INDUSTRIAL MAINTENANCE ENGINEER THE MAGAZINE FOR MRO PROFESSIONALS
TOOLS, EQUIPMENT & PPE ABRASIVES TRAINING
FLUID POWER COMPRESSION JOINT ASSEMBLY
ALSO IN THIS ISSUE: LINEAR PROFILE RAIL SYSTEM REPLACEMENT TOTAL PRODUCTIVE MAINTENANCE INTEGRATED DUST EXTRACTION CMMS SPOTLIGHT AND MUCH MORE
CONTENTS Industrial Maintenance Engineer
November/December 2017 Vol.2 No.4
60 Your chance to become an IME product tester 61 Reader Giveaways 62 Products 64 Using the reader enquiry service
BEARINGS & SEALS SPECIAL REPORTS 8
34 Selecting replacement linear systems
10 Hannover Messe 2018 12 Acoustic solutions
14 Spin-on filters and separators
37 Compression fitting assembly
16 CMMS Spotlight
40 Hose clip selection
19 Total Productive Maintenance
42 Fluid condition monitoring
OILS, LUBRICANTS & GREASES
TOOLS, EQUIPMENT & PPE
23 Lubricant considerations
44 BS EN ISO 6789-2:2017 47 Abrasives training
48 Integrated dust extraction
26 Anti-vibration mounts
50 Getting started with thermography
28 Back to the future
52 Wearable technology
HEALTH & SAFETY
30 Tsubaki completes its G8 series
54 Tools to increase efficiency
58 Head protection in hazardous
32 Quick-Flex couplings
environments NOVEMBER/DECEMBER 2017 IME 1
INDUSTRIAL MAINTENANCE ENGINEER
EDITORIAL STUART DUFF PAUL DAVIES JAMES MOORE
email@example.com GROUP MANAGER OLIVER SHANNON
firstname.lastname@example.org SALES EXECUTIVE STEVEN MARTIN
email@example.com DESIGNER HARRY GWINNELL GROUP PRODUCTION MANAGER CAROL PADGETT PRODUCTION ASSISTANT CLAIRE SWENDELL DISTRIBUTION MANAGER KARL CLARK
HUMAN ENDEAVOUR As with any job that depends on technology in some capacity – it’s a struggle to think of many that don’t – the role of a maintenance engineer has witnessed a great deal of evolution… and a smattering of revolution too. The shift in approach with regard to when and how maintenance should be carried out is probably chief among them, with the two converging strands of IT and OT following close behind. You might be forgiven, in among all the talk of Industrie 4.0 and Industrial IoT, for thinking that the human element has been cast aside – in a ﬁgurative sense, if not a physical one. But when it comes to detailed understanding of products and processes, is there really a viable substitute for human interaction? The 200,000 people who attend Hannover Messe to engage with in excess of 5,000 exhibitors presumably don’t think so. Yes, IT and machinery are among the pillars on which the production facilities of the present and future are built, but human beings are still the bedrock. The theme of the 2018 event, ‘Integrated Industry –
Connect & Collaborate’, serves (to our mind, at least) to reinforce the point. While connectivity and networking are vital elements in the digitalisation of industry, networking on an interpersonal, human level is essential to disseminate knowledge and expertise in how the future path will be mapped out. The advancement of technology has already proven to be of obvious beneﬁt to those working at the MRO sharp end, whether it’s through the use of 3D printing to compensate for the unavailability of discontinued parts or automated data collection to alleviate the burden of time-consuming and potentially error-prone manual processes. Equally crucially, the facilitation of greater supply chain collaboration through cloud data allows all aspects of a maintenance regimen to be catered for in a timely and transparent way. Ultimately, the rise of the machines need not be something to be viewed with a suspicious eye – as long as the human element is not overlooked and remains the cornerstone of the operation.
PUBLISHER BRYAN SHANNON PRINTED BY WYNDEHAM GROUP LTD PUBLISHED BY HAMERVILLE MEDIA GROUP
Regal House, Regal Way, Watford, Herts WD24 4YF. Tel: (01923) 237799 Fax: (01923) 246901 Copyright © 2017
19 Total Productive Maintenance
26 Anti-vibration mounts
INDUSTRIAL MAINTENANCE ENGINEER is a business journal for MRO professionals. It is available free to the trade via leading distributors and specialist outlets throughout the UK.
58 Oscillating multi tools
Head protection in hazardous environments NOVEMBER/DECEMBER 2017 IME 3
NEWS 2018 — THE YEAR OF ENGINEERING The Year of Engineering is a year-long government campaign to support the engineering profession in recruiting the next generation of engineers. Throughout 2018 the campaign will showcase the variety and creativity of modern engineering to improve understanding of what engineers do, aiming to promote the full range of engineering disciplines and job types to young people, their families and teachers. The initiative is looking for “fun and innovative ways” to bring the campaign to life and reach under-represented groups of young people. It is looking for support in order to paint a more positive picture of an exciting industry that makes real improvements to people’s lives. Backed by a range of partners including Shell, Science Museum Group, Royal Academy of Engineering, STEM Learning and The Big Bang Fair, the campaign is also calling on support from industry to: • work with the campaign and other partners to create exciting and impactful initiatives and events; • raise the proﬁle of an organisation as an exciting employer by showcasing the forward thinking work that it is doing; • join ‘open door’ and ambassador programmes to share what you do; • use the Year of Engineering brand to identify your own activity or event under a collective banner; • use the campaign’s communication materials and #YOE to be part of the conversation; • share inspiring stories of engineering careers. For more information follow @YoEgovuk on Twitter.
4 IME NOVEMBER/DECEMBER 2017
NFPC CHRISTMAS TRAINING COURSE OFFER The National Fluid Power Centre has a number of special discounts available on its training courses in the run up to the festive season. For example, NFPC is offering 20% off the current price of its Stage 2 Industrial Hydraulics Course, provided it is taken between 4th-8th December using Code NFPCDEC20%. The course itself will focus on installation, commissioning, testing and fault diagnosis and involves a high degree of ‘hands-on’ practical training to support the further development of the vital skills required to manage and maintain today’s complex systems. Devised for those with experience, the course is designed for Plant Managers, Engineers, Technicians and Craftsmen involved in the maintenance and management of ﬂuid power systems. For engineers working Oﬀshore, NFPC can allocate speciﬁc course time to the Stage 2 Industrial programme to cover speciﬁc Oﬀshore applications and carry out relevant practical tasks. For more information visit www.nfpc.co.uk
TEMPERATURE MEASUREMENT ABB has released a new in-depth handbook explaining how to maximise temperature measurement accuracy in industrial applications. Titled ‘Industrial temperature measurement: Basics and practice’, the handbook provides a detailed explanation of the key areas that users need to consider when implementing and operating temperature measurement technology. The handbook is suitable for both novices and those with more experience in temperature measurement. Written by ABB’s temperature experts, the 320-page book is divided into nine main chapters, covering a variety of topics including the principles of temperature measurement; sensor and transmitter options and how to select them; ensuring accuracy through calibration and veriﬁcation; and the options available for explosive and SIL applications.
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SEMTA SKILLS AWARDS The Semta Skills Awards celebrate the talented individuals and companies that make the advanced manufacturing and engineering sector one of the highest skilled sectors in the UK. Free to enter, submissions can be made in more than one of the eight award
The Royal Academy of Engineering has called for “profession-wide culture change and regular benchmarking of progress” in order to create a truly inclusive culture within the UK engineering profession. The initiative follows the publication of a unique survey of workplace cultures, which shows that inclusion benefits all engineers — but there are some discrepancies between experiences of inclusiveness at work. According to the survey, said to be the ﬁrst to measure workplace culture in engineering, UK engineers are described by their own peers as good at problem solving, safety-conscious, proud, loyal, team-oriented and ﬂexible. However, many engineers describe their culture as friendly but impersonal, with a strong attachment to tradition and oﬀering too little support in relation to career development. Over 7,000 UK engineers responded to the survey. The results are published in a report called Creating cultures where all engineers thrive, which shows that some 77% of those surveyed said they like their job ‘most or all of the time’, and 82% would recommend engineering as a great career choice to family and friends. Only 3% of respondents are planning to leave the profession permanently (for reasons other than retirement) in the next 12 months. Those who took part saw the beneﬁts of working in an inclusive profession, with 80% of those surveyed saying that feeling included at work increased their motivation and 68% saying it increased their overall performance. However, the survey found that gender and ethnicity make a signiﬁcant diﬀerence to how engineers perceive the culture of their profession. For example, being in a minority in engineering gives women and black and minority ethnic (BAME) engineers a consistently diﬀerent perspective on its culture. Male (82%) engineers were signiﬁcantly more likely than their female (43%) colleagues to say their gender is irrelevant to how they are perceived at work. BAME (85%) engineers were more likely than their white (58%) colleagues to report that assumptions are made about them based on their ethnicity or nationality. Loraine Martins MBE FRSA, Director of Diversity and Inclusion, Network Rail, a member of the steering group overseeing the survey, said: “With only 9% of UK engineers being women and only 6% coming from a black, Asian or minority ethnic background, we clearly need to do more to improve diversity in the engineering profession. This will require a signiﬁcant culture change, if our vision of an inclusive profession that is welcoming, respectful and supports career development for everyone, is to be realised.” For more details on the survey, visit www.raeng.org.uk
1. Apprentice of the Year Award (Sponsored by MBDA UK) 2. Higher Apprentice of the Year Award (Sponsored by the Education and Training Foundation) 3. Skills Champion of the Year Award (Sponsored by BAE Systems) 4. Skills Innovation of the Year Award (Sponsored by Siemens) 5. Training Partner of the Year Award (Sponsored by Rolls-Royce) 6. SME Investment in Skills Award (Sponsored by Jaguar Land Rover) 7. Technician of the Year Award (Sponsored by EAL) 8. Diversity in Engineering Award (Supported by Wise) The Semta Skills Awards 2018 will take place on Thursday 1st March 2018 at the Park Plaza Westminster Bridge, London. The event will be hosted by BBC presenter, journalist and engineering advocate Steph McGovern. Visit www.semta.org.uk for more information.
