for a range of different industries including: Chemical, Oil, Gas, Energy, Pharmaceutical, Food and Beverage amongst many others worldwide. Bespoke Filtration Solutions Croft specialises in custom filtration solutions, these are manufactured specifically to the Customer’s unique requirements and can be ordered as ‘one-off’s’ to small batches. Typical filter designs include: basket strainers, duplex filters, cone filters, cylinder filters and screen filters in perforated plate, wedge wire and woven wire mesh. Croft’s experience within the market alongside their drive for innovation allows the company to solve unique filtration problems that Customers are faced with.

Self-Cleaning Filters In 2013 Croft became distributers for HiFlux Filtration A/S, a Danish manufacturer backed with 50 years experience within the filtration industry. As a result of this Croft have been supplying many industries with quality SelfCleaning filters designed to reduce downtime and operating costs for the user.

Metal 3D Printing

With different models available for applications such as: Cooling, Refining and Filtering, the SelfCleaners use a plunger or a series of scrapers to remove waste caught on the filter element inside the housing. This improves the flow through the filter and the lifetime of the element. The captured particles are

In 2013 Croft invested into Additive Manufacturing, specifically Selective Laser Melting (SLM) in order to develop new innovative filtration solutions. Additive Manufacturing (AM), also known as metal 3D printing, is the process of creating a 3 dimensional component through a series of layers.

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then be ejected from the system without the need to stop the process or change the element, saving on downtime.

Benefits of the AM process, such as: part weight reduction, multipart to single component and expanded design capabilities, allow Croft’s customers to re-think their approach to their designs in order to improve the efficiency and utility of their parts or to deliver other supply chain advantages. Quality of both product and service has been the key to Croft’s success; the Company takes great pride in understanding their customer’s needs,

quickly supplying them with a quality product that exceeds expectations. For more information about Croft’s filtration solutions or Croft’s Additive Manufacturing services: Call: 01925 766265 Email: sales@filters.co.uk

June 2019

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Designed for Optical Innovation, Engineered to Last Since 1991, Knight Optical has established a reputation built on reliability and excellence amongst the engineering and manufacturing industries working on both large- and small-scale, high-specification projects globally that require guaranteed lead times. Custom Optical Components

Whether you are specifying bespoke optical components for aerospace, marine, rail or even structural and civil engineering, Knight Optical offers a wide-ranging product offering across a range of custom-specific requirements to meet any specification in every engineering division. Regardless of the design or complexity, Knight Optical will manage your order all the way through its production process. From handling prototyping development at conception through to providing full production runs at completion stage, we are accustomed to supplying your industry with superior optical components. In addition to our custom capabilities, we also stock over 3,000 optics ready for instant dispatch.

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Knight Optical is synonymous with high quality; this stems from our teamâ&#x20AC;&#x2122;s meticulous attention to detail â&#x20AC;&#x201D; from the industry-recognised standards we follow.

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SUB-ASSEMBLIES | SAPPHIRE | GERMANIUM | PRISMS | First-rate customer service is of vital importance to Knight Optical and to make sure we are offering you an outstanding level of care; we dedicate a technical sales adviser to follow your project through from start to finish. From our team of graduate technical sales advisers, you are allocated a personal account manager who has the capability to interpret technical drawings and advise on material selection, tolerances and surface specifications.

Contact Us Today To find out how Knight Optical can help with your current project, get in touch with our multilingual sales team. Alternatively, visit our website for our full range of stock optics.

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Knight Optical’s QA department visually inspects each and every component to assure conformance with your surface quality requirements. Using a MIL- RF-13830 and MIL-M-13508 compliant scratch/dig master, our QA team certifies that your precise specifications are met, and your order arrives ready for implementation.

By ordering your optical components through Knight Optical, you can be assured that we will provide you with a metrology-tested and quality-assured turnkey solution for all your optical needs.

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Quality and first-class customer service are two leading assets that steer the position of Knight Optical’s industry-leading status. Our objective is to lead the way in engineering breakthroughs by providing the industry with optical components of the very highest quality.

Our team of highly skilled on-site metrology technicians test every order placed. Operating from our fully equipped state-of-the-art Metrology Laboratory in the UK, our team of technicians ensure your optical specifications are met — such as transmission, reflection, optical density and focal length. After testing, each order is dispatched with its accompanying metrology test data, providing our customers with full transparency.

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June 2019



ENGINEERING UPDATE

Salmon Waste success with new pasteuriser for go-ahead Isle of Lewis With aquaculture production sites widely dispersed throughout remote parts of Scotland’s Highlands and Islands, the logistics of fish waste collection and treatment is always going to be difficult…. or is it? Not content with being at the thin end of the wedge, the Isle of Lewis is leading by example with its Creed Integrated Waste Management Facility (IWMF), located just outside Stornoway. Owned and operated by Comhairle nan Eilean Siar (CnES), the Local Authority for the Western Isles, the manager and his team at this progressive plant believe firmly in continuous improvement, minimising, maximising and optimising the methods of managing waste from the island’s population of approximately 22,000. Undeterred by the challenges of a limited electrical grid and logistical costs typically associated with island life, the Creed IWMF has grown steadily to include a combined heat and power plant (CHP), electric boiler and thermal store, a wind turbine and a hydrogen system comprising electrolyser, storage and refuelling station, and a 960m3 anaerobic digester (AD) plant. Most recently, through careful planning and it has be said, no shortage of patience, Creed also now features the equipment required to take in and process seven tonnes per shift of salmon waste, as David Macleod, Head of Municipal Services at Comhairle nan Eilean Siar explains:

‘what we wanted to invest in – a pasteuriser’ “We always had an eye on how we could use fish waste but before we could invest in equipment, we needed commitment and guarantees from the fish companies about continuity of supply. We did our homework and our Plant Manager Donnie MacMillan visited installations in Scotland to find out about their experiences. But we were still very much in a chicken and egg situation. We had the digester – producing biogas, but we knew we wouldn’t have enough heat to warm up what we wanted to invest in – a pasteuriser. Buying a good quality pasteuriser – not too big or not too small – would enable us to meet ABP (Animal By-Product) regulations, which require the waste to be treated for one hour at 70 degrees C. Thankfully, when we were able to bring in our new thermal store, together with getting the guarantee from the fish industry, we were able to go ahead. We are a local authority of course – not at a commercial enterprise, so we

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can’t go ahead with quick purchases. We have to continuously adapt”. A salmon processing facility on the Island of Lewis was identified as the main source of supply for salmon waste, although deposits from other marine fish farms would also head to Creed IWMF from time to time.

‘determined to make it work’ He continued: “We were restricted into a very tight space by regulations that demand separation of what can be housed in so-called clean and dirty areas, which is rather ironic at a waste management facility – but we had no choice. The late Hugh Vaughan (from Landia) had no hesitation in coming up here to measure everything out. He was determined to make it work. We needed an ensiling tank, which effectively is a buffer/pre-treatment tank. With the space restrictions, Landia were able to provide a 10m3 unit, which sits just in front of the 8m3 pasteuriser. It was a very tight fit, but it worked”. The ensiling tank is equipped with an 18.5kW stainless steel long shaft chopper pump, which recirculates and blends the salmon waste (mainly left-overs from the filleting process) into a smooth purée, before being discharged into the pasteuriser – fitted with Landia’s sideentry propeller mixer and dry-installed chopper pump. The one-hour (minimum) process at 70 degrees C meets ABP (Animal By-Products) regulations, fully approved by vets. “It had to work” said Donnie MacMillan. “We’d made a commitment to the salmon industry - and unless we could keep our promise, it’d mean a big financial burden. The Landia guys worked flat out from start

to finish. There was no wriggle room, but they skidded everything in and nailed it, first time”.

‘positive environmental and economic impact’ Prior to its arrival in Stornoway, Landia had assembled the units, tested every nut and bolt - and ran a trial process with water. The ensiling tank, pasteuriser and Landia personnel then left Shropshire early on a Sunday morning – with installation on the Isle of Lewis commencing 24 hours later. The pasteurised fish waste – a 7 cubic ton batch per shift - is now integrated with household food waste and garden waste for Creed’s anaerobic digestion process, making a positive environmental and economic impact by not sending it to landfill or having it transported off the island. Some of the electricity generated by the CHP is sent to a hydrogen system to produce hydrogen and oxygen. This is captured, compressed and delivered to the salmon hatchery. Oxygenation is essential to aquaculture, and hydrogen is used in a small fuel cell to provide electricity to the remote site, which sometimes suffers from failures of the electrical network. Backups have traditionally been in the form of ageing diesel generators, with associated higher CO2 emissions and delivery costs. The hydrogen system at Creed includes a refuelling station, and some of the hydrogen will soon be used to refill a dual-fuel Refuse Collection Vehicle (RCV) operating on hydrogen/diesel. Landia 01948 661 200

www.landia.co.uk

EDITOR’ S CHOICE ENGINEERING PDATE

Our parent company Muller Coax was established 58 years ago and is now a recognised leader in valve design and innovation within the valve industry. We are synonymous for quality, experience and reliability in valve technology, this has been the case since the beginning of our dynamic development and it will continue to stay that way. Valve pictured was built for a specific application for one of our many blue chip clients, below is a case study and solution provided to match the requirement. APPLICATION: Customer required high pressure 2” BSP valve for

June 2019

controlling water at 200 bar for fast shut off and giving feedback position sensing. SOLUTION:The Muller Coax 5 VMKH50 valves meets all the criteria with leak tight shut off, and full open and close cycle of 200 milliseconds with reliable position sensors fitted. The reliable proven high valve solution met all the clients exacting criteria. For details of how we can assist with your requirements contact co-ax valves uk: john.osborn@coaxvalves.co.uk or visit www.co-ax.com.

NEW FP400 A LOW PULSATION DIAPHRAGM PUMP • Five diaphragm technology • Delivers up to 4.6 l/min • Low pulsation and low vibration • Great linearity and controllability

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To discuss your application further contact our dedicated team of experienced technical pump engineers. KNF Neuberger UK Ltd Ave 2, Station Lane Ind Est, Witney, Oxon, OX28 4FA Tel: 01993 778373 info.uk@knf.com www.knf.co.uk

New Inclinometer range! Visit our website for more information

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June 2019 The system is sensitive to ultra thin metal contaminant flakes and foils that are difficult to detect in ultra-thin premium products, including deli meats.

Chocolate, confectionery, nutrition bars, cookies and biscuits are typical low profile foods where it can be beneficial to look for metal contaminants from multiple angles.

Another food metal inspection ‘world first’ from Fortress Fortress Technology has launched yet another food inspection world breakthrough - a metal detector that inspects low profile, high value products vertically and horizontally concurrently to achieve the highest sensitivity on the planet.

he Interceptor DF (Divergent Field) is a result of the company’s longstanding expertise in metal detection and its more recent development of the two channel, two frequency Interceptor range. “The ability to choose the direction of the inspection field is itself groundbreaking,” says Fortress European Managing Director Phil Brown. “Performance wise, nothing else on the market comes close to the Interceptor DF when looking for thin, non-spherical metal contaminants in products,” claims Phil.