NOVEMBER/DECEMBER 2017 IME 5
EMAIL YOUR NEWS STORIES TO IME@HAMERVILLE.CO.UK
MANUFACTURING BOOST Britain’s manufacturers are enjoying buoyant conditions on the back of export markets going from strength to strength according to a major survey from EEF, the manufacturers’ organisation and accountancy and business advisory firm BDO LLP. According to the EEF/BDO Q3 Manufacturing Outlook survey, manufacturers have taken the continued political upheaval and uncertainty at home in their stride, taking advantage of the upswing in the Eurozone in particular, as well as the synchronised upswing in global trade. This boost in trade has benefitted all sectors, with the boost to confidence about individual firm performance translating into a positive picture for both recruitment and investment intentions in the near term. The latter is being aided by an improvement in profit margins. In contrast to confidence about their company performance, however, the same cannot be said for their outlook for the UK economy where confidence indicators have dropped for the second quarter in succession in response to weak consumer spending and political uncertainty. Moreover, inflationary pressures have not completely subsided, with recent sterling depreciation likely to provide another ripple of price increases in the coming months. Commenting, Ms Lee Hopley, Chief Economist at EEF, said: “Manufacturers appear to have taken the recent political upheaval in their stride and are taking advantage of growing world markets to make hay while the sun shines. This period is likely to be the peak, however, and we are likely to see a more stable picture in the coming months rather than any further significant acceleration. “There is little doubt that Brexit is likely to weigh on sentiment over the next twelve months with uncertainty over the UK’s terms of exit. As such, it is vital the Government sends a signal to industry and investors in the UK and overseas that it is doing everything in its power to get growth of the UK economy back on the agenda. This must include a bold and ambitious cross -government industrial strategy.” Tom Lawton, Partner and Head, BDO Manufacturing, added: “Despite the economic and political uncertainties, manufacturers’ continue to be a force to be reckoned with, delivering a strong performance as well as increasing both investment and employment plans to make the most of the strengthening export opportunities available to them. “However, manufacturers’ confidence about the UK economy has continued to fall for the second quarter running. With growing opportunities around the world, particularly the Eurozone, manufacturers’ need stability and certainty in government policy (including Brexit) to provide the right environment for them to commit to the significant capital and research investment required to support continued growth.” For more information visit www.eef.org.uk
6 IME NOVEMBER/DECEMBER 2017
New research from Dustcontrol UK has found that one in five food industry decision makers admit to recognising dust as an issue – but fail to do anything about it. 23% said it was ‘a big issue, one which we address regularly’, while 21% of respondents said, ‘a massive issue, where we have put certain procedures in place’. The remaining 35% didn’t believe that dust was an issue in their workplace. James Miller, Dustcontrol UK’s General Manager, commented: “The ﬁndings of the study are certainly eye opening. Dust is a prevalent issue in the food industry and to ﬁnd that one in ﬁve key decision makers are aware of potential problems yet don’t address them is concerning. Dust is often underestimated and seen as a nuisance rather than a genuine hazard, when it very much is.”
SHOW OF STRENGTH Why does a new brochure on Loctite Universal Structural Bonders have an image of a freight train on its front cover? The company says it is because it depicts an application that sums up what makes this new technology such an important development. The coupler that connects the engine with the wagons is an assembly bonded with just 3g of Henkel’s new Loctite hybrid adhesive that cured in one hour. This powerful example demonstrates the cure speed, strength and durability of the new range. Two Loctite Universal Structural Bonders are detailed in this new tri-fold publication — the fast and versatile HY 4090 and HY 4080, which is said to be ideal for when the design calls for extra strong impact resistance.
UK MANUFACTURING: THE BIGGER PICTURE
UK MANUF UFACTURING FACTURING 2017/18, THE F FA FACTS
2.6 MILLION EMPL EMPLOYEES
10% % OF UK OUTPUT 44% OF UK EXPORTS T
Both reinforcing and acting as an interesting companion piece to the most recently available IHS Markit/CIPS UK Manufacturing PMI data, EEF and Santander have teamed up to release new ‘facts and ﬁgures’ which illustrate the underlying strength of British manufacturing. Giving a degree of context for the MRO sector, IME considers some of the ﬁndings. British manufacturing continued its climb up the global rankings as growth returned last year. Launching the 2017 manufacturing fact card, data from EEF, the manufacturers’ organisation and Santander shows that Britain is now the 8th largest industrial nation with an annual output now worth $249bn. This sees the country having moved up from 9th place last year (according to United Nations Conference on Trade and Development statistics). In the post-Brexit world, manufacturing will increasingly provide Britain’s link to the world and it currently generates 44% of total UK exports. The sector is also vital for the nation’s future source of income, undertaking some 70% of total R&D by Britain’s businesses. Data around employment is equally impressive, with 2.6million people working within the manufacturing sector across the country. The largest individual sector is food and drink (16%) while the chemicals & pharmaceuticals and transport sectors both account for 14% of output each. It is these two sectors which also head up the manufacturing innovation league table, with ONS figures revealing that pharmaceuticals accounts for 34.4% of UK innovation, and transport 33%. As a sector, the manufacturing good news story continues into comparable pay rates, offering higher wages than other sectors 8 IME NOVEMBER/DECEMBER 2017
70% OF BUSINESS R&D 13% OF BUSINESS INVESTMENT Supported ed by: b
HOW IS MANUFACTURING MANUF CTURING SPREAD AROUND AROUND THE UK?
KEY Manufacturing fa acturing output outp (£bn)
Number employed in manufactur fa acturing, 000s Manuffa Manufacturing acturing as a % of regional employment emp % of regional output % of manufactured actured exports destined for f EU
North East Northern Ireland 54.9%
Yo Yorkshire and Humberside 15.5bn
North We West 46.4%
West M Midlands 47.0%
East of England Wales Wa 67.1%
South East South We W West 41.7%
43.4% Source: ONS
with highly paid, highly skilled jobs. Average earnings have increased from £31,489 to £32,047, still sitting well above the take home totals from services (+£4,499) and some £3,748 more than
the whole economy average pay. Furthermore, manufacturing is spread across the country – the North West remaining the biggest regional powerhouse, producing over £24bn output.
Five things to know about UK manufacturing: • Britain is the 8th largest manufacturer in the world by output • Manufactured exports are up, driven by a global upswing in demand and some support from a weaker Sterling • EU markets still dominate for exports, accounting for 48% of manufactured exports in 2017 Q2 • The public are ambitious for the sector, with 70% of UK adults saying Britain should aim to be a top five manufacturing nation • Manufacturing is set for change, with industry gearing up for the 4th Industrial Revolution (4IR) Manufacturing also helps power the engine of the West Midlands (£17.5bn) and East Midlands (£15.9bn), with their strength across the aerospace and automotive sectors. A reminder of the post-Brexit challenge is ever present as EU markets still dominate for exports, accounting for 48% of manufactured exports in 2017 Q2. The UK’s largest single export destination is the United States, followed by Germany and France. Lee Hopley, Chief Economist of EEF, commented: “With government facing lots of major policy decisions on everything from our future trading relationship with Europe and the rest of the world to the detail of a long-term industrial strategy, it is vital that they have the right industry facts at their fingertips. Our latest annual fact card reveals that manufacturing’s share of the economy remains stable at 10%, but the sector makes a much larger contribution to vital exports and innovation. “With the focus on industrial strategy, this year we highlight the varying strengths we see across manufacturing sub-sectors, from the strong R&D performance of pharmaceuticals and transport to the high export intensity of machinery and chemicals.” Paul Brooks, Head of Manufacturing at Santander Corporate & Commercial, added: “Manufacturing remains a key part of the UK economy and it is really encouraging to see that the UK is now the 8th largest manufacturer by output in the world, and that the majority of UK adults believe we should be aiming to be in the top five. With strong manufacturing figures reported from across the country, it is crucial that we continue to support manufacturers in all regions of the UK. Despite uncertainty around Brexit, manufacturers are seizing opportunities to increase their now more competitive exports, with the sector accounting for 44% of UK exports. With the top 10 export destinations featuring markets both within and outside of the EU, Santander is committed to helping manufacturers reach new markets.”
For more information, and to download the EEF / Santander fact card, visit www.eef.org.uk Readerlink 004
INDUSTRIE 4.0 REACHES THE NEXT STAGE The interplay between automation and energy technology, IT platforms and artiﬁcial intelligence is driving the digital transformation of industry. With the lead theme ‘Integrated Industry – Connect & Collaborate’, Hannover Messe 2018 spotlights the potential of this development. IME takes an early look at next year’s super-sized exhibition and conference. Humans, machines and IT – these are the cornerstones of tomorrow’s factories. However, only with networking will they reach their full potential. “The new connectivity – that is, the organisation of networks – is taking Industrie 4.0 to the next stage,” said Dr. Jochen Köckler, Chairman of the Managing Board, Deutsche Messe AG. “With ‘Integrated Industry – Connect & Collaborate’ we highlight how connectivity in industry facilitates completely new forms of business, work and collaboration. The result: more competitiveness, better jobs and new business models.” Factory and energy technologies are more eﬃcient than ever. So is data analysis. Industrial IT platforms push their way into the market. Artiﬁcial intelligence and machine learning enable machines to make decisions. Engineers digitally simulate entire production chains. New players and new business models emerge, blurring boundaries between industries. “Hannover Messe is the place to experience the rapid development and impact of Industrie 4.0,” emphasised Dr. Köckler. “Companies from all over the world demonstrate robots, automation technology, IT solutions and software as well as platforms for networking. Only in Hannover will you see the digital transformation of industry as a complete system.” The lead theme ‘Integrated Industry – Connect & Collaborate’ is relevant to many branches of industry. For example, ‘Smart 10 IME NOVEMBER/DECEMBER 2017
Supply’ in the age of digitalisation opens up new perspectives for industrial subcontractors: supply chain management, simultaneous engineering, optimised production runs, and minimal error rates – all of this is possible when suppliers and customers see each other as development partners and collaborate as equals. The new connectivity also changes the role of factory workers, who now have direct access to all relevant production and machine data.
Intelligent machines support them in their decision-making. Industrial IT platforms play a crucial role. Collecting, analysing and merging large amounts of data from diﬀerent sources, combined with the respective industry expertise, makes it possible to develop internet-based services that bridge traditional industry boundaries.
Hannover Messe is the world’s leading trade fair for industrial technology. With its core focus on ‘Integrated Industry’ and ‘Integrated Energy’, it is the No. 1 global platform for Industry 4.0. The show will next be held from 23 to 27 April 2018 in Hannover, Germany, and will provide a comprehensive overview of the latest visions and technologies for the digitisation of production and energy systems. Next year’s showcase features ﬁve parallel shows: IAMD (Integrated Automation, Motion & Drives); Digital Factory; Energy; Industrial Supply and Research & Technology. In addition to the sizeable exhibition space, more than 80 conferences and forums will explore the lead theme. Visit www.hannovermesse.de/en or follow @hannover_messe for more information.
AIR GUN SAFETY
MINIMISING INJURY WHEN BLOWING WITH COMPRESSED AIR The air gun is one of the most used tools in production environments, but unfortunately it can also create a number of workplace injuries. It was from a ‘safety ﬁrst’ perspective that Silvent set about developing the new Pro One. IME looks at the background to its creation. Today, argues Silvent, there are considerable differences between different work groups when it comes to the working environment. For office employees, a good working environment often involves ergonomic furniture, which supports the body’s natural movements. In manufacturing and maintenance operations, however, it is still all about reducing the risk of accidents in the workplace. Such was the genesis of Pro One, a hand-held tool developed for industrial use and designed to minimise the risk of injury when blowing with compressed air. In its past development projects, Silvent’s focus was the technology behind the products, in order to offer quiet, safe solutions for blowing with compressed air. However, also underpinning this development was an ambition to produce an ergonomic design that would minimise the 12 IME NOVEMBER/DECEMBER 2017
risk of repetitive strain injuries. Accordingly, early on in this process the company began a collaboration with Veryday, a design agency with expertise in industrial design. Silvent’s Head of Technology, Rasmus Tibell, said: “Our collaboration with Veryday has allowed us to combine the best of both worlds in the new product – Veryday’s unique expertise in ergonomic design and our own technical expertise when it comes to blowing with compressed air.”
Inspired by users In order to meet the needs and make work easier for people who use compressed air daily, Silvent carried out several user studies. Men and women from the manufacturing sector were interviewed and asked to answer questions about their blowing operations, air gun properties and stowage. A prototype was then created based on the responses from the user studies and Silvent then conducted further research where
operators got to comment on the prototype’s design. “Based on the compiled results, Silvent gave us free rein to develop the handle’s exterior design without being limited by internal, technical solutions. This gave us the ability to create the best possible solution for the user,” says Hans Himbert, Industrial Designer and partner at Veryday. With Silvent’s subsequent technical input, practicalities permeate Pro One’s lightweight, slim design. The robust hand tool is made of a flexible, durable material well-suited to challenging industrial environments. Its ergonomic handle allows several different grips to make work easier and reduce the risk of repetitive strain injuries, whilst it is also designed to fit both small and large hands. It also features two hang-up options – by the trigger or by the specially designed lug. Both surrounding areas are reinforced to withstand increased wear.
The trigger itself is designed to provide “the best possible blowing force control”, ensuring the operator has full control over the infinitely variable blowing force. Because trigger opening force is independent of pressure, the risk of repetitive strain injuries is reduced. Similarly, it is equipped with a patented check valve to avoid recoil and peak-sound pressure when disconnecting – and this is also said to reduce the risk of joint injuries and, importantly, hearing loss. The connection is also fitted with a filter that prevents large particles from entering the air gun. Pro One has a ¼” metal connector. In terms of accessories, the Pro One can be fitted with an optional air shield to reduce the risk of eye injuries. The air shield has sufficient pressure to protect the operator from dust and small particles. It can also be supplied with a 300 millimeter long air gun pipe. As alluded to above, one of the key dangers relating to air guns is hearing loss or tinnitus, as the tools can generate harmfully high noise levels when blowing. Pro One is fitted with a specially designed, patented nozzle in stainless steel which allows an
“The design of the nozzle enables a reduction in sound level of more than 10 dB(A). The ear perceives this as a half of the noise level, which in turn reduces the risk of hearing damage and makes a big difference for both the operator and the surrounding people.”
effective blowing force with a low noise level. The nozzle creates a concentrated jet of air which reduces turbulence, thus enabling a more targeted, effective blowing force. Silvent’s Rasmus Tibell explained: “The design of the nozzle enables a reduction in
sound level of more than 10 dB(A). The ear perceives this as a half of the noise level, which in turn reduces the risk of hearing damage and makes a big difference for both the operator and the surrounding people.” Pro One is approved by SUVA and meets OSHA’s requirements for blowing with compressed air. Even prior to the tool’s recent launch, it received two design awards – a Red Dot Product Award and International Design Excellence Award (IDEA).
For more information on the Silvent Pro One, circle readerlink 201 NOVEMBER/DECEMBER 2017 IME 13
IME takes a look at two product innovations from MANN + HUMMEL.
SPIN-ON FILTERS AND SEPARATORS Wavelock The WAVELOCK spin-on ﬁlter system can be used for the filtration of oil and fuels. The design of the head and spin-on filter is said to offer numerous advantages such as defined untightening and tightening torque. This makes servicing and mounting easy and safe. The filter system consists of a filter head and spin-on element. It combines proven technology with a new design of the interface between the head and spin-on filter. This enables clearly defined mounting and disassembly forces. The filter change can be easily and quickly made without the need for tools. In addition, component cleanliness is considerably improved and the risk of a contamination of the fluid circulation system is reduced. The patent pending solution also prevents servicing errors and the use of filters with a lower quality. The modular design of the system and 14 IME NOVEMBER/DECEMBER 2017
different combination possibilities with the company’s filter media enable the system to be used as a main fuel filter, fuel prefilter or oil filter for different specifications and volume flow rates. Fuel filter sizes are available up to approx. 400 l/h and oil filter sizes are available up to approx. 55 l/min.
StarBox2 The new StarBox2 spin-on separator covers a wide range of volume flow rates and offers advantages for compressors with a variable drive speed. There are two application options: the separator can be used energy-efficiently with low pressure drop or used for high performance and compression with higher flow rates. The separator has been developed for use with mobile and stationary compressors with an output of up to approx. 55 kW. StarBox2 covers the FAD range of 1.5 to 6.5 m3/min and can therefore be used in a wider performance range than conventional spin-on separators. This in
particular oﬀers advantages for compressors with a variable drive speed. The efficient flow design and new sealing concept reduce flow loss and therefore also the drive energy required by the compressor. This reduces the energy costs which account for around 75% of the total costs of a compressor. StarBox2 enables two application options. In ECO mode, it realises energy and cost savings through up to 25% less pressure drop. In comparison with conventional spin-on separators, over its lifetime it realises energy savings of up to 600 kWh and therefore makes a significant contribution towards the reduction of the production costs of compressed air. In high flow mode, it achieves up to a 20% higher flow rate (FAD) with the same filter size.