Believed to be the first ever multiorientation, multi-scan food metal detector, the Interceptor DF is especially sensitive to very thin metal contaminant flakes and foils that are difficult to detect on low

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

ENGINEERING UPDATE

profile foods, including chocolate, confectionery, nutrition bars, cookies and biscuits. The Interceptor DF can also be used to inspect small thin packages of conductive products like cheese and deli-meats with a high value and high market image, for example steak burgers, Parma ham and Parmesan cheese. Rather than scanning a select number of frequencies, the conveyor-style metal detector inspects raw, cooked and packaged products using multiple field directions. To increase food safety, the Interceptor DF system addresses several previous limitations - notably orientation, size, geometry and position of metals. It’s especially reliable at detecting very thin flakes and foils that could be introduced to premium foods in the mixing, rolling, cooking, scoring, moulding, slicing or baking processes.

The new Interceptor DF uses multiple field patterns to inspect products horizontally and vertically at the same time.

Innovation in action Different to other multi-scan metal detectors on the market, the unique Fortress system uses multiple coil sets to instantaneously drive the electromagnetic fields in different directions. Rather than missing a metal contaminant because it hasn’t aligned with a specific field, the Interceptor DF looks for signals over a broad spectrum, from multiple angles. The stronger disturbance from one field compensates for the weaker signal from another. This increases the probability of identifying and rejecting products containing non-spherical metals by over 100%, including difficult to spot flat metal flakes. “By taking control of something that’s inherently difficult to control - contaminant orientation - Fortress is once again proving itself to be a leader in the food safety inspection market,” states Phil. To increase supply chain transparency and product traceability, Contact Reporter software, included as standard, produces a full log of events. These electronic records can be viewed, filtered and exported, and can be used to supplement or replace manual documentation. For fast set up and ease of use, the Interceptor DF learns and recalls the signature of any given product with just one pass. Halo automatic testing can be added to reduce the risk of human error when manually testing the performance of the detection system.

www.fortresstechnology.co.uk

Rapidox 2100-OEM-RSB Small but mighty. Effortless integration into products and processes. The compact design (4.5â&#x20AC;? x 3.0â&#x20AC;?) allows integration into the tightest of spaces yet comes with the same performance specifications and features of our exisiting OEM analysers. The board is fitted with a robust cabled zirconia sensor, which is ideal for providing fast and accurate remote in-situ gas analysis over the the full oxygen range 10-20ppm to 30% O2. Zirconia oxygen sensors are extremely rugged and particularly suitable for monitoring inert atmospheres and aggressive industrial applications directly within manufacturing processes such as metal 3D printers, soldering ovens and furnaces.

www.cambridge-sensotec.co.uk sales@cambridge-sensotec.co.uk + 44 (0)1480 462142

June 2019

ď&#x201A;?

ENGINEERING UPDATE

KAWASAKI ROBOT IS CHOSEN FOR CAST OF THOUSANDS In the ultra-competitive world of robotics, more and more manufacturing companies are turning to Kawasaki Robotics to provide practical, affordable, long-lasting and future-proof solutions to their automated production needs.

Take the recent example seen at Ryobi Castings UK, based in Carrickfergus. The company is a world leader in the manufacture of complex castings, especially for the automotive market, and produces some of the most complicated aluminium die-castings imaginable. These are designed for use across a variety of applications and include finished castings of complete engine blocks (both open and closed deck) through to the intricate bracketry found throughout most modern, lightweight vehicles and on to also include transmission casings (automatic and manual) and clutch housings. Ryobi on-site operators have been trained by Kawasaki Robotics UK to operate the 14 Kawasaki Robots installed at the plant. The robots are used to remove the raw castings direct from the casting machines and place them onto nearby machining centres for the necessary post-cast working. Since the Kawasaki robots were installed in March 2014, many thousands of operations have been performed with absolute precision and without a single fault. Keeping spirits up Another success shows the true diversity of the applications in which Kawasaki Robotics continue to win orders in the face of stiff competition.

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One of their more spirited successes has seen Speyside Cooperage in Alloa specify two Kawasaki robots to work alongside specialist tooling in the refurbishment of traditionally built oak barrels. Here, the robots have eliminated a number of Health & Safety concerns for personnel by taking the near-complete barrels and positioning them inside a large lathe for finishing. Previously done by hand, the process was both arduous given the size and weight of the barrels, and also potentially dangerous as they needed placing with some accuracy onto an enclosed lathe. This is now made into refreshingly light work thanks to the Kawasaki Robotics team. Warrington-based Kawasaki Robotics is home to one of the UKâ&#x20AC;&#x2122;s most experienced robot application teams. The company also offers potential customers a unique facility â&#x20AC;&#x201C; the opportunity to simulate just about any application for a robot, using its own global robotic simulation platform. This permits potential users to more accurately determine and calculate the myriad of parameters necessary prior to arriving at a decision to automate either an entire process or just a simple single task. The company can organise free-of-charge demonstrations on request.

ENGINEERING PDATE

June 2019

• Vibration Sensors (IEPE + 4-20mA) • Test & Measurement Sensors • Hazardous Area Vibration Sensors • Seismic Sensors • Hydrophones • Vector Sensors • Proximity Probes • Vibration Switches Certiﬁcations Including FM, CSA, ATEX and IECEx Offer Compliance to Customers Worldwide • Cable Assemblies • Enclosures • Vibration Transmitters • Supportive Instrumentation

New Inclinometer range! Visit our website for more information

WORLD-CLASS SENSORS FOR INDUSTRY derby.ac.uk/EngineeringUpdate

RMIG is the world's largest manufacturer and supplier of perforated metal and its related products. We know our customers’ requirements for price and quality and meet their demands with uncompromising service. Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below. Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.

+44 (0)1767 651058

www.kdpes.co.uk

Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements. Rolling and forming We can roll, bend and form perforated sheets to match your design. Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications. For more information please contact us www.rmig.com email: info.uk@rmig.com Tel: 01925 839610

Cutting We can cut and shape perforated sheet to meet the needs of your final application.

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June 2019



ENGINEERING UPDATE

Thousands of sector professionals flock to the Health & Safety Event 2019 – naming it “the best yet” The Health & Safety Event that took place in April this year at the NEC, Birmingham, with the co-located fire, facilities and security shows, saw more than 11,733 visitors pour through the doors over three key business days, making it the most successful event to date. Those who visited had the opportunity to network, attend seminars and sessions from industry leaders and gain access to the latest products and innovations. With 149 exhibitors showcasing their latest health and safety-related products and services, and more than 30 hours of expert presentations and educational context on offer across the three days, this year’s Health & Safety Event – the fifth at the UK’s premier exhibitions venue – was the biggest and best yet. In partnership with the British Safety Industry Federation (BSIF) and the British Safety Council (BSC), and supported by key sectoral, regulatory and media organisations, the Health & Safety Event 2019 – which took place from 9 to 11 April – provided an unrivalled opportunity for industry professionals to network and learn about the latest developments, technologies and theories to help reduce occupational risks and protect people at work. Education was at the heart of the event and, with four seminar theatres playing host to more than 35 presentations, seven expert-panel discussions and a VIP breakfast briefing on each of the three mornings, there was truly something for everyone. There was standing-room only at most of the sessions, with visitors keen to hear what the cream of the health and safety profession and industry had to say. According to event visitor Alison Thomson: “The speakers at the Health & Safety Event were great – delivering thought-provoking sessions, including on lone-worker safety and using forklift trucks.” Visitor Melanie Tennela added: “I have been coming to this event for four years and this was the best yet. The atmosphere was buzzing, and the conversations were flowing. I really appreciated the seminar sessions and will be making some changes to our own training material as a result, especially regarding mental health at work.” Exhibitors, too, were unanimous on the success of the event, commenting on the number of leads generated, fruitful conversations held, and enquiries made. Driver-training provider Road Safety Prospects Ltd said: “Another fantastic Health & Safety Event. We were literally rushed off our feet with people queueing to talk to us!” Access-equipment specialist TB Davies Ltd was similarly delighted: “It has been a really busy event. We’ve come away with strong leads from blue-

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chip companies and lots of interest in our products. We’ll be back in 2020!” Rebooking’s overall were very high, with a whopping 75 per cent of stands for the 2020 event snapped up during this year’s show. Western Business Exhibitions Portfolio Director, David Bishop commented: “The Health & Safety Event is getting bigger and better every year, as the number of visitors pouring through the doors and range of exhibitors using it as their main promotional platform testify. The feedback from both parties this year has been hugely positive, with visitors raving about the variety of educational content and innovative products and services on offer, and exhibitors delighted with the quality and quantity of leads they received. We’re already looking forward to next year’s event, which promises to be even more successful!” The Health & Safety Event also encompassed the Safety & Health Excellence Awards, which took place on the evening of 10 April at the VOX Conference Centre on the NEC site. The awards celebrate innovation and achievement in 14 categories, and 525 guests gathered to cheer on their colleagues and peers over the course of a highly entertaining evening, hosted by top comedian Sean Lock. See hilights from the show in the video below:

ANNOUNCING Industrial Applications and Scientific Vacuum Technologies

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W WW.WNI E . C O. U K / LI VE

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ANNOUNCING: Taking place in the heart of the midlands at the NAEC Stoneleigh, Warwickshire With manufacturing in the UK thriving, revel in the industry positivity by showcasing your company at WNIE Live 2019, the UK's longest running electronics, embedded and manufacturing event. WNIE LIve features a huge amount of unique content over the two days, including exhibitors, conferences, seminars, workshops and round-table debates. New for 2019 is the Marketplace, The UK Manufacturing and Automation Pavilion and the PCB Pavilion Marketplace. YOU WON’T FIND THIS CONTENT ANYWHERE ELSE, EVEN ONLINE!

To get a floorplan and pricing please call, visit www.wnie.co.uk/live or email live@wnie.co.uk

CALL NOW: + 44 (0)1428 609 382 YOUR UK EVENT WITH GLOBAL REACH AND CONTENT NETWORK

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BE AN EXHIBITOR... What’s New in Electronics Live delivers a comprehensive 2-day event covering the whole spectrum of the electronics, embedded, design, manufacturing and engineering industry. With an international exhibitor list of companies showing products and services to support this sector, plus conferences, workshops, discussion panels and live features, WNIE Live IS the unmissable event of 2019.

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Events

June 2019



ENGINEERING UPDATE

PPMA Total Show 2019 showcasing the latest developments in processing and packaging

taged every three years, the NEC, Birmingham will host the UK’s largest processing and packaging machinery exhibition, PPMA Total Show 2019, which runs from 1 to 3 October 2019. With over 400 exhibitors and 1,600 brands all under one roof, this year’s show provides visitors with an unrivalled opportunity to experience and discover solutions for increasing output and efficiencies through the whole production cycle; from filling and packaging machinery and processing equipment, to robotics, automation and vision systems. Exhibitors will showcase the latest products and solutions in processing and packaging machinery, robotics and industrial vision systems. Leading companies already confirmed as exhibitors include: Gordon Strapping, Dustcontrol UK, Citronix, Concetti Group and James Mae Group. Add to this the FREE to attend, industryresponsive conference programme and first-class speaker line-up tackling key industry issues, and this years’ event will offer a practical, informative and valueadded visitor experience – and on an even larger scale than before. The Enterprise Zone – a hub of knowledge sharing, learning and networking PPMA Total Show 2019 will offer visitors a focal point for learning, networking, and live debate via its Enterprise Zone. Alongside providing dedicated meeting areas and activities, there will be a full conference programme across all three days of the show. It will also play host to a series of workshops, presentations and interactive panel discussions, with insightful keynote addresses covering topical issues and industry trends. Case studies, panel discussions and presentations will provide visitors with real life examples of best practice in manufacturing and excellence in processing and packaging production, aiming to motivate and inspire visitors to improve their businesses. Topics will include the Factory of the Future @ 2050, Industry 4.0, how artificial intelligence is shifting the possibilities of manufacturing, as well as issues affecting the future of food manufacturing and processing. Another significant issue on the agenda will be the strategy for plastics in a circular economy. David Harrison, PPMA Group Exhibition Manager, explains, “The great

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plastic debate remains a topical area of conversation among PPMA members and end users alike and will feature in the conference programme during the show. We have invited a panel of experts to discuss the new narrative for packaging - to reduce, redesign and replace, with transformative innovation.” PPMA BEST Engineering is of vital importance to the UK economy, generating 23% of the UK’s total turnover. Therefore, with an annual shortfall of 59,000 engineering graduates and technicians to fill core engineering roles, there is much work to be done. As part of the drive to encourage more young people to pursue a career in engineering and to develop a better understanding of how to connect schools with employers to access high quality, engineering focused engagement activity, this year’s PPMA Total Show will host an education hub. This will offer guidance on apprenticeships and how companies can access funding through the PPMA’s charitable arm, PPMA BEST (Business, Education, Skills and Training). “Through its leadership of the BEST initiative, the PPMA Group is determined to play its part in proactively addressing the current shortage of skills,” explains Andrew Mint, “The skills gap represents an enormous challenge for members. We simply don’t have enough new blood coming into our industry, especially those with hands-on skills, and there is still a requirement for higher levels of engineering skills.” For more information on BEST, please go to: www.ppmabest.org.uk. Networking and relationship building Adding to the appeal of the Show is the extensive networking opportunities available. The PPMA Industry Awards 2019 will be held at the National Conference Centre (NCC) in Birmingham. Now in its eighth year, this prestigious awards ceremony brings together more than 300 industry professionals and stakeholders from the world of processing and packaging machinery and celebrates the finest examples of innovation, smart manufacturing and entrepreneurship. There are 12 Awards categories, ranging from innovative technologies in processing, packaging, robotics, vision systems and ancillary equipment, to achievements in sales, export and the environment. The ‘Apprentice of the

Year’ Award serve to acknowledge the most promising young talent within the processing and packaging, robotics and automation and industrial vision industries. Companies that have developed a comprehensive apprenticeship or training programme have the opportunity to be recognised too through the PPMA BEST Award. The Awards will be hosted by UK television presenter and magician Stephen Mulhern, who has appeared as a host on Britain’s Got Talent, Catchphrase and Big Star’s Little Star. Award entry submissions are FREE and companies are encouraged to submit their entries by the deadline of 17 July 2019. For further information on the Awards and details on how to enter, click here. Dr Mint concludes: “PPMA Show 2018 drew the largest ever audience to a PPMA event, surpassing all our expectations. From the incredible range of new products to the vibrancy of debate during the conference, last year’s show reinforced our confidence that the industries we serve never stop developing and looking for new ways to achieve growth. “This is an especially important time for the industries we represent. We’re entering a phase where political changes are set to impact our business dealings internationally. We believe that this year’s PPMA Total Show will provide visitors with an array of product launches and thoughtprovoking content to help them drive their business forward in these uncertain times.” Visitor registration for the PPMA Total Show is now open. To register and attend the event for FREE, visit the PPMA Total Show website at: www.ppmatotalshow.co.uk

1-3 OCTOBER 2019 NEC, BiRmiNgham

ThE COmPLETE PRODUCTiON LiNE EVENT

FREE

TO aTTEND REgiSTER NOW OWNED & ORGANISED BY

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Events



ENGINEERING UPDATE

June 2019

Agenda announced for PROFINET, PROFIBUS and IO-Link seminar Manchester, 26 June

Presented by PROFIBUS and PROFINET International and hosted by Endress+Hauser, this free-to-attend event addresses the key practical issues arising from the use of digital communications technologies in automated manufacturing and process industry applications, with particular attention to Industry 4.0 and the Industrial Internet of Things (IIoT). Covering key application areas such as control systems and energy management, pulp & paper, chemical, utilities, pharmaceutical, mechanical handling and logistics, robotics, automotive engineering, electrical and electronics assembly, packaging and printing, it focuses on the practical aspects of using PROFINET, PROFIBUS and IO-Link, from system design and safety considerations through to faultfinding and maintenance. Live Demonstrations Supported by live demonstrations and an exhibition with demonstrations of actual tools used in configuration and maintenance, the seminar will be of great value to Designers, Production/System Engineers, Instrument Technicians/ Engineers and C&I Engineers involved in the design, operation and maintenance of modern automated factories and process plant.

providing state of the art digital communications addressing all the needs of manufacturing and process industries, significantly lowering capital expenditure on installation, commissioning and maintenance. They offer unprecedented integration of automation, control, monitoring and safety systems using standardised and widely supported communications and networking solutions.

charge to pre-registered delegates from the User community, i.e. companies that own, operate, design, build or maintain automated process plant and manufacturing facilities. The event will provide delegates with an excellent networking opportunity and the ability to speak to experts.

With nearly 80 million nodes installed worldwide, PROFINET, PROFIBUS and IO-Link are truly market leaders,

This seminar is ably presented by specialists from PI UK member companies. Attendance is free of

In case of difficulty contact Ann on tel: +44 207 193 8018 or email admin@profibus.org.uk

Click here for more information and online Registration

Draft Agenda Time

Item

Presenter

09:15 – 09:30 09:30 – 10:00

Welcome and introduction to exhibitors PROFIBUS International and basics of PROFIBUS & PROFINET PROFIBUS network design for Process Industries PROFINET network design Coffee and exhibition Industrial network commissioning and testing PROFIBUS and PROFINET device configuration tools. IO-Link for the “last metres” communication Lunch and Exhibition Industrial networks safety & security Update on Industry 4.0, IIoT, TSN and APL Summary, questions & close

Andy Smith, E+H Mark Freeman, Siemens

10:00 – 10:30 10:30 – 11:00 11:00 – 11:30 11:30 – 12:00 12:00 – 12:30 12:30 – 13:00 13:00 – 14:00 14:00 – 14:30 14:30 – 15:00 15:00 – 15:15

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Andy Smith, E+H Andy Williams, Siemens Dave Tomlin, Hitex and Xing Ye, Ideal Networks Phil Waterworth, Endress + Hauser Derek Lane, WAGO Peter Brown, CSA Group Derek Lane, WAGO Andy Smith, E+H

10th ANNIVERSARY EXHIBITION

Sensors & Instrumentation Live will be celebrating its landmark ten year anniversary with the biggest event in the show’s history – taking place in Hall 2 at the NEC Birmingham from Wednesday 25 to Thursday 26 September 2019. By bringing together market leaders, visitors will have the opportunity to explore all things sensors, test, measurement and control under one roof. In addition to discovering hundreds of products and solutions on offer from exhibitors, inuencers and decision makers will be able to pick up invaluable knowledge from experts, key institutions and organisations in a number of the show’s exciting and informative feature areas.

Sensors & Instrumentation Live

Headline sponsor

Sponsors

te g o r

ies

2019

EXPLOSION SAFETY and

PRESSURE RELIEF SOLUTIONS Consulting. Engineering. Products. Service.

www.rembe.de

Inc.

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Ltd.

www.rembe.co.uk

www.rembe.it

S.r.l.

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June 2019



ENGINEERING UPDATE

Trant Automation Control & Technology, based near Southampton, Hampshire, is the epitome of innovation, with a growing order book as a result We have been developing industrial control systems for many years now, continually staying ahead of the curve by embracing new technologies and applying best practice. Our award-winning ‘digital engineering’ approach here at Trant Automation Control & Technology (ACT) has reaped considerable benefits for clients who rightly expect best-in-class solutions for mission-critical infrastructure. For example, we are now only one of two companies in the UK able to machine, assemble and certify explosion-proof (EX) enclosures for hazardous environments.

It is testament to Trant ACT’s in-house expertise that we have secured full partnership with Technor Marachel, a first-class supplier of EX enclosures and equipment, giving us the ability to complete projects in just a few short weeks, rather than months.

Trant ACT a major competitive advantage.

We have gone from strength to strength in other areas as well, winning large orders in the water, oil and gas, process automation, nuclear, energy and pharmaceutical sectors.

This enables us to simulate entire plant environments and equipment in full 3D, with complete interaction with PLC systems.

Dealing with all aspects of design, build and testing of automation systems, we are able to create bespoke solutions for all types of industrial automation. We specialise in control panels, from small bespoke pumping station panels, controlled by relay systems, to largescale motor control centres, controlled by industrial controllers and graphic user interface. With our in-house software development team, we can configure a range of PLC, HMI and SCADA equipment from manufacturers such as Rockwell Automation, Siemens, Mitsubishi and Schneider. The ability to keep both the manufacturing and software development under one roof gives

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In addition to our industrial software development capabilities, Trant ACT has also branched out into the world of 3D simulations.

Even more exciting than this however is our ability to render these 3D environments in virtual reality at our dedicated VR facility. From visualisation of projects prior to build, to HAZOP investigations, training and even remote site visualisation and operation, the possibilities for this new technology are endless. Stuart Rice, General Manager of Trant ACT, said: “These are exciting times are for the company, with a sustained increase in staff, a substantial increase in orders and an extensive tender book.” For more information about Trant ACT, part of the Trant Engineering parent company, and the products and services that it can provide to solve your industrial automation needs, please contact stuartR.Rice@trant.co.uk



ENGINEERING UPDATE

June 2019

The Challenges of Accurate Interface Measurement Interface or multiphase level measurements exist throughout the oil & gas streams as well as petrochemical. While level measurement technologies have come a long way in effectively measuring liquids and solids, multiphase level measurement continues to be the biggest challenge and opportunity that exists today to which there is no perfect technology. However, experience has shown that process optimization and increased uptime can still be achieved in many separator applications through reliable, best-in-class, level technology. Magnetrol® recognizes that interface measurement is a key concern for these industries, as well as many others. With that in mind, MAGNETROL has developed a white paper addressing the challenges and considerations around interface measurement and currently available technologies for process optimization.