For more information on filters and separators from MANN + HUMMEL, circle readerlink 202
MAINTENANCE MANAGEMENT Eﬃcient production requires a ﬁrst-class maintenance regime — and investment in aneﬀective CMMS system can help companies on their journey to attain this standard. This month, IME considers two businesses which have selected Mainsaver CMMS from Spidex Software to gain greater control of their maintenance programmes. Earlier this year, Spidex Software announced that chilled pastry manufacturer Bakeaway had selected Mainsaver CMMS for its production facility at Corby, Northamptonshire. The implementation also includes SpidexWM , SpidexBI and SpidexdRA from its popular range of optional web-based add-ons. Bakeaway’s £2m production facility was opened in 2011 and manufactures a full range of ready-made chilled raw pastry, including shortcrust, puﬀ, ﬁlo and all-butter varieties in addition to a range of prepared doughs for sweet items such as cookies, scones, ﬂapjacks and gingerbread. With a customer base that already includes major supermarket chains and foodservice distributors, Bakeaway has ambitious plans for expansion buoyed by resurgent public interest in home baking inspired by TV shows such as “The Great British Bake Oﬀ”. Until recently, the company had managed its plant maintenance using a variety of manual methods, but recognised that to support its declared mission of becoming “the UK’s number one manufacturer in the chilled home baking category” would require a ﬁrst-class maintenance regime. Bakeaway decided that it would invest in CMMS to attain this standard and the ﬁrm’s Jamie Murphy compiled and dispatched a detailed requirement speciﬁcation to a number of CMMS providers. On the basis of initial responses, a shortlist of product demonstrations were then scheduled and following sight of the software, all but two contenders were eliminated. In the very detailed evaluation that 16 IME NOVEMBER/DECEMBER 2017
Fujiﬁlm Speciality Ink Systems, based at a state-of-the-art facility at Broadstairs, has selected Mainsaver CMMS from Spidex Software.
“There was certainly a feeling among the engineers that time spent double-entering information from worksheet to computer could be more productively spent on the tools.”
The Fujiﬁlm SIS facility has won ‘Process Plant of the Year’ at the Best Factory Awards on four occasions.
followed, Mainsaver CMMS from Spidex won out, assessed to be the most complete solution in terms of software functionality, project management expertise and aftersales support. Reference calls to other real-life Mainsaver customers in the bakery sector provided the clinching body of evidence. In August, Spidex announced that Fujiﬁlm Speciality Ink Systems had also selected Mainsaver CMMS to support “best-practice management of maintenance” at its manufacturing site in Broadstairs, Kent. There, the business develops and manufactures inkjet systems for a wide variety of processes and, over the last decade, the company has extended its product oﬀering from the heritage analogue range upon which its reputation was founded, to pioneering precision UV curing digital inks. The company’s state-of-the-art facility at Broadstairs has won ‘Process Plant of the Year’ at the Best Factory Awards on four occasions and is viewed as an exemplar of world-class manufacturing performance. Until recently, the facility utilised legacy maintenance management software that had been in place for some years. Ironically, the CMMS was generating signiﬁcant quantities of paperwork because it required each work order to be printed out and CMMS project lead Adam Murrell said: “At the end of each day there was often a bustle of engineers around the PCs, each of them trying to enter work order data into the CMMS that they’d already logged on paper.” Adam could see the ﬂaws in the workﬂow, and he wasn’t the only one. “There was certainly a feeling among the engineers that time spent double-entering information from worksheet to computer could be more productively spent on the tools.” Following an evaluation of other CMMS options, Adam requested an online demonstration of Spidex’s Mainsaver solution and subsequently arranged a more detailed functionality run-through on site. He said: “From an eﬃciency perspective, we liked the options Mainsaver gave us for mobile paperless working, the way users can locate an asset by
Production monitoring Spidex has been appointed as the UK reseller for Blackbird’s production monitoring hardware, Factbird. The standalone units, requiring only a power supply and a connected sensor, can be installed in under an hour – independent of your existing IT network – and will start delivering live production data immediately. Stored securely in the cloud, this data can be accessed remotely via PC, tablet or mobile phone. Using the data, the system can reveal how eﬃciently the lines are operating, how much of each product has been produced so far and how diﬀerent shifts compare performance-wise. Key metrics such as Overall Equipment Eﬀectiveness (OEE) are available in real-time at the click of a button alongside the equipment performance tracker. From a maintenance perspective, the hardware shows the number of line stops, how long changeovers have taken and calculates the accumulated lost production time per line. Users can then register a cause for each lost-time event in order that recurring problems can be identiﬁed and remediated. Spidex is currently in discussions with Blackbird to create an interface with Mainsaver so that plant downtime data is relayed directly to the CMMS and work orders created automatically, based upon designated stoppage types.
clicking on a schematic layout of the site and the live real-time performance dashboards. “Spidex also oﬀered a highly structured and detailed implementation plan, which accurately reﬂected our own view of the project’s importance.” Another important factor – as is common throughout modern manufacturing industry – is the increasing number of audits the company is required to undergo. Adam revealed: “We are continually assessed by external bodies for compliance within a range of regulatory frameworks including health & safety, environmental and ISO standards.
Each of these audits demands a very high standard of record-keeping for traceability, and those records must be available for examination for years afterwards. “Compliance is a hugely important aspect of 21st century manufacturing. It’s no exaggeration to say that our CMMS requirement was as much about audit performance as process improvement and we are looking to Mainsaver to underpin activity in both areas.”
For more information on Spidex Software circle readerlink 203 NOVEMBER/DECEMBER 2017 IME 17
TOTAL PRODUCTIVE MAINTENANCE
SMC Business Development Manager Jeﬀ Careless, who advises customers on all aspects of Total Productive Maintenance (TPM), tells IME how taking a holistic approach to equipment maintenance can yield signiﬁcant improvements to production eﬃciency. Total Productive Maintenance is helping all sorts of organisations, from global corporations to specialist SMEs, to maximise business efficiency. Often it is small changes in the manufacturing process that make the biggest impact. SMC Pneumatics has been promoting manufacturing efficiency for nearly 40 years with its Continuous Improvement strategy at the heart of the company’s business philosophy. When talking about TPM with customers, the ﬁrst thing I do is put it in context as part of our commitment to Continuous Improvement in all aspects of an organisation’s business operation. But the area where the biggest returns can be achieved often with just small changes is Overall Equipment Eﬀectiveness (OEE) throughout the manufacturing process. It’s here that we can advise the Maintenance Engineering team on how to develop and implement changes that are focused on proactive
and preventative techniques for improving equipment reliability. But ﬁrst, let’s just dispel some myths about TPM. Like many aspects of the “new” connected industry revolution, it is not actually new. It is simply a diﬀerent approach
to business eﬃciency. An eﬀective TPM policy combines human intervention with the latest support technology using in-line diagnostics to pre-empt potential maintenance issues. Essentially, TPM brings together the roles of the production and maintenance teams with the emphasis on empowering operating staﬀ to help maintain their equipment. With the right TPM programme, you can create shared responsibility for equipment that encourages greater hands-on involvement from production staﬀ. This enables the maintenance staﬀ to focus on overarching issues such equipment quality, site health & safety, back oﬃce TPM and process improvements.
How does it work? So let’s look at what exactly is involved in a TPM programme. The original concept was developed back in the 1960s, consisting of the 5S Foundation (Sort, Set in order, Shine, Standardise and Sustain) with Eight Pillars of activity supporting this. NOVEMBER/DECEMBER 2017 IME 19
019_IME_NOVDEC_17_Layout 1 10/10/2017 11:31 Page 20
Pillar 1. Autonomous maintenance
Action Routine maintenance, eg cleaning, lubricating, inspection
Team responsibility Primarily Operator with Maintenance Engineering support if required
2. Focussed improvements
Proactive problem solving to achieve ongoing improvement in equipment operation
Operator and Maintenance Engineering teams working co-operatively
3. Planned maintenance
Scheduled maintenance tasks based on predicted equipment failure rates
Primarily Maintenance Engineering team working with Operator to schedule maintenance to minimise downtime
4. Training & Education
Address skills and knowledge gaps to achieve TPM goals
Operators, Maintenance Engineers and Managers
5. Maintenance Prevention
Use accumulated team TPM knowledge to improve equipment design and operation
Operators, Maintenance Engineers and Managers
Design fault detection and prevention into production operation; eliminate recurring faults
Maintenance Engineers with feedback from Operators
7. Oﬃce TPM
Apply TPM techniques to back oﬃce and admin functions
Maintenance Engineering team reduce waste and improve admin functionality
8. Safety, Health & Environment
Maintain a safe and healthy working environment for all staﬀ
Maintenance Engineering team eliminate potential H&S risks
6. Quality Maintenance
It is fairly obvious how adopting the 5S Foundation creates a clean and well organised workplace: 1. Sort and Set in order tools and parts making them easier to ﬁnd 2. Shine – it is easier to spot ﬂuid leaks, shavings from metal wear or material spills in a clean work area 3. Standardise – create standard of regular inspections to ensure workplace is clean and tidy 4. Sustain – empowered staﬀ ensure all these standards are maintained Assuming the 5S Foundation is in place, the Eight Pillars of TPM are shown in the table.
Roadmap to an eﬀective TPM programme The most eﬀective way to then implement 20 IME NOVEMBER/DECEMBER 2017
your TPM programme is to run Pillars one to four in parallel with both the production line operators and the maintenance engineers. The aim of this division of labour is to encourage operators to take responsibility for the day to day running and maintenance of their equipment so freeing up the maintenance engineers from routine shop ﬂoor activities. With their “free” time, they can concentrate on implementing Pillars ﬁve to eight. Here’s a simple roadmap to implementing your TPM programme which allows you to pilot it ﬁrst in a single problem area: Identify Trial Pilot Area – e.g. equipment that is easiest to improve or an obvious
bottleneck in production or an operation with recurring problems. Equipment restoration – clean up all pilot area equipment so it can operate as well as possible and then be monitored for potential improvement or re-design. Accurately measure OEE – track OEE on the target equipment to identify all potential areas where productive time is being lost. Address major OEE losses – having identiﬁed the most signiﬁcant causes of lost production time, use this data to create your TPM programme and create a cross-functional team to implement it. Launch your Proactive TPM Programme – launch and integrate your TPM programme with all Operator, Maintenance Engineering and Management teams!