The Basics of Interface In the oil & gas and petrochemical industries, the need for reliable interface measurement arises whenever immiscible liquids, those incapable of mixing, reside within the same vessel. The lighter medium rises to the top and the heavier settles at the bottom. In oil production, for example, water or steam is used to extract oil from a well. Well fluids then route to production separators where they settle into their primary constituents as a hydrocarbon over water interface. Interfaces can form between liquids and solids, liquid and foam, and liquid and gas; but the emphasis here will be concentrated on liquid/liquid interface (often with a vapor space above the top/lighter liquid). Immiscible liquids meet along an interface layer where they undergo some amount of emulsification. This emulsion layer (also referred to as a “rag” layer) may form a narrow, distinct boundary, but more frequently it is a broader gradient of the mixed liquids. Generally, the thicker the emulsion layer, the greater the measurement challenge.

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Interface Measurement Challenges While monitoring the top, or total level, is critical for safety and overfill prevention, knowing the level of an interface is necessary for maintaining product quality and operations efficiency. If there is water in oil that is not separated effectively (water carryover), then this can induce processing problems, equipment failures and unplanned shutdowns. If there is oil in water (oil extraction), then there can be production loss, environmental fines, penalties and forced shutdowns. Of all the level switches and transmitters available, only a handful are suitable for reliable interface measurement. The leading interface measurement technologies include guided wave radar (GWR), buoyancy-

based displacers and magnetostrictive, RF capacitance, nuclear/gamma radiation and thermal dispersion. Ideally, the technology utilized for interface applications does not have to differ from other level instruments installed at the facility in order to maintain familiarity with users. Standardizing on a technology helps reduce training, installation & commissioning, maintenance and downtime.

More Information To learn more about interface measurement challenges and the technologies available to more accurately monitor interface, download the interface white paper. The white paper covers: • • • •

interface challenges; case studies in Oil & Gas and Petrochemical; comparison of level technologies for interface measurement; and the future of reliable interface measurement.

interface.magnetrol.com

www.phoenix-mecano.co.uk

June 2019

Valves

Fittings

Hose

The Right Connection For Your Hygienic Process • Hose Assemblies • Fittings & Accessories • Ball & Butterfly Valves • Filters & Strainers

• Actuated Valves • Pumps • Bespoke Fabrication • Asset Management

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01772 323 529 Engineered Products

01772 323 529 • dixoneurope.co.uk •

• C U S TOM ER S E RVICE • I NNO VATIO N • M A NUFACTURING • QUALITY • TECHNICAL EXPERTISE • UNCOMMON EXCELLENCE • DESIGN •

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June 2019 Edition 34

MVK FUSION …is an opportunity to standardize modular processes, opening the door to a one-module strategy

IO-Link button systems

IO-Link inductive couplers

IO-Link

The PROFINET/PROFIsafe module unites three basic functions of installation technology: 01 Standard digital sensors and actuators 02 Safety digital sensors and actuators 03 IO-Link

Safety valves

02 Safety

Standard IO

MVK Fusion makes complex configurations easier because they can be done entirely by the engineering tool in the safety control system. Software developers and electrical engineers no longer need in-depth knowledge of other manufacturers’ tools and manuals. MVK Fusion makes it possible to have fewer fieldbus modules per unit. Some applications might only require a single module. This opens up new opportunities for many automation applications!

What makes the MVK Fusion fieldbus module unique is its variety. It combines three basic functions: standard digital sensors and actuators, safety digital sensors and actuators and IO-Link. • The two standard digital ports can be configured as inputs or outputs – they are customizable for each application. • The four safety ports ensure that almost all digital safety requirements are integrated into the installation. • The two IO-Link ports offer a wide range of functions: they integrate smart devices into the fieldbus system and they also enable the system to be expanded cost-effectively via IO-Link hubs. MVK Fusion simplifies installation by minimizing the number of modules required.

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Safety door systems

IO-Link hubs IO-Link distance sensors

IO-Link pressure sensors

This combination is new and innovative. It enables unique and groundbreaking automation concepts to be realized. Installation becomes simpler and faster.

One Module with Extreme Range

IO-Link valve islands

Flexibility within Safety Applications MVK Fusion integrates all safety aspects into one module: • Safety sensors signals are transmitted over the three safe input ports, each of which have two channels. Emergency stop buttons, light curtains, two-handed units, safety doors, etc. can be qualified up to Performance Level e. • The safety output port has two safe outputs that can be configured according to the application (PP, PM or PPM switching). You can integrate a wide variety of actuator types like double valves and valve islands that still qualify up to Performance Level e. • A special Class B IO-Link port ensures that IOLink devices like valve islands and hubs can be easily and safely switched-off complying with safety standards up to Performance Level d. MVK Fusion lets you achieve high safety standards, protecting both man and machine.

Electromechanical safety switches IO-Link transponder systems Two-handed devices

Safety Configuration within a Mouse Click MVK Fusion makes configuring safety sensors and actuators extremely easy: select the safety function in the safety control system engineering tool, and within a few mouse clicks configuration is done. The users – usually the software developer or the electrical engineer – do not require any special knowledge to configure the module. The MVK Fusion module eliminates the extra verification work step (CRC calculation) and doesn’t require additional manufacturer-specific software. This speeds up the process because it prevents entry of incorrect data.

High Performance MVK Fusion is excellent for high power applications when reliability cannot be compromised. The module is one hundred percent compatible with PROFINET solutions. MVK Fusion is suitable for Conformance Class C (IRT), Shared Device and Netload Class III applications.

June 2019

Emergency stops

Smart IO-Link sensors

Double safety valves Key and selector switches Foot switches

IO-Link analog converters

DC motors Solenoid interlocks

Door switch IO-Link inductive sensors

Valves Safety command devices

Only One Module per Mechatronic Component With our fieldbus module MVK Fusion, we’re advancing the standardization of modular processes for the users. This makes it possible to realize new and groundbreaking concepts for the automation industry. Installations will become easier and quicker. Hopefully, only one module per component will be needed.

IO-Link temperature sensors Enabling switches IO-Link grippers

Laser scanners

Digital sensors

Michael Greiner, Senior Product Manager

Light curtains Control solenoid for guard locking

THAT’S COOL!

A Wide Range of Uses and Comprehensive Diagnostics Rugged, fully-molded metal housing made for a wide range of uses – like extreme welding applications.

The safety address is set directly on the module via rotary switch – MVK Fusion can also be restored to its default setting via the address 000.

MVK Fusion saves error information with a time stamp on an integrated web server, even in the event of power failure, helping you identify errors and reduce downtimes.

Unique to the market, the module can be used in at very high altitudes: up to 3,000 meters (10,000 feet).

The module functions at high outdoor temperatures (up to 60° C) in combination with high currents (up to 16 A). We offer an optional heat sink is for these extreme conditions, which extends the life of the module.

When it’s hot outside (temperatures up to 60° C) or if the module is under high current (up to 16 A), it’s possible to mount the MVK Fusion module onto a heat sink so that the module will continue running under extreme conditions.

Every single channel is monitored for problems like overloads, sensor shorts or short circuits – the comprehensive diagnostics detect errors quickly, so they can be analyzed and fixed.

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June 2019



ENGINEERING UPDATE

Gratnells Engineering supports DEM Sports inner city Cricket initiative DEM Sports recently revealed an updated Concertina Cricket Net and Multi-Sport Foldaway Net System, engineered by Gratnells Engineering. These unique fold away, space saving systems have been designed to promote cricket at grassroots level, primarily for use in schools without fields or where space is at a premium. These versatile nets can be used as a safe place for containing any ball games, sporting practices, coaching sessions or disciplines; including but not limited to cricket, batting, bowling, catching, rounders, football and hockey. DEM Sports is an innovative cricket equipment supplier specialising in the production and installation of highquality cricket ground equipment for universities, schools and both professional and amateur clubs. Gratnells, historically known as the leading name in school storage in over 68 countries of the world, has developed its engineering arm into a multi-sector manufacturer capable of providing high-volume laser cutting, powder coating and bespoke metal solutions to a wide range of customers.

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As well as developing the refined design of the DEM Sports nets, Gratnells Engineering provided a laser cut, powder coated finish with protective foam pads over the metal posts. The net system is either fixed to a wall, post or fence and uniquely folds back to 50cm, extending out to 8, 10 or 12 meters depending on the size that is ordered. The Multi Sport variation measures 10m x 6m and folds back to approximately 82cm for storage against a wall. If required the whole playing area can be enclosed using a sliding front net. Extending the nets for use requires two people but takes only minutes to perform. As well as encouraging health and fitness and increasing overall physical activity, the aim is to make games like cricket available to all children, even those who attend inner city schools with tarmac yards or similar areas not ideally suited for practice. Participation in sport is thought to have a number of positive effects on children from improving coordination, interaction

with others, teamwork, fitness, confidence and mental well-being. As part of ongoing anti-childhood obesity initiatives, the Government recommends 30 minutes of activity per day is required for children in the school setting. Equipment such as DEM Sports nets will enable more schools to meet these standards. It is hoped that more schools will be able to invest in this initiative by tapping into funding levied from the soft drinks industry, earmarked for improving school sports facilities and promoting healthy living; or through Funding 4 Education, which enables schools to purchase or lease sporting equipment. Based in Harlow, Gratnells Engineering has supported a number of campaigns such as the F1 in Schools’ program, the Year of Engineering and most recently, developed key relationships with educational institutions in the local area. Anthony Byrne, Gratnells Product Manager, commented, “Gratnells has a long history of supporting ideas that aim to help children succeed. We were delighted to work on refining this DEM Sports equipment as it has the potential to unlock inner city play spaces and combat obesity. We look forward to seeing the nets being used by children all over the UK soon.”

The Royal Society for the Prevention of Accidents

IOSH Managing Safely

VISIT US

The practical solution to managing health and safety risks

STAND

SH3220

The IOSH Managing Safely course is a practical solution to managing health and safety risks in your workplace, giving your workforce the practical knowledge to increase productivity, improve safety measures and enhance your reputation. Delivered with a tailored approach at training centres throughout the UK, in-company and via e-learning.

www.rospa.com/iosh-managing-safely +44 (0)121 248 2233 | enquiries@rospa.com

June 2019

Modula: the 4.0 product in a smart 4.0 factory At a time when the computerisation of businesses and the human-data interchange is more and more important, the solution is an automated factory and the Modula VLM represents a solid response to the 4.0 approach. Modula is a VLM based on the idea of taking back floor space and converting it into vertical space. To give you a concrete example, an 840 m2 warehouse becomes just 14 m2 of floor space and a vertical distribution of 16 metres in height, giving you a compact and lean factory which has its workers in mind. So, the principle behind these VLMs is goodsto-man and not man-to-goods, avoiding long journeys on foot for operators, human error, incomplete picking lists and physical effort. Picking is actually automated, so operators avoid having to perform unnecessary moves to reach the products. Access to Modula VLMs is completely computerised via a graphic touch screen user interface with colour display and intuitive icons that simplify the learning process for operators. The uses for a Modula VLM are wide and varied. For example, they can be used as automatic dispensers that provide assembly areas with the materials needed on the production line. Or they can be set up as a store, or used as a buffer for the production line or as a spare parts warehouse. Whatever the operator's "role", they no longer have to inspect shelving to find the materials they are looking for: it's the system itself that finds the materials, records stock levels and issues repeat orders whenever necessary. Here's another feature: the vertical shelving is modular and potentially infinitely expandable. The savings a business can make by adopting an intra-logistics system like this are huge and there are various VLM models with different specifications. We start with the minimal footprint of the Modula Slim which has a depth of less than 1.6 metres, and we go up to the Modula OneTon with a tray and bay width of 4100 mm and a payload per tray of 990 kg!