Getting started At SMC, we can bring to bear a host of experience when it comes to designing and implementing an eﬀective TPM programme for customers. Through many years of working with customers from across the UK manufacturing industry, we have developed a dynamic portable display that demonstrates how we can help you deliver TPM as part of a programme of Continuous Improvement. Our modular display enables us to engage with employees wherever they are on site, highlighting the issues that directly impact on your business eﬃciency. Working with your engineering and production line teams we will create a TPM programme, tailored to your speciﬁc business needs. This will address staﬀ skills gaps with appropriate training delivered by our own highly experienced Learning & Development team; identify where you can reduce waste such as compressed air leaks which on average run at 20% of all compressed air generated equating to thousands of pounds in lost materials. Working together we will help you achieve a signiﬁcant increase in factory throughput and productivity.
For more information or to arrange a TPM consultation, circle readerlink 204
OILS, LUBRICANTS & GREASES
LUBRICANT CONSIDERATIONS IME reports on a recent lubrication audit carried out by New Tech Lubes. Recently New Tech Lubes paid a visit to a company manufacturing pies in order to audit current lubrication stocks with a view to rationalising them, ensure all lubricants met the correct standards for use in a food production facility and to offer alternatives from its extensive range of H1 and 3H registered lubricants. As part of this process, the company visited the production area to talk to maintenance and production personnel to gain as much feedback as possible in terms of problems and reliability of equipment, methods used to apply lubricants, schedules of lubricant application and, of course, the type of lubricant used. What was discovered in many cases was confusion over which lubricant to use, how often it should be used and, in some cases, where it should be used. In addition, it appeared that hidden grease points and pivot points requiring lubrication
were being overlooked altogether. The dilemmas continued in the purchasing department, which was trying to maintain a bewildering list of lubricants from diﬀerent suppliers in the stores, with no method of tracking the use of these products, or who had used them and where. It became apparent that, over the years, suppliers had not been updating products, or taking note of the increasing quantity of lubricant being consumed. In order to aﬀect change, an understanding of lubrication, its application and control needed to be shared with all those who were involved in the maintenance of production machinery. A simple point by point presentation was delivered, explaining why things needed to change and how individuals could improve reliability, reduce costs and increase production. Having rationalised and reduced the number of lubricants on site, it allowed New Tech Lubes, in conjunction with the site
engineers, to monitor usage. Prior to this, the only reliable ﬁgure concerning lubrication was an annual spend of an eye watering £36,000. As problem areas were identiﬁed, they were able to be dealt with these one by one, starting with a conveyor chain prone to corrosion due to water wash down. Although the chain had been lubricated regularly, the oil used was a mineral oil hydraulic ﬂuid which was easily washed oﬀ with water and the cleaning ﬂuids used. This was changed to a hydrophobic ﬂuid and addivated to improve adhesion to chain surfaces. Operators who were lubricating machinery as part of clean down regimes were shown where hidden lubrication points were and issued with the correct lubricant for the machine, and all operators used the same lubricant – reducing lubricant compatibility issues and allowing performance to be monitored. High temperature conveyor chain lubricant application was identiﬁed as a NOVEMBER/DECEMBER 2017 IME 23
OILS, LUBRICANTS & GREASES
problem as, during production, it was diﬃcult to gain access to apply lubricant. As a result, this chain was only lubricated at weekend downtime where it was perceived that soaking the chain was the best method, which created an over-application leading to the dripping of oil within the oven. This problem was cured by ﬁtting an automated lubrication system and application of a high temperature H1 registered oil, FS Techno Carb Super 2. This allowed application at any time and only enough lubricant was then needed to lubricate the conveyor. For some reason, in the past three years diﬀerent grades of hydraulic ﬂuids had been used, and no one knew why. This had led to confusion on the shop ﬂoor as to which to use. By assessing machine requirements, it was found only one grade was required and allowed site engineers to assess consumption of each hydraulic system. A fully synthetic Hydraulic ﬂuid, FS Hyd Oil, was introduced in order to deliver long life and maximum system protection. 24 IME NOVEMBER/DECEMBER 2017
Having identiﬁed which systems were consuming most, it was time for leak detection. As FS Hyd oil is water clear, it is not always easy to spot leaks, but as New Tech Lubes manufactures its own hydraulic ﬂuids, a bespoke solution could be oﬀered. A dye, compliant with H1 requirements, was introduced, which was blended into all new product supplied. In the following three to four months, consumption of hydraulic ﬂuids dropped by more than 80%. The impact of this reduction in consumption cannot be overstated. Not only is the cost reduced, it also frees up maintenance staﬀ to address other problems. Another issue identiﬁed was high wear on chains due to corrosion. Once again a full analysis of the problem has led to a change in lubricant used which is able to provide much better protection. And ﬁnally, the introduction of a simple but eﬀective auto lubrication system, which prevents over application of high temperature oven lubricant, has led to another reduction in
consumption. The end result is that maintenance engineers are able to stop ﬁre ﬁghting and start maintaining and developing, allowing for even more eﬃciency in the plant. In addition, breakdowns and interrupted production problems have decreased. And that eye watering £36,000pa spend is now down to £14,000. The moral of this story is simply this. Be sure that whoever you go to for advice seeks as much information about your process and requirements as possible. If they don’t, they will be struggling to oﬀer a good solution/product that meets your needs. Have to hand and share as much information as possible. Include machine performance history such as breakdowns and what caused them. You never know, it may be possible to improve over original lubricant speciﬁcation.
For more information on products and solutions from New Tech Lubes, circle readerlink 205
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AVOIDING THE PITFALLS OF ANTI-VIBRATION MOUNTS Geert Keustermans, Market Manager for General Industry and Distribution at Trelleborg’s industrial antivibration solutions operation, considers three common oversights during the installation of anti-vibration mounts. When it comes to isolating and attenuating vibration and noise, the general consensus is that correct specification delivers optimised performance. But is that enough? Or are we compromising performance during the installation process? Best practice for the speciﬁcation of anti-vibration mounts is well documented. Product choice has never been more abundant, and leading manufacturers are digitising the product selection process with convenient smart phone apps. Together, this means that facility engineers are well equipped to make informed choices when it comes to reducing harmful vibration in moving machinery. Manufacturers of anti-vibration technology continue to invest heavily in developing solutions which deliver optimised performance throughout the product lifetime. In order to reap these beneﬁts, however, it is vital that engineers avoid a number of installation pitfalls which may impact negatively upon performance. These include poorly installed mounts, vibration short circuits and any contributing parasitic stiﬀness. Let’s look at each of these in more detail:
Poorly installed mounts Before beginning the installation process, ensure all surfaces are clean, dry and free from debris. To maintain correct alignment when 26 IME NOVEMBER/DECEMBER 2017
Incorrect installation of an anti-vibration mount
lowered on to the mounts and also to prevent damage to the asset or individual during the installation, the equipment being mounted should be lifted carefully onto suﬃcient supports. Whilst it may be tempting to lift the equipment just enough, always consider how much space is required to freely access the ﬁxing points. Where possible, space should be created to allow installation engineers free access to these areas. This is essential to facilitate a more eﬀective mount installation. Once the area has been correctly prepared, the process for installing most anti-vibration mounts is generally uncomplicated, but due care and attention must be given to the accuracy and positioning of the ﬁxing points, as well as the orientation of the mount and its components. The top and bottom ﬁxing points should be parallel to one another and horizontal before they are ﬁxed into place. When tightening each ﬁxing point, avoid rotating the top of the mount relative to its base – the orientation of the entire mount in plan view, should be either longitudinal or lateral rather than at an abstract angle.
Vibration short circuits Like many other systems, the successful installation of resilient mounts will be dependent on minimising weaknesses, especially when the machine is in motion. Many of these weaknesses occur during the installation process and are preventable. If left unattended, the performance of the anti-vibration mount will be hindered. These ‘short circuit’ issues can be attributed to two main factors – absence of due diligence and insufficient planning. Things to consider are that transit chocks have been removed from the mount prior to installation, the guards at each end have been unlocked and that no tools are jammed beneath the set once the equipment is lowered onto its new mount. These may seem like obvious points to check, but they are aspects of installation that are commonly missed and lack of care can have a profound impact on the performance of your mount investment.
Insuﬃcient planning can lead to numerous installation challenges, including the use of incorrect assembly bolts or the poor positioning of ﬂoor plates. If the assembly bolts are too long, they may come into contact when the mounts are loaded or when the machine is switched on and starts to move. Likewise, when the set is in motion, the ﬂoor plates may meet, which will impact how much vibration and noise can be isolated.