Storage solutions also include an internal bay that constitutes the ideal solution for companies needing to minimise their use of floor space, whilst the external bay offers an excellent ergonomic workspace for operators having to pick heavy products. VLMs can then be connected to anthropomorphous robots, lifting equipment, zero-weight cranes and other automation systems to create a lean, compact factory able to communicate with other systems and automated devices. VLMs transform the whole process: in the past, operators had to use a ladder to reach a component, hold on tight at a height of 3 metres, keep track of the event with picking slips and then record it all afterwards. A simple operation like this would require 4 people, while today you need only half that number. VLMs could be equipped with a Modula Cloud device that means you can receive incoming warning signals when any faults in the machine are detected, keeping the customer informed in real time and providing adequate support for preventive maintenance activities. This exchange of information will be essential in the factory of the future. This is an added value that makes it possible to collect and monitor, in the Cloud, all data associated with the VLMs in order to keep track of their operation at all times and provide a service whose goal is to consolidate the relationship between company and customer, resulting in benefits both for the Modula production process and also for the customer. The result is that the Modula system processes a large amount of data that can then be transmitted to help people use the systems, or intervene in real time in the event of improper use, or provide information well in advance of the next maintenance task.

+44 0844 902 8945 | uk@modula.com | www.modula.com 68|

ď&#x201A;?

ENGINEERING UPDATE



ENGINEERING UPDATE

June 2019

Inspection robot for inter-car connection systems delivers the future The HARTING Technology Group is setting the standard for system development with the commissioning of a new inspection robot for inter-car connection systems. "These additional test options mean we’re expanding inspection expertise in this area. This is another big step for the HARTING Technology Group, which enables us to offer our railway customers a complete solution package," said Christian Schumacher, Managing Director, HARTING Customised Solutions (HCS), at the official commissioning of the robot. Schumacher welcomed some 80 guests, together with Matthias Wiehe, Head of Global Project Engineering. This development means the HARTING Quality and Technology Centre (HQT) will be able to test inter-car cables under realistic operating conditions. The entire life cycle can be simulated in accordance with the route profile, allowing the load of the socalled ‘jumper cable’ to be adjusted and documented. The investment in this additional testing option completes the service package that HARTING has previously offered. The core competence of subsidiary, HARTING Customised Solutions (HCS), has long consisted of expert advice, conceptional design and selection of the right components, according to the latest railway standards; as well as the production of complete inter-car systems. "This

investment gets us fit for the future. We can support our customers’ engineering needs even more effectively, thanks to our many years of experience and outstanding testing capabilities. This saves time and money. We can provide complete support from design through the final release and production of the inter-car systems," Wiehe adds. Compact and secure connections for railway HARTING has been a specialist in the railway sector for years and offers a wide range of products and solutions. To save energy and make optimum use of available space, the company’s rail engineering developers are always looking for new solutions. Even components such as connectors require attention because they can make a significant long-term contribution towards reducing rail vehicle operating costs. Consequently, HARTING introduced the Han® 1A connector series, which enables high-performance connections for small to medium-sized electrical assemblies in rail vehicles as well as reliable, fast Ethernet. The new interfaces require only minimal space and are easy to install. The portfolio offers a broad range of solutions, from IP20 connectors for the control cabinet, through to protection class IP65 and all the way to contact inserts for interference-proof data transmission (shielding). The new plastic connectors reduce the dimensions of the previously smallest rectangular connector in the industry sector, Han® 3A, by 30%. The system is modular as it uses eight different contact inserts (each in versions for pin and socket), which are used for transmitting data, signals or power. In addition, there are plastic housings, locking mechanisms, mounting frames, cable adapters and strain reliefs, which are equipped with different coloured elements for error-free coding.

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transmission even in environments subject to heavy-duty stresses and loads. For connector use, this means the transmission of data and signals must be protected effectively against electrical and magnetic interference. The Han® 1A is particularly well-suited for such applications since it offers inserts which, in addition to Han® D contacts and PE, have a double slot for a shielding plate. This enables the protected transmission of signals and power up to a maximum of 10 A/400 V. Han® 1A: Features for the railway sector The Han® 1A is particularly suitable for supplying power to door drives and entry systems. Adapters and contact inserts for M12, D-coded, and M12 X-coded, are also available to ensure trouble-free data transmission in rail vehicles. M12 D-coded enables shielded data transmission to Cat. 5, while M12 X-coded enables transmission to Cat. 6A. Due to its modularity and the large variety of inserts, the Han® 1A is suitable wherever small drives, sensors and devices are required. In traffic engineering, this could be feeding door drives and entry systems, lighting, headlights, loudspeakers, screens, scoreboards, warning and alarm lights, push buttons, wipers or beepers. The HARTING Technology Group has supported the rail sector for years, and the company’s extensive portfolio of products and solutions will be on show at Railtex at the NEC, Birmingham, from May 13th to May 16th. Visit Stand E65 (next to the Seminar Theatre) to find out more. Han® 1A advantages at a glance: • •

•

Compliance with relevant railway standards

•

Railway standards require that protectors provide trouble-free

•

Space savings of up to 30%: Compact connector for traffic engineering Versatile deployment: Transmission of data, signals and power with up to 12 contacts High flexibility: Modular system of inserts and accessories for indoor and outdoor applications (IP20/IP65) Reduced installation time: Fast connection set-up with snap-in technology, no screws required Cost reduction: Lighter connectors and shorter installation times.

Corrosive environments. Costly blowdowns. Hidden costs. Don’t let your efficiency evaporate.

This is why level matters. Steam production is responsible for up to 60% of your total energy consumption. Which means any inefficiency can cost you a small fortune. That’s why Magnetrol® matters. We’ll help you identify hidden costs, improve production and reduce downtime. And we have the broadest portfolio of level instruments to optimize your entire steam generation and condensate recovery process. That’s critical. Because at your plant, level matters.

Download the Steam Generation Optimization Kit at steamgen.magnetrol.com

June 2019



ENGINEERING UPDATE

CHROME PIN INCREASES LIFE OF ROLLER CHAIN CP Chain, which offers an increased wear life of five times that of standard Roller chain, is now available ex-stock from Donghua.

onghua Limited is the UK arm of the Hangzhou Donghua Chain Group of Companies which produces in excess of 30 million tonnes of chain per year. Since we established a UK office and distribution centre in the West Midlands in 2009, we have continued to broaden the range of chain available direct to the UK market. From June, we will introduce another new chain to the UK – Chromised Pin (CP) Chain. Bob Wellsbury, managing director of Donghua Limited, explains: “CP Chain is a Roller Chain that is designed with a Chrome pin as well as a solid bush. Adding a chrome surface coating to the pin results in a super-hard pin which extends the

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wear life of the chain by up to five times that of standard Roller chain. With a 1100 Vi surface hardness, CP Chain is ideal for high wear applications where there is dusty and dirty conditions and the chain needs to work hard.” Pins used in Donghua Roller chain are made to exact specifications to deliver high strength whilst the bushes are designed to achieve high wear resistance. Bob added: “Donghua chain was used in the UK under well-known western brand names for over 20 years before I established the UK company. The Donghua Chain Group produce an extensive range of chain which it distributes worldwide and, since 2009, I have been extending the product range that is

available direct in the UK. Our move to larger premises in 2017 increased the warehouse space to 25,000 square feet enabling us to carry more stock, add further unique products to our UK portfolio as well as extend our technical workshop facilities for Universal Attachment Chain and Bespoke Chain and develop our Testing Laboratory facilities.” Products recently added to the UK stockholding include Pintle Chain, Polymer Chain and pilot bore & taper bore Sprockets and new Chain accessories include H1 Food Lubrication and Hot Wax lubrication. The new CP Chain is available in O8B to 16B, ANSI 40 to ANSI 80, simplex and duplex. For more information email sales@donghua.co.uk or call 01902 866 200 Find your nearest stockist at https://www.donghua.co.uk/locate-a-supplier

June 2019



ENGINEERING UPDATE

Dixon Quick Release Couplings Quick release couplings from Dixon comprises of a full range of interchange couplings for both hydraulic and pneumatic applications, engineered to the highest specification in order to flawlessly fit existing hoses and couplings. The range of manual quick release couplings is ideal for applications where full and smooth flow paths need to be maintained. Dixon specialise in the bespoke design of speciality couplings to meet the requirements of our customer including miniature and high pressure automatic connect couplings.

contamination, wasted time identifying connections and equipment damage caused by incorrect connections. The HT-Series Correct Connect™ colour bands provide a solution by helping to easily identify seals, materials or sizes for an application and helps with preventative maintenance schedules.

Dixon range head to dixoneurope. co.uk or ask us for our Quick Couplings brochure today by contacting our customer sales department on 01772 323529

A wide selection of materials including Steel, Aluminium, Brass, 316 & 303 Stainless Steel are available; thread configurations including BSP & NPT and body sizes ranging from 1/8” through to 2” ensure compatibility in a variety of installations.