Contributing parasitic stiﬀness More often than not the image of plant sitting on top of anti-vibration “springs” is not an accurate reﬂection of real world applications. Almost all machinery will have other connections such as exhaust outlets, electrical cables, water inlet or outlet pipes, hydraulic piping, compressed air tubing and earthing straps. Each additional connection contributes a
level of stiﬀness to the equipment and will have a parasitic eﬀect on the performance of the mounting system. Particular attention must be given to any hydraulic hoses and exhaust bellows, which are the worst culprits when it comes to altering the performance of an anti-vibration mount, due to their high levels of tensile strength and the fact that they are connected furthest away from the centre of gravity. Machinery with multiple additional connections can still be successfully mounted onto an anti-vibration mount, but changes will need to be made. Each additional connecting point will need to be replaced with a ﬂexible alternative, ensuring that the speciﬁed material has a multi-directional stiﬀness which is signiﬁcantly lower than the anti-vibration mounts selected. This re-speciﬁcation process will also ensure the mount can correctly isolate excessive vibration.
Correctly aligned anti-vibration mount
Optimising the performance of any anti-vibration solution requires best practice in both speciﬁcation and installation, but the beneﬁts do not end there. Following installation best practice can improve product longevity and reduce the likelihood of unplanned mount maintenance and machine downtime, which of course translates to a more proﬁtable application.
For more information on anti-vibration mounts and other anti-vibration solutions from Trelleborg, circle readerlink 206
BACK TO THE FUTURE Headquartered in Manchester, Renold plc’s range of industrial chain, gearboxes and couplings are speciﬁed for use in diverse power transmission, lifting, conveying and processing applications – from cement making to chocolate manufacturing, subway trains to power stations and escalators to quarries – around the world. But did you know it also supplied the chains that helped power British Cycling to gold? IME reveals more. Amongst the latest corporate updates and discussions of the company’s continuing ‘STEP 2020’ programme of improvement, Renold’s 2017 Annual Report also outlined the firm’s key involvement in recent British Olympic success with the “cutting edge chain technology platform” behind the manufacturer’s Synergy chain – which has long been known for its industrial applications – helping the GB Cycling team to achieve world and Olympic glory. It is a development which sees the business return to its roots, as the document attests. It reveals: “Way back in 1880 when the few cyclists on the roads were more than likely riding high on a Penny Farthing, young engineer Hans Renold achieved a signiﬁcant technical breakthrough when he invented the bush roller chain. This innovative chain technology solved many problems inherent in existing solutions and brought a new level of performance, eﬃciency and ﬂexibility to the transmission of mechanical power. “Renold’s ﬂedgling business grew steadily, providing power transmission chains to the industrial applications of the day. What this new technology really needed however, was a mass market application. Enter John Kemp Starley, 28 IME NOVEMBER/DECEMBER 2017
who in 1885 brought to market his safety bicycle. The ‘Rover’ bicycle included many groundbreaking features including the use of chain to drive the rear wheel. This synergy of technology and application proved a perfect match and resulted in the rapid growth of both bicycle and roller chain industries.” The section in the Annual Report continues: “Pedal forward 130 years and the bicycle has been transformed – stronger, lighter and capable of incredible performance. In the chain world, Renold has built a global business serving a huge array of industries and applications. Following the example of its founder, Renold has dedicated itself to the relentless pursuit of better chain technologies – stronger, highly durable and extremely eﬃcient. “In 2011, British Cycling was looking for a drive chain that could meet the incredible demands of elite level competition both in the Velodrome and on the BMX track. After some discussion between British Cycling’s R&D Team and Renold Engineers it was felt that the requirements could be met using Renold’s Synergy chain technology platform. “Following a great deal of collaborative work between British Cycling and Renold Chains, along with the University of Bristol, Renold engineers were able to optimise their pre-existing chain design which culminated in
the chain that was used to great eﬀect by the Great Britain Track Cycling team in both the London and Rio Olympic Games. Tony Purnell, part of British Cycling’s R&D Team, is quoted as saying: “As part of British Cycling’s no stone unturned philosophy it was obvious that chain design was an area of interest and we have been impressed by the undoubted expertise and obvious willingness of Renold to work with us on this project.”
For more information on Renold Chains’ industrial applications, circle readerlink 207
POWER TRANSMISSION The G8 RS Roller Chain is said to oﬀer a 20% improvement in service life over the previous designs and features a special corrosion suppressing oil which inhibits rust and improves durability.
EIGHTH WONDER Tsubaki has been celebrating its 100th anniversary this year. IME considers some of the company’s latest initiatives, including the completion of the eighth-generation revision to a number of its core ranges.
Tsubaki was founded in Japan in 1917, initially to make bicycle chain. A few years later industrial chain production began and was so successful it quickly became the company’s main product offering. In 1972, Tsubakimoto Europe B.V. was established – the same year that the micro chain was launched. 1988 saw the launch of the ﬁrst generation of Lambda lube-free chain whilst the business celebrated the new millennium with the building of a new state of the art manufacturing facility in Kyotanabe, Japan. The acquisition of KabelSchlepp GmbH in Germany, the establishment of Tsubaki Deutschland, plus founding of a subsidiary in India all happened in 2010. At the very start of its centenary year, Tsubaki opened a new subsidiary in Madrid to serve the Spanish and Portuguese markets. This is part of a global strategy to strengthen regional marketing, which, in recent years, has seen new operations set up in Shanghai, Tianjin, Indonesia, Mexico, Malaysia and Shijizhuang (China). 30 IME NOVEMBER/DECEMBER 2017
Now, as cited on the company’s special centenary website, Tsubaki manufactures more than 20,000 types of chain. Based on the transmission and conveyors of industrial chains, it has expanded its business into four areas: chain; power transmission units and components; automotive parts; and materials handling systems. As of March 1 this year, the manufacturer completed its G8 Series line-up by introducing the upgraded standard RS roller chain. Previously released were the Neptune anti corrosion chain, Lambda Food Grade lube-free chain and the new Heavy Duty range. Tsubaki Europe, applicable to its UK customers, has recently launched a new website to inform and support its end users, providing a comprehensive point of reference to explore its range of high performance chains and accessories. Characterised by a “fresh aesthetic and an intuitive user experience”, the new site has been designed to oﬀer industry and product insight to help inform component or service selection for speciﬁc applications. The new site contains sections for each individual industry served, and the major
applications within them. Technical information, including the entire range of Tsubaki catalogues and industry ﬂyers, is available for download, resulting in an extensive interactive knowledge base that can positively inform any end user purchasing decision.
Next generation As noted previously, a key product launch this year has been the eighth-generation, G8 Series of its RS Roller Chain and its Heavy Duty Drive Chain. RS Roller Chain is the company’s standard, designed to meet the needs of most applications, whilst Heavy Duty Drive Chain is an endurance chain with a high maximum allowable tension for particularly demanding situations. The G8 RS Roller Chain is said to oﬀer a 20% improvement in service life over the previous designs and a special corrosion suppressing oil is applied to the chain in the ﬁnal stage of manufacture to inhibit rust and improve durability. Developed in-house, this oil does not leave a sticky residue on the chain surface, making handling cleaner and more
pleasant. The new G8 chain is available in 11 sizes from RS40 to RS240. The G8 Heavy Duty Drive Chain has been designed to ensure greatly improved performance and is aimed at applications requiring the movement of large loads at low speeds. This chain provides increased strength as a result of a new heat-treatment process, thicker material, and innovative geometry while remaining the same size as the standard type of chain. It is available in three variants: • The RS-HT Roller Chain, which features ‘highly precise seamless bushes’ that have doubled the service life. This innovation greatly reduces maintenance needs. • The Super Roller Chain features a new link plate design which increases the load capacity by 5-10%. • Super-H Roller Chain has a 20% increase in maximum load by providing a ring coin on the inner plate. It oﬀers users the possibility of using smaller chains, which will reduce costs and save space.
For more information on Tsubaki’s range of products, circle readerlink 208
“The G8 RS Roller Chain is said to offer a 20% improvement in service life over the previous designs and a special corrosion suppressing oil is applied to the chain in the final stage of manufacture to inhibit rust and improve durability.”
Application areas: food and beverage Tsubaki has developed a special chain for the tray packing machinery widely used in the food and beverage industry. It is internally lubricated so that it is clean in use and does not need regular re-lubrication. The manufacturer’s Traypacker Chain is a development of its Lambda solution, which uses a special sintered oil-impregnated bush. Like the latest generation of the Lambda Lube Free chain, the Traypacker is impregnated with NSF-H1 food grade lubricant as standard. Naturally, hygiene is paramount and standard lubricated chain can cause contamination of the machine, ﬂoor and end product, possibly resulting in increased maintenance requirements, damaged products and reduced proﬁt. Furthermore the lubricated chain itself gets contaminated by dust, glue and paper particles, preventing lubrication to reach the critical areas. To prevent such problems lubrication can be minimised or completely shut oﬀ, however this can cause chain stiﬀness and uneven elongation of the chain strands, which may lead to production errors and early replacement of the chain. With Traypacker Chain, the internal lubrication cannot transmit to products, which eradicates contamination. In addition, the consistent internal lubrication is said to combat the risks of uneven wear and elongation, and does away with the need to apply expensive food grade lubricants.
Signiﬁcantly, Traypacker Chain is slightly narrower than standard Lambda chain, a requirement for most tray packing machines. Further, the machines require pushers to be ﬁtted to the transport chain and for this Tsubaki’s designers have developed a bespoke solution in which the attachments are mounted by an engineered extended pin that allows ﬂexible spacing so that diﬀerent packing conﬁgurations can be accommodated.