Dixon also offer Dry Disconnect and Safety Breakaway Couplings and Adapters; to find out more about the

T: +44 (0) 1772 323529

Contact Gill Platt @ Dixon Group Europe Ltd

E: marketing@dixoneurope.co.uk

New to the range are our Correct Connect™ colour coded ISO 16028 Interchange HT Series couplings ideally suited for overcoming the challenges associated with product cross

QUICK RELEASE COUPINGS FREE ge han Interc P AP ble Availa

01772 323 529 • dixoneurope.co.uk • sales@dixoneurope.co.uk

The Dixon Family of Quick Release Couplings offers complete Interchanges to all major manufacturers • Sizes from 1/8” to 21/2” • Full Interchange Guide Available

• C U S TO MER SERVIC E • IN N O VAT I O N • M A N U FA C T U R I N G • Q U A L I T Y • TE C H N I C A L E X P E RTI S E • U N C O M MO N E X C E L L E N C E • D E S I G N • C U S TO ME R S E RV I CE • I NNO VAT I ON

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June 2019

Overcoming Torsional Vibration In The Drive Train Vibration can be present in any drive train, whether it is the low level naturally occurring type produced from combustion engines or electric motors, as a result of their speed and number of cylinders or stator poles, or being induced as a result of other factors. Either way, vibration if left unchecked, can be the root cause of pre-mature wear or even catastrophic failure within a drive train. In this article, David Proud General Manager of Reich Drive Systems UK explains how to overcome the potentially damaging effects of vibration using drive couplings with a high torsional flexibility Many drive train problems encountered with rotating or reciprocating equipment can usually be traced back to some form of vibration being generated by whilst in operation. There are many factors that can influence the type and severity of the vibrations being produced. Some may relate to equipment moving slightly over time, out of balance items, poor alignment between the different drive train elements during installation, or instances where the vibrations occur as a result of the natural characteristics of the engine or motor. The naturally occurring vibrations from combustion engines or electric motors are somewhat predictable, usually low level, and the effects can often be minimised to a large extent by giving detailed consideration to the way the items are mounted or isolated. However, there may be instances where this has not been possible, or where particular operating conditions or a specific configuration causes vibration to be intensified. For example, within a diesel engine, the number of cylinders, their firing order and speed of operation induces torque pulses, adding to the normal torque being transmitted through the drive train. These torque pulses pass through the drive train in the form of torsional vibrations, which are often much more difficult to identify, as they do not exhibit the same visible characteristics as vibrations caused for example, as a result of a misalignment issue.

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Torque pulses also add a twisting effect on the drive train and the various elements react in the same manner as a spring might, by releasing the energy generated by the initial twisting motion â&#x20AC;&#x201C; but in the opposite direction. The rate at which this happens is determined by the stiffness of the different elements in the drive train, which in turn determines the frequency of the system. The effects of the excitation introduced to the driven system by the engine will also vary depending upon the engine RPM. Where this frequency matches the natural frequency of the system, resonance will occur. In normal use, engine RPM varies between idle and operating speeds. As it does so, it can pass through any critical areas without issue, providing the transition is achieved quickly. If however, if the engine RPM remains in the critical region for long periods, whether this is at idle or at usual operating speeds, problems resulting from torsional vibration will occur. To avoid these issues, a detailed torsional vibration review should be undertaken, and calculations made, which will allow the selection of a drive coupling suitable for the specific application Drive couplings are much more than just a physical connection between drive elements. They protect the drive train through their ability to accommodate mechanical discrepancies, such as axial, angular or radial misalignment and also mitigate other factors such as shock loads, starting frequencies, temperature variation, environmental

June 2019

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conditions, and of course vibration. Selecting a drive coupling which has the correct torsional stiffness characteristics is the first step to ensuring that vibration does not become the prime cause of failure. As part of a comprehensive range, Reichâ&#x20AC;&#x2122;s Arcusaflex coupling has been designed to absorb high levels of torsional vibration and shock loading, protecting drive trains against overload conditions. This highly flexible flywheel coupling provides a torsionally soft connection between the internal combustion engine and a driven machine. The highly flexible torque transmission characteristics are achieved using a discshaped rubber element that is subjected to a torsional load and enables both, the absorption of high torsional vibrations together with the compensation of major misalignments. The inside diameter of the rubber disc element is vulcanised directly to a taper hub or bolton sleeve. The toothed profile on the circumference of the element provides a virtually backlash-free, positive plug-in connection to the coupling flange. Shaft-to-shaft connections where required, can be achieved by Arcusaflex shaft couplings consisting of flywheel couplings of the standard design, equipped with a second hub. The process of coupling selection for any application should always be given detailed consideration, to take into

account all of the factors which the coupling is likely to encounter in service. Discussing the application with a reputable coupling manufacturer, and providing them with the information needed to undertake a torsional analysis, will ensure that the recommended coupling will be capable of accommodating the natural frequencies, whilst at the same time reducing any effects from torsional vibration. Engineers who have experienced pre-mature failure of existing coupling types should also consider whether excessive torsional vibration has played a part in that failure, and take steps to ensure that any new coupling has been selected following a torsional analysis of the application. With a history spanning over 70 years, REICHKUPPLUNGEN has built up unrivalled expertise in the design and manufacture of drive couplings for use across a wide range of industries and applications. The company has earned an enviable reputation not only for the quality and performance of their product range, but also for their ability to provide application and customer specific solutions through the companyâ&#x20AC;&#x2122;s D2C (Design to Customer) philosophy.

www.reich-uk.com

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June 2019



ENGINEERING UPDATE

Kennametal introduces its Mill 4-12KT, the next generation of tangential shoulder milling New tangential shoulder mill features an innovative triangular-shaped margin design providing cutting edges with exceptional strength

ennametal today announced its new Mill 4-12 KT , the next generation of tangential shoulder mills, producing high quality floor surface finishes for nearly all steel and cast iron applications. “The Mill 4-12 KT uses15% lower cutting forces, an important consideration with today’s lighter duty, 40-taper machine tools,” said Tim Marshall, Senior Global Product Manager. “That allows customers to feed faster without putting additional stress on the spindle. And in long overhang situations or where the part fixturing is less than optimal, lower forces equate to less chatter, reduced edge chipping, and smoother surface finishes.” Mill 4-12 KT has tangentially mounted inserts with four cutting edges per insert for reduced tooling costs. Seven corner radii from 0.016" (0.4 mm) to 0.122" (3.1 mm) are available, along with coolantthrough, medium and coarse pitch cutter bodies 2" (50mm) to 8" (200mm) in diameter. With an axial depth of cut range from 0.019" to 0.472" (0.5 to 12mm), Mill 4-12 KT covers most shoulder milling applications. Multiple factors contribute to significant performance increases, even in aggressive cutting conditions: The tangential, “on-edge” insert design also allows the insert to take advantage of the strength of the carbide thickness more so than radially mounted inserts found on traditional milling cutters.

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Mill 4-12 KT has tangentially mounted inserts with four cutting edges per insert for reduced tooling costs

The innovative triangular-shaped margin provides cutting edges with exceptional strength.

Mill 4-12 KT cutter bodies are available in medium and coarse pitch.

A shallow pocket design, allows the core size of the cutter body to be very robust. The axial and radial seating surface designs provide exceptional stability.

The Mill 4-12 KT is the perfect complement to Kennametal’s existing shoulder milling portfolio. This includes the Mill 4-11 and Mill 4-15, cutters known for their ability to generate shoulders with high quality wall surface finishes.

TR Fastenings, international specialist in the design, engineering, manufacture and distribution of high quality industrial and Cat C fastenings principally to major global assembly industries.

Security Fasteners TR Fastenings specialise in a range of security products, including screws, nuts and installation tooling. These items are ideal for protecting valuable equipment or ensuring products are tamper-proof. Machine Screws I Self Tapping Screws I Wood Screws I Self Drilling Screws I Nuts I Drivers

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Browse the full range in our new Security Fastener Handbook by scanning here: View our installation videos for step by step guides here:

June 2019



ENGINEERING UPDATE

Rapidly Develop Touchscreen Process Control and User Interfaces with PanelPilotACE Lascar’s PanelPilotACE is a unique industrial control display platform ideal for the rapid development of touchscreen automation and user interfaces - without writing code. There’s no need to start from scratch, instead develop your application using Lascar’s free Design Studio software which provides powerful, easy to use drag and drop tools to build the complex functionality you need. Forget months of programming and hardware headaches, get a development edge with PanelPilotACE and deliver your project on time! PanelPilotACE has two display sizes, both competitively priced, with the 4.3” (SGD 43-A) at £179.95 ex VAT and 7” (SGD 70-A) at £299.95 ex VAT. These feature highresolution capacitive touch screens, four 16-bit bi-polar analogue inputs, eight digital input/output pins, two alarm outputs, four PWM outputs, RS232 comms, RS485 and Modbus comms (requires add-on board for SGD 43-A), CAN bus (SGD 70-A only, requires add-on board) and FTP transfer of logged data via wired Ethernet (SGD 70-A only). These are extremely capable units for the price point, with discounts available on volume purchases. Free to download for evaluation, the PanelPilot Design Studio software offers a wealth of functionality for building multi-page, intelligent display interfaces, allowing you to add background images, text elements, analogue and digital style meters, touch screen navigation, complex logic statements, serial communications, data logging, trend graphs and maths functionality. The Design Studio ‘Maths Builder’ provides powerful tools for performing, with a full range of mathematical operators available, from simple addition and multiplication, to exponential and trigonometric functions. These functions can be applied to most properties and variables within an application, such as calculating power from two analogue inputs. PanelPilotACE offers data logging capabilities, supporting

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high-resolution analogue and digital logging together with fully customisable on-screen graphing. You can monitor up to four 16-bit analogue inputs at any time with each data set holding over 1 million individual readings and sample rates from 5 seconds up being supported. The software includes an emulator, so you can design and test your interface for free before buying any hardware. PanelPilotACE development kits that include a development board for testing all the input/output functionality along with the display are also available. The PanelPilotACE University on the Lascar website provides video tutorials and shares templates and graphics for you to use in your display project. Alternatively, we offer a “one-stop” Custom Design service where our experts can build your display project for you. Download the PanelPilotACE Design Studio Software for free to try before you buy Lascar Electronics | 01794 884567 | sales@lascar.co.uk www.PanelPilot.Online/EngineeringUpdate

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June 2019



ENGINEERING UPDATE

TOUCHPATH LAUNCHES NEW WAREHOUSE MANAGEMENT SYSTEM

New ‘TouchWMS’ features help companies optimise shift performance and productivity International supply chain solutions provider TouchPath (www.touchpath. com) is launching the latest version of its ‘TouchWMS’ warehouse management system, which includes a number of new features. The TouchWMS power-picking Control Centre, which delivers proven productivity increases of 50% is now supported by real time graphical KPI screens that display the progress and performance of individual pickers against the picks that have been assigned to them: a bar chart shows how many picks have been assigned and how many remain. Other KPI screens show overall picking and put-away progress. A series of sequential tasks can now be assigned to each individual at the beginning of each shift (for example picking in one zone followed by put-aways in another followed by cycle counting). When a warehouse worker logs onto the system via a handheld, mobile terminal or desktop they are automatically presented with instructions for the tasks that have been assigned to them. The system tracks every team member’s activity throughout their shift, in real time while the system’s KPI screens allow supervisors to spot bottlenecks and reallocate resources across zones to optimise shift performance. With this latest version of TouchWMS they can now

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analyse productivity across an entire shift, as well as compare individual productivity levels. The cycle count (or perpetual inventory, PI) has now been enhanced to enable the pre-definition of a variance value above which a regular warehouse supervisor is not permitted to post adjustments without senior management sign-off. The system now also provides full analysis of cycle count progress annually to ensure that audit targets are reached. TouchWMS allows warehouse zoning, location and item storage types to be predefined, is RFID-enabled for greater speed and accuracy and allows picking routes to be optimised to speed customer order fulfilment. Goods are registered on arrival at the warehouse and are visible in the system before passing Quality Inspection if required, after which they are placed in inventory. Items can be tracked internally and throughout the supply chain, for full traceability: all inventory movements are automatically logged including order and document numbers to identify shipments and deliveries. Enquiries allow the user to track serial and batch numbers, determine the exact location of specific items in the warehouse and get a clear view of their inventory. TouchWMS supports the full range of warehouse processes, from goods receipt

and guided put-away to task management, stock allocation to orders with automatic replenishment of pick locations if required, single-order pick and pack, multi-zone wave picking, sortation and pack or bulk pick to pallet with pallet consolidation. Other processes supported by the system include load management, the generation of multi-lingual dispatch notes, and shipping pallet labels, plus integration with most carriers, who receive automated end-of-day consignment details. TouchWMS can be integrated with all mainstream ERP and other supply chain and legacy systems or run as a complete stand-alone solution. It is multi-lingual for both user interface and shipping documentation and currently supports 12 languages. TouchPath systems’ technology captures more supply chain information for better business performance and faster ROI. Its unique custom-off-the-shelf (COTS) systems use building blocks that allow TouchPath software to be fully tailored with no limits, in line with user-defined business rules and processes, at a lower price and with faster deployment, according to the company. TouchPath has operations in the UK (Halifax HX1 5ER) and the USA (High Point, NC 27265).