NOVEMBER/DECEMBER 2017 IME 31
Hot mill table roll couplings using high-speed split covers
Single-ended spacer design
DURABLE COUPLINGS FOR HARSH ENVIRONMENTS Nigel Pickford, Principal Application Engineer at the Timken Company, discusses low-maintenance solutions for shaft connections in a variety of applications and outlines the beneﬁts of the ﬁrm’s Quick-Flex Couplings. Created around the principles of easy installation and trouble-free maintenance, achieved with few components and novel design, the Timken Quick-Flex coupling provides a reliable low-maintenance solution for shaft connections. The coupling’s basic design comprises two hubs connected by a removable insert and surrounded by a cover. The hub’s integral jaws provide the space for the flexible elastomeric element. 32 IME NOVEMBER/DECEMBER 2017
The Quick-Flex coupling design also has two optional variations – the single- and double-ended spacer versions. These options enable large spans to be connected between horizontal or vertical shaft ends. The coupling functions and delivers torque while accommodating angular, radial, and axial misalignment. This means that the couplings are suitable for use in high-speed positions between the prime mover and transmission input, and in low-speed, high-torque positions between the transmission output shaft and driven machine. The inserts are constructed of a single
moulded elastomeric component with a radial part line. This feature facilitates the insert placement and removal without moving or disassembling the equipment – both creating signiﬁcant labour and time savings and also avoiding the otherwise necessary disturbance of either machine shaft. For further application ﬂexibility, the inserts are available in a range of hardness, with increasing hardness equating to higher torque capability. Surrounding the insert is a cover, which in turn is secured to the hub. The cover is available in either steel or aluminium;
one-piece or split. The design and coupling size dictate the maximum speed and torque ratings. For instance, the smallest size is suitable for speeds up to 12,000 rpm, while the large size can transmit torques up to 188,800 Nm. At overload, the Quick-Flex coupling can deliver twice the nominal rating. This high-speed capability is enabled through all-over machining. Every coupling size is available with three grades of hardness inserts. Each grade of hardness, with its pertinent torque rating, provides the designer with a choice of stiﬀness. There is also a high-temperature insert for applications up to 175°C. The single-ended spacers are particularly useful for centrifugal pump installations. Removal of the spacer facilitates pump impellor withdrawal and the associated required maintenance. The double-ended design allows for the spacer to be either a tube or shaft, and is suitable for large spans, up to 3000 mm; for example those found in paper-making equipment. The Quick-Flex urethane inserts are compatible with a great many lubricating oils and food materials. As an option, hubs are available in stainless steel. Speciﬁc chemical compatibility can be conﬁrmed through your local Timken representative. Operating and maintaining the Timken Quick-Flex coupling is very simple. The absence of lubricant eliminates the problems associated with seal failure, grease/oil loss and contamination, and the premature failure those can bring. The maintenance operation is simply sliding the cover(s) to the side, unwrapping the element and re-wrapping its replacement, and then sliding the cover(s) back in place. The main images illustrate a setting in which Timken QF250 Quick-Flex couplings were used to successfully replace existing gear couplings that had suﬀered oil leakage. The QF250 with high-speed split cover has proven to work well on table rolls in a hot mill. Standard Timken Quick-Flex hubs are available in the following conﬁgurations: pilot bored; with ﬁnish bore and keyway; tapered to
Quick-Flex coupling with high-speed cover
accept a range of shaft adapter types; or splined. The ﬂanged hubs can be prepared with spigot location for an accurate register. The Timken ﬁnish bored and keywayed hubs are provided with two set screws per hub as standard. Each insert hardness level is colour-coded for ease of identiﬁcation and each grade has a diﬀerent stiﬀness that, when appropriate, allows for the operator to change the torsional properties and behaviour of the system. This is particularly useful when issues with torsional vibrations are encountered. Timken engineers can provide coupling characteristics in support of system torsional vibration analysis. A capability “Low/Med/High” rating comparison with other mechanical coupling types is provided in the table above, which includes lubrication requirements as well. The numerous advantages of the Timken Quick-Flex coupling clearly make it both a good choice for a new project, as well as a winning replacement for an existing installed base.
For more information on the Timken Company’s range of products and services circle readerlink 209
Timken Quick-Flex Couplings – Summary • Can replace virtually all styles of couplings in high- and low-torque applications for plant standardisation. • Solid and split covers handle higher speeds and increased torque. • Design dampens transmitted torsional vibration and shock to help extend the life of the coupling and surrounding components. • Couplings accept misalignment, up to 2°. • Timken inserts reduce downtime and replacement costs because inserts can be replaced without moving or disassembling the driving or driven equipment. • Great for inventory reduction because the only spare part required is a urethane insert that can be replaced in just a few minutes. Applications: • Motor to gearbox. (Low torque/high speed) • Gearbox to driven equipment. (High torque/low speed) • Motors to pumps.
NOVEMBER/DECEMBER 2017 IME 33
BEARINGS & SEALS
SELECTING REPLACEMENT LINEAR SYSTEMS Bob Love, Business Development Manager at Schaeﬄer UK, outlines the top ﬁve points that engineers, maintenance technicians and service providers should consider when replacing linear proﬁle rail systems in existing machinery. When a linear system has reached the end of its useful life, often the easiest thing to do is to replace it with a like-for-like linear system from the original equipment supplier (OE-fitted brand). However, this may not necessarily be the best choice for your machine or your business. Replacing a linear system with a product from an alternative linear supplier could be more beneficial, both in the short term and over the complete lifecycle of your machine. 34 IME NOVEMBER/DECEMBER 2017
Shorter production downtime
Reduced lifecycle costs
Whether the linear system is part of a special purpose machine tool, automated handling system, pick-and-place machine or part of a production line refurbishment, in the short term, choosing an alternative linear supplier’s product could result in a faster delivery time, allowing your machine(s) to be up and running again sooner, thus minimising production downtime to your business.
If the replacement linear system is higher/premium quality, over the long term, it is likely that your machine’s lifecycle costs or Total Cost of Ownership (TCO) will be reduced. While the initial purchase price of the linear system may be higher, over the complete lifecycle of the machine, the potential savings that can be achieved in the form of improved energy eﬃciency (e.g. by using lower friction components) and reduced maintenance costs
from alternative manufacturers must be replaced as a complete carriage(s) and rail(s) system. This is necessary as replacements will be based on matching external boundary dimensions with acceptance of diﬀering internal geometry. When a supplier receives a linear system enquiry for replacing existing used product, certain factors need careful consideration before a suitable product for a single-, two- or three-axis positioning system can be selected. Although not all the technical data will be available to hand, certain key features of the linear system need to be established if performance of the new system is to be maintained, while enabling sourcing from alternative original manufacturers:
(by using better sealing, special protective materials or corrosion-resistant coatings) often more than outweigh the initial higher purchase price of the premium linear product.
Key factors to consider In this article, ‘linear systems’ and 'linear proﬁle rail systems' refer to a complete rail(s) and carriage(s) assembly. Replacement linear systems
1 Size and length of the rail(s) and carriage(s), ball or roller type It is important to provide the linear supplier with accurate information on the size and length of the rail(s) and carriage(s), as well as the type of carriage (ball or roller). Do not simply rely on the markings. It may be that the size marking is visible on the carriage(s) but even if it is, overall system height, carriage length and the rail length should be measured for the system and provided to the supplier. If the rails are butt jointed, joint position(s) should also be indicated (e.g. Ball type carriage size 35, overall length 110mm, overall system height 48mm. Rail length 760mm, one-piece rail). 2 Rail end dimensions, symmetrical or non-symmetrical Rail end dimensions should be provided. These include whether the dimensions are symmetrical or non-symmetrical, as well as the centerline of the ﬁrst and last hole to the end of the rail for both ends (e.g. symmetrical, both ends, 20mm). 3 Number of carriages per rail and design style The number of carriages per rail and the design style are also important. Typically, the design style of the carriage(s) is either rectangular or ﬂanged but other more obscure styles do exist (e.g. two carriages per rail, ﬂanged design style). 4 Number of rail sets, in parallel, in the machine The number of rail sets, in parallel, in the machine needs to be provided (e.g. 2 parallel rails per set). 5 Type of machine being maintained The type of machine is important to the support staﬀ in selecting your precise product, as much information can be included from knowing the
base application. Providing a photograph of the application to the linear supplier can also prove very useful. For example, a simple pick-and-place machine will operate satisfactorily on standard precision-grade product with a 'normal' or 'clearance-free' option. However, in a machine tool, providing a linear system with a light or medium preload will be critical, together with a higher precision grade product (e.g. vertical machining centre). In addition, depending on the machine type and operating environment, various options are sometimes speciﬁed for the linear system such as coatings or special lubricant, seal kits or lubrication accessories for speciﬁc conditions (e.g. food-grade grease or coating, wipers, double seals, or a permanent lubrication feed).
Application experience is vital From this base data provided in the ﬁve points above, a reliable selection of a replacement linear system can be made by a reputable supplier with qualiﬁed, trained support staﬀ who also have application experience. This enables a replacement linear system to be supplied that will help restore your machine to production performance, even when the original loading, speed, acceleration, stiﬀness and precision grade details are not available. Ensuring that you receive the right replacement linear system to enhance the life of your machine means you must direct your enquiry to manufacturers of linear systems (or their distribution partners) who possess the necessary in-house expertise to discuss and specify your requirements in the necessary depth to allow you to get your production going again and help you reduce your Total Cost of Ownership.
For more information on products from Schaeffler, circle readerlink 210 NOVEMBER/DECEMBER 2017 IME 35
TEP STEP BY S
Nero Pipeline Connections demonstrates the steps required to assemble a compression joint correctly.
COMPRESSION FITTING ASSEMBLY Nero’s expertise with single and twin ferrule compression fittings means it has a great understanding of the common pitfalls faced by engineers. There are only a few steps to assembling a compression joint correctly. However, if just one of them is overlooked, it can create problems further on in the process.
Cutting and preparing the tube The ﬁrst step towards getting a compression joint to seal correctly starts with how to cut the tube in the right way. Using a roll cutter isn’t recommended as they can create an inconsistent ﬁnish and warp the end of the tube. In most situations, a hand hacksaw or reciprocating saw is the best solution as they create a very clean cut without any distortion. It is also important that the cut is as straight as possible and that the inner and outer edges have been cleaned using a deburring tool. Using this method will ensure the tube will pass through the compression nut and seat on the ﬂat face inside of the
Lubrication, lubrication, lubrication Both twin and single ferrule use a similar method to create a compression joint, by tightening the nut on to the body. The cutting rings or olive are squeezed around the outside of the tube to create a groove or channel which should allow some rotation but no forward/rearward movement. In this process the nut, olives, ﬁtting body and tube are all creating friction and generating heat. A quality cutting compound helps prevent against any distortion or galling of the threads during the initial assembly. Every component should be well coated in compound before assembly to ensure any unnecessary damage.
Forming the compression joint The most important tool in this section is a vice. Every single compression joint should be created using a well secured bench vice. More often than not, problems can be found buried in a system where an engineer has formed a compression joint in place. With such a large
range of sizes available in the compression range, there is also a reﬂection in the amount of physical force required to create a perfect seal. This is a step in the process that must not be overlooked and will almost certainly lead to system failure if ignored. After applying a generous amount of lubricant to the components, re-assemble the ﬁtting and place the ﬁtting body into the vice while keeping the compression end as horizontal as possible to aid with the seating of the tube. Place the cut end of the tube into the ﬁtting, ensuring it passes through the olive and squarely meets the ﬂat seat inside the ﬁtting body. Tighten the nut by hand and proceed to mark a baseline on the tube and nut. This mark will be the starting point to measure the amount of turns applied. With the correct size (or adjustable) wrench, hold the tube with one hand and tighten the compression nut until it is felt to grip the tube. Using the mark as a starting point, proceed to turn the compression nut another 1 to 1½ turns whilst keeping a ﬁrm grip on the tube. Depending on what size joint is being NOVEMBER/DECEMBER 2017 IME 37
“A quality cutting compound helps prevent against any distortion or galling of the threads during the initial assembly. Every component should be well coated in compound before assembly to ensure any unnecessary damage.”
assembled, an extension to the wrench might be needed to generate the right amount force required to get to the full 1½ turns. If creating multiple joints, it would be a good idea to use a ‘pre-installation body’ tool, one tool per size will be required and this will prevent any potential damage to the ﬁtting body during initial compression.
Inspection Loosen the nut and remove the tube from the ﬁtting or pre-installation body. After cleaning the remaining compound, there should be a perfectly formed compression joint which might allow some turning movement of the ferrule/olive but must not allow any forward or backward motion. If there is any irregular movement in the olive, this will either be a result of under lubrication or over tightening and the process will need to be repeated using 38 IME NOVEMBER/DECEMBER 2017
new components and the damaged end of the tube removed.
location and tighten, adding another 1/16 of a turn to fully re-seat the olive.
For more information on compression fittings from Nero Pipeline Connections, circle readerlink 211
To install the freshly formed compression joint, simply place the tube in to the ﬁtting in
HOSE CLIP SELECTION
With manufacturers continuing to develop an ever greater number of hose clips for diﬀering applications, the decision of what to use is growing exponentially. JCS speaks to IME about the options available to engineers. As an engineer, there is nothing more infuriating than finding you have the wrong size or type of fitting to complete the job. No matter how well prepared you are, it is impossible to carry every component for every eventuality. Ever more so is this the case for engineers with a requirement for hose clamps. With an almost never ending list of types, including Nut and Bolt, Double Ear, Single Ear, Self-Closing, Over-centre and Herbie Clip to name but a few, the decision of what to stock your tool box with is a diﬃcult one. So which do you choose? Many hose clamps have been designed to do the speciﬁc job at the lowest possible price. As such, many manufacturers will use clamps only suitable for a certain size of hose and which are only convenient in the manufacturing stages. Ideally, engineers need a strong, easy to use clamp with a large adjustment range to cover many diﬀerent hose sizes – a worm drive hose clip is therefore an ideal solution.
Up for the task How can we be sure the worm drive clip is up to the job? For standard duty clips there are a 40 IME NOVEMBER/DECEMBER 2017
number of diﬀerent applicable standards depending on the country and industry. The chart shows the most common and, as you can see, operating requirements for the British Standard BS5315 are far in excess of all other standards. The only way to ensure you have a clip that meets this high standard is to look for the British Standard Kitemark. All JCS Hi-Grip products, Zinc Plated Mild Steel, BS.304 and BS.316 Stainless Steel carry the BSI Kitemark. In addition, to ensure all clips exceed this standard, JCS internal standards are set at least 20% above the operating requirements of BS5315. It is worth mentioning that some hose clamps feature continuous perforations along the band –
this is normally sold on the misconception that the clamp has a larger adjustment range. In reality the reason for manufacturing clamps this way is because it is cheaper. The BS5315 states the recommended size adjustment range, as the screw housing is measured to closely ﬁt against the relevant hose diameter. JCS clips follow the BS5315 recommendations to ensure all clamps perform to the highest standard across their full adjustment range.
Heavy duty There will of course be applications where the standard worm drive hose clip will not be suitable – wire reinforced hoses, particularly
large or high pressure applications for example. For such occasions, JCS oﬀers a range of heavy duty clamps known as Hi-Torque. Hi-Torque clamps have a straight line housing which ensures every thread of the hardened rolled stainless steel screw is fully engaged with the fully perforated band. This special feature, together with the high tensile stainless steel band means Hi-Torque oﬀers at least twice the strength of ordinary worm drive hose clips. When used correctly, Hi-Torque oﬀers a cheaper, more versatile and easier to use alternative to Nut and Bolt type clamps. In testing, Hi-Torque has proven to consistently provide superior clamping force and sealing ability onto diﬀerent types of hose, with the added advantage of a much larger adjustment range. One of the issues with using worm drive hose clamps – particularly on soft wall rubber hose – is the potential for damage to the hose itself. For example, where clamps are tightened it can be very easy to cut into the hose. Add to this vibration from an engine or similar, and it can result in complete failure as the hose clamp cuts deeper and deeper. To help prevent this many companies up-turn the edges of the clamp band, however this only moves the sharp point and hose damage can still occur. JCS uses special material with a rounded edge for the clamp bands on all products which oﬀers superior protection, with the sharp point that can cause damage and cut the hose being removed completely.
For more information on the range of hose clips available from JCS Hi-Torque Ltd, circle readerlink 212
“Ideally, engineers need a strong, easy to use clamp with a large adjustment range to cover many different hose sizes – a worm drive hose clip is therefore an ideal solution.”
Hose clamps for every application With such a broad range of uses, JCS has supplied clamps to every corner of the globe for some rather peculiar applications, but by far the strangest was the use of Hi-Torque by an American university. As part of the study, the university was tracking the movement of walruses in Alaska – though securing a tracking transmitter to the animals turned out to be quite the challenge. A suitable method of securing the transmitter to one of the tusks needed to ensure the transmitter did not become dislodged and cause harm to the animal. The securing method also needed to be impervious to constant immersion in saltwater and very low temperatures. After several attempts (and expensive losses) using adhesives and various strapping methods, it was decided Hi-Torque clamps were the answer. Made from Marine Grade BS.304 Stainless Steel and with a rounded band edge, the clamps provided the ideal solution. The method was used successfully for over two years with no failures and, most importantly, no harm to the animals.
NOVEMBER/DECEMBER 2017 IME 41
FLUID CONDITION MONITORING Use of test strips to monitor ﬂuid condition could be a big help for those looking to adopt predictive maintenance, according to Acustrip. Fluids are the lifeblood of human bodies, vehicles, and machines. When in good condition, they can help to combat stress, wear, fatigue and, more importantly, keep things running smoothly. In the case of vehicles and machines, use of the correct fluids, replaced at optimum times, will give the longest service life – this is done through the use of set maintenance programmes. By monitoring the condition of the fluids, it is possible to determine when remedial action may be necessary, or even to indicate that an earlier change than usual is necessary. Active preventative
42 IME NOVEMBER/DECEMBER 2017
maintenance programmes depend on good information. By monitoring ﬂuid performance, over time you could predict when a piece of equipment is under stress, needs adjustment and is due a ﬂuid change. On the market today there are a number of simple, quick, visual tests that can be utilised to help set up such a programme. Wear metals monitoring with regular testing of the lubricants, oils and other machine ﬂuids helps deﬁne corrective actions