Service Solutions Renold Gears offers fast gearbox refurbishment of all makes and types of industrial gearboxes. All gearboxes are returned in an â&#x20AC;&#x2DC;as newâ&#x20AC;&#x2122; condition with a full 12-month warranty. We also provide a comprehensive range of services including holding critical spares, training, commissioning support, together with oil condition, temperature and vibration monitoring.

+44 (0) 1706 751 000 gears.sales@renold.com www.renold.com

June 2019

Power Continuity is a must for Automation Power Continuity will eliminate all power dips and spikes forever allowing your robotic automation to operate 24/7 without disruption A Hot summer with little or no wind would create the setting for the ’Perfect Storm’ where the delicate balance between available power and capacity, turns into an harmonic nightmare for our Gird supplies. Commonly the effect is spikes and brown outs caused by the increasing reliance on Alternative Energy sources ( Wind & Solar ) which have inherent harmonic distortion issues .The greater the percentage of such Alternative Energy the Grid produces, the more vulnerability to Spikes and brownouts. Power Continuity engineers provide a site survey to confirm the power status of your existing Production facility that will expose whether it is robust enough to withstand spasmodic power disruption or even Gird Failure. Prevention is better than cure. Failure isn’t an option, but it can happen. Why live with Power Issues when Power Continuity can eliminate them? Where to start:• There are a number of obvious points of concern. • Is your site struggling to cope with the excessive demand. • LV breakers tripping out due to a power surge • HV Breakers tripping out due to faults up stream. • Aged UPS or wrongly spec’d UPS can let spikes or brownouts through. • Lack of maintenance or any maintenance records. • NO provision to ride out power dips or spikes. • Installation of seamless automatic power protection systems Power Continuity can ensure the power into your production facility is resilient by designing & installing dual power protection supplies supporting

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as a minimum an A Feed & B Feed. That’s just the start of the journey.

Power Continuity can prevent your failure dips before they happen

Power Continuity will provide the design for N+N Uninterruptible Power supported by rapid start Synchornised Generators, with forever-capacity fuel tanks. Hope is NO substitute for Power Continuity 24/7.

Take a few moments to check ‘is my company at risk” test, click here.

Had enough of outages. Call Power Continuity! Click Here Power Cuts? Yes they do & will happen especially during the HOT summer months. How? Transformers can trip out, overheat, die with age or the most common, digger damage, & Breaker failure. Sub Stations upstream trip out.

Power Continuity have decades of installations across the UK , all operating 24/7 power protecting the backbone of UK infrastructure. We do the same for you. When Power Continuity is your site main contractor then we ensure the best practice at all times to deliver within budget and ahead of Schedule. We install everything ourselves in house. We even witness test the compete system in front of you, with a PowerContinuity engineer by your side.

We Design. We build. We Install. No If’s or Buts. We Monitor and maintain power continuity 24/7

We are Power Continuity Call us on 0845 055 8455 www.powercontinuity.co.uk

June 2019

Combining tradition and technology to secure heritage and brand The relationship between UK manufacturing and the uptake of robotics and automation remains an ongoing and sometimes sensitive topic for discussion. Whilst there are many manufacturers who readily embrace the opportunities that automation can bring, there are others, especially those producing traditional hand crafted items, who feel they must reconcile the benefits of technology, with what may be a heritage spanning many decades and any potential impact on their brand. The introduction of 4 automated production cells by Wade Ceramics clearly demonstrates the concept of combining technology with traditional manufacturing processes to deliver increased output, improved quality and consistency. Designed and manufactured by Wood Automation & Control’s Systems Division, the automated cells not only deliver the anticipated results, but also reinforce the meticulous standards for which Wade have become renowned. As one of a number of thriving ceramics companies in Stoke, Wade Ceramics has an established record of change, including streamlining its product range in 2000 to focus on luxury decanters, and opening a new factory and investing in new machines and kilns in 2010. Increasing production demands were the catalyst to further improve production processes through the introduction of automation. Wade Ceramics operates across two production sites in Stoke, with the Bessemer Drive facility specialising in the production of flagon containers supplied to several premium-brand alcoholic spirits manufacturers. The production here is made up of a combination of refillable and non-refillable versions and both standard and sometimes intricate bespoke designs. As one might expect of a hand-crafted product, production of the flagons is an intricate process. Each flagon passes through multiple stages, beginning with casting in clay through to decoration and inspection of the final glazed product prior to packaging and despatch. Each flagon is fired twice in the company’s two kilns; initially following the casting and fettling stage and then again once the coloured glazing that gives each The introduction of the 4 automated production cells, designed and manufactured by Wood Automation & Control’s Systems Division, clearly demonstrates the concept of combining technology with traditional manufacturing processes to deliver increased output, improved quality and consistency

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flagon its distinctive finish has been applied. At every stage, each container needs to be produced to the tightest possible tolerances to ensure it meets the company’s strict quality standards. As each flagon takes between 16 to 20 hours to produce, it is essential to minimise the risk of any problems occurring during the various manufacturing processes.

Quality and consistency driven by automation There were a number of objectives identified by Wade Ceramics when preparing the case for automation, and discussing possible solutions. These included introducing technology to maintain the highest levels of consistency and eliminate potential quality issues. Once such example was the positioning of individual flagons prior to the first kiln firing. Flagons situated too closely together risked becoming fused during the firing process, resulting in them being scrapped. The introduction of two robot cells incorporating ABB robots situated at the in-feed to the first kiln ensured repeatable product positioning in this area. Each cell includes a machine vision system which

locates the flagon as it is presented to the in-feed area of the kiln, and ensures it is subsequently placed correctly by the robot to prevent it fusing together with other flagons during firing. Inconsistencies in the glazing around the base of the flagons were also issues where the company turned to automation as the solution. The glaze, which is applied as a powder coating, gives each container its distinctive colour. Wade Ceramics’ high product quality standards demand that the glaze must be evenly applied over the complete surface of every flagon. Previously, imprecise wiping following the application of the glazing powder caused some of the powder to be removed from the bottom of the flagons, resulting in an uneven finish. The solution developed by Wood Automation & Control’s Systems Division was a robotic cell incorporating an automated ‘foot wiping’ system to ensure precise and consistent wiping of each flagon base without removing the glazing powder. This cell also uses an ABB robot, which picks up each flagon and presents it to a rotating cleaning mat for wiping, before passing it to the conveyor of the second kiln.

The cells use ABB robots to handle and process products through the various production stages

June 2019 Simon Miles, Applications and Proposals Manager – Wood Automation & Control’s Systems Division, explained the challenges that had to be overcome when developing the solution to this application. “One of the biggest hurdles in developing the foot wiping cell was the need for the robot to be able to keep pace with the powder glazing machine. To keep everything perfectly synchronised, we needed to complete foot wiping process within a target Takt time of just 16 seconds.” To achieve this meant not only getting the products to the robot from the glazing machine, but also making sure that the flagons were properly tracked when they arrived at the robot and when they were subsequently arranged on the Kiln batts, located on the out-feed conveyor to the second kiln. “Getting the process exactly right involved extensive testing to arrive at the optimum configuration that would allow the cell to operate at the maximum speed,” says Miles. “To ensure that the robot stays within the target Takt time, the system tracks the position of the flagons as they enter the foot wiping cell, allowing the robot to pick up each flagon squarely. Similarly, once the flagon base has been wiped, the robot places the finished unit in a specific location on the kiln batt on the out-feed conveyor, enabling it to get into position to accept the next flagon as quickly as possible.”

A further complication was the capability of the cell to include an extra step required for non-refillable flagon variants. This required the robot to remove a temporary plastic cap shield from the top of the flagon as it exited the glazing machine and prior to placement onto the kiln batt. Thorough testing by Wood Automation & Control’s Systems Division, together with the accuracy and speed of the robot, means that both the foot wiping process and removal of the plastic caps for non-refillable flagons can be comfortably performed within the target cycle time. A further benefit, as a result of the improvements delivered by the robotic foot-wiping process, is that the flagon reject rate has now fallen to just 1.5 per cent.

Extensive testing ensures smooth installation As a production operation running 24 hours per day and 7 days a week, Wade Ceramics needed to ensure that the installation of the new automated cells would not inhibit production. To minimise the potential for any disruption, Wood Automation & Control’s Systems Division built all four cells at their Northampton site. Working in close cooperation with Wade Ceramics’ engineering team, the systems were extensively tested to ensure they would be ready for operation as quickly as possible once installed at the company’s Bessemer Drive site.

“The complexity of this project, coupled with the need to get the automated system up and running as quickly as possible once it was installed, meant carrying out thorough testing to ensure any initial problems were ironed out,” explains Simon Miles. “As a result, we were able to install everything on site within a brief two week shutdown with production being ramped up as the system became fully operational.” The company’s ability to maintain a high production output without compromising the quality of its products has delivered a key advantage over its competitors, which has been greatly enhanced by its use of automation. “The methods that we use, together with the design of our production process and the improved performance achieved through our use of automation, enables us to produce around 3.5 million flagons per year, more than any of our competitors, whilst maintaining the very highest standards of product quality,” explains Stuart Shickell. “We now have the best of both worlds, using automation and robots to boost our efficiency whilst maintaining the traditional hand-crafted look and feel of our products that is core to our reputation.”

www.the-atg.com

Automated Systems UK Wood is a leading global supplier of bespoke manufacturing and control solutions for industrial automation. Our solutions drive the production lines and supply chains of many leading companies, allowing our clients to: • • • • • •

Reduce investment risk Increase productivity Improve resource utilisation Optimise stock levels Reduce energy consumption Build competitive advantage

Services: • • • • • • • • •

Medical Technology Ireland 25-26 September 2019 PPMA Total Show 1-3 October 2019 Robotics & Automation 29-30 October 2019 Wood Automated Systems UK Tenter Road Moulton Park Industrial Estate Northampton NN3 6AX Tim.bednall@woodplc.com

Simulation Proof - of - principle Bespoke turnkey system design Robotics and vision integration CE marking Manufacturing Commissioning Installation After sales service and support

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June 2019



ENGINEERING UPDATE

Is any memory card suitable for industrial applications? Since their introduction in the 1990s, memory cards have remained among the most successful, trusted and low-cost storage solutions available. Consumer memory cards are cheap and commonly used to store images, videos, audio and text in portable devices such as cameras and smartphones. However, they are often also deployed for industrial applications that they are just not designed for. Industrial-grade memory cards incorporate tough, reliable and highquality components that can perform reliably over long periods of time to ensure maximum availability, minimal downtime and better return on investment. Industrial requirements are vastly different from personal or

consumer use, being often not only mission critical but also safety and life critical. As more industrial systems become autonomous or require little to no human intervention, the efficiency of data storage and the timely access, delivery and analysis of information have never been more crucial. Basing a decision on card capacity is a common mistake. For instance, believing that a “32GB card will be plenty of storage for our application”. SD cards have different modes, such as High Capacity (HD) and eXtended Capacity (XC), and may not work in every application, so it’s worth checking card compatibility from the outset. Ideally, customers in the industrial sector should make purchasing

decisions based on the total cost of a solution rather than immediate, shortterm costs. Total cost of ownership may seem trivial for an SD or microSD card but when we factor in downtime of kit, engineering resource, logistics and human resource, not to mention customer dissatisfaction and any knockon effects, it really is important to make the right decision from the design stage. So, how do you choose the right storage solution for industrial applications? Key considerations include (but are not limited to) reliability, endurance, data integrity, capacity, speed and compatibility. It may sound confusing, but by understanding what the cards are being used for and how much data is being written to them, the right solution can be found. An additional advantage of industrial-grade cards is that they are highly customisable and can be tweaked specifically for your application, for example to prolong card lifespan or use less power. Expertise is on hand to guide you through the different types of memory cards, the pros and cons of each to ensure the right first time solution. www.simms.co.uk sales@simms.co.uk 01622 852800

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Increase your competitive and operational advantage through our quality, precision optical components alongside almost 30 years of customer service. Custom Optical Solutions

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www.knightoptical.com info@knightoptical.com (UK & ROW) +44 1622 859 444 (USA & Canada) +1 401 583 7846

Quality Assurance

As a customer of Knight Optical, you will benefit from exceptional commitment to quality in all respects. Your individual specifications are vitally important to us, which is precisely why pre-despatch testing is rigorous to the highest degree. Our onsite quality assurance and metrology departments take personal responsibility for ensuring each and every component that leaves our premises does so in strict accordance with customer requirements.

Partnerships and Support

Building partnerships with our customers is a key priority for Knight Optical. Our multilingual sales and technical support specialists are at your service at all times. We are committed to doing all we can to support your objectives and to understanding not just your requirements, but your reasoning behind them.

Designed for Optical Innovation, Engineered to Last

June 2019



ENGINEERING UPDATE

Low cost, high efficiency evaporative and free cooling for IT and industrial facilities. Let EcoCooling sweat the hard stuff so you don’t have to. Cool your factory and data centre with the same low-cost solution! Pioneers in the design and manufacturing of energy efficient, natural cooling technology, EcoCooling products provide tried and tested solutions for the cooling of factories and data centres, at a fraction of the capital and operational costs of refrigeration-based alternatives. Direct fresh air and evaporative cooling solutions are simple, safe and natural. Proven technologies that provide a 90% reduction in operational cooling costs when compared to A/C and guaranteeing temperatures below 23C in facilities all year round.

ROI for data and comms Systems From 5kW to 5MW, our modular cooling systems can be used for all cases. Depending on the installation and operation of our control systems, return on investment can be achieved in under a year. Below are operating cost calculations for our external ECP product. For a free site visit and exact cost calculations for your project and location please contact us directly on 01284 810586.

Running Costs and Performance (ECP standard CREC system) Type of System

EcoCooling

Coefficient of Performance

2.0

27.0

Total Electricity Use (kW)

3.7

Effect on PUE

0.5

0.04

Annual Usage (IT Environment) = 8760 hours

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Operating Costs

EcoCooling

Savings

Electricity Use (kW h)

438,000

32,412

405,588

Electricity Cost (£)

43,800

3,241

40,599

Water Use (m3)

145

Water Cost (£)

145

Total Cost

£43,000

£3,386

£40.414

CO2 Impact

235 tonnes

17 tonnes

218 tonnes

EcoCooling’s 17 years’ continuing expertise in warehouse and industrial space cooling twinned with over 250 telecommunications and data centre installations see them ideally positioned to meet the energy based challenges of Industry 4.0; sensor implementation, automation and the increasing necessity for data and communications systems. EcoCooling provide an all-in one solution for efficient space cooling and dedicated IT equipment cooling in a range of flexible configurations, optimised for your individual facility and supply temperature needs. External EcoCoolers can be combined with Modular and scalable products offer efficient fresh air-cooling solutions for facilities of all sizes, whether that be small sector server rooms, modular edge data centres or standard colocation and cloud facilities. The EcoCooling range has been designed to cover all bases with minimum complexity and impact on day to day running of your facility. The modular, Plug & Play CloudCooler® range is UK manufactured and designed for rapid deployment to IT facilities as all-in-one standalone units. Installation is carried out by approved installers with minimal disruption and systems are straightforward and simple to use for operators. Maintenance is perfectly catered for too. The inherent simplicity means the systems are reliable but should spares and support be needed, both are kept in stock and available directly from our site in Bury St Edmunds, Suffolk. A free site visit and quotation make it easy to see the projected cost savings for your facility with minimal effort on your part. Remote deployment and monitoring for your system continue this hands-off approach for clients. Letting EcoCooling take the strain of saving money and lowering your carbon emissions. Clients include Talk Talk, Co-op, BT, Cambridge University and more.

ecocooling.co.uk | cloudcooler.co.uk sales@ecocooling.co.uk | 01284 810586

June 2019

SAVE UP TO 90% ON YOUR COOLING COSTS

ECOCOOLING: THE EVAPORATIVE AND FREE COOLING SPECIALISTS Why EcoCooling?

UK wide network of installers ready to quote today!

-Internal and external ranges -New build and retrofit -Energy efficient natural cooling -Solutions for public sector, data centre and industrial spaces -No harmful refrigerants -Made in the UK and part of a UK Installation Network -Maximum reliability and complimentary support 3500 UK Installations including Cummins Diesel, Carbogen and Hydraforce

sales@ecocooling.co.uk | T: 01284 810586 www.ecocooling.co.uk | www.cloudcooler.co.uk

EcoCooling FRESH AIR COOLING

PIEZORESISTIVE OEM PRESSURE

TRANSMITTER 4 LD…9LD WITH I²C INTERFACE

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June 2019



ENGINEERING UPDATE

Explosion Safety

Q-Flap RX™ explosion isolation flap valve Explosion Isolation is absolutely necessary for a comprehensive safety concept. Without explosion isolation, the safety concept is not just insufficient, it also represents wasted money for operators, because: Throughout the industry, vessels, silos and other parts are often connected to each other by pipelines. If a dust explosion occurs in one equipement, this also enhances the risk of flames and pressure propagation to other parts of the plant. Pre-compression and flame jet ignition exacerbate the explosion severity in interconnected vessels. The result is a series of secondary explosions that may cause even more catastrophic damage. An explosion isolation system prevents deflagrations from propagating and thus minimises the effects of an explosion. Adjoining plant components are optimally protected. A distinction is made between active and passive systems: Passive isolation systems such as explosion isolation flap valves make use of the overpressure of the explosion for their operating principle:

explosion isolation flap valves are typically only installed in nominal pipe sizes up to DN 400, especially on decentralised aspiration systems of the food industry, for example, larger nominal pipe sizes between DN 450 and DN 710 for central dust extractors can quickly become necessary. In the grain, wood and heavy industry, nominal pipe sizes from DN 800 to DN 1250 are mainly applied.

Passive explosion isolation - this is how it works

Optimum fulfilment of requirements instead of one-for-all

Passive explosion isolation systems respond purely mechanically to the propagation of pressure through its constructive design. Under normal operation, an explosion valve in a pipeline is kept open by the available flow. When an explosion occurs, the valve is closed by the spreading of the pressure front, thus effectively preventing the pressure and the flames from propagating any further.

The standard EN 16447 defines the general requirements for explosion isolation flap valves. Like any standard, it can only provide general recommendations and specifications, but cannot address every application in detail.

One function, different requirements Even if the function of an explosion isolation flap valve is size-independent, the requirements for a wide variety of processes and industries vary greatly. While in the pharmaceutical and chemical industries in particular

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Obviously, however, an explosion isolation flap valve DN 250 used in the chemical industry must meet different requirements than its DN 1250 counterpart installed in a grain or wood processing plant. While the first application above all requires a high-quality design, the operators of grain mills or particleboard plants with their characteristic large pipe diameters want safety devices that are as easy to handle as possible.

The Q-Flap RX™ explosion isolation flap valve, a joint development of the explosion safety specialists REMBE (Germany) and RICO (Switzerland), offers three different design versions. Developed on the basis of many decades of experience the two companies have accrued with regard to the different customer requirements, the nominal pipe sizes from DN 140 to DN 710 feature an inspection flap, the largest nominal pipe sizes (up to DN 1250), on the other hand, have a modular design so that maintenance and servicing can be carried out easily and thoroughly. Through the swing ´n slide closing principle integrated into the nominal pipe sizes up to DN 710, the valve blade not only rotates into the closed position, but also slides horizontally into the closed position at the same time. This ensures an even more reliable sealing of the entire cross-section. In addition to the features mentioned above, the Q-Flap RX™ enables high KSt values, flexible installation distances and maximum strengths. www.rembe.de

ENGINEERING PDATE

June 2019

T +49 2961 7405-0 T +44 1234 783366

T +1 704 716 7022 T +39 02 62033057

Your Specialist for

PRESSURE RELIEF SOLUTIONS Consulting. Engineering. Products. Service.

www.rembe.de

Inc.

www.rembe.us

• • • •

Ltd.

www.rembe.co.uk

www.rembe.it

S.r.l.

VDF 70 - 70 lpm

No foaming, cleaner coolant, longer tool life Reduced running costs, low maintenance Element-free, no filter element replacement costs The environmentally friendly one-pass solution

Aeration&Mixing Ltd Sheffield UK T: +44 (0) 1302 215 156

Web: http://www.aerationmixing.co.uk E-mail: enquiries@aerationmixing.co.uk

VDF 1000 – 1,000 lpm

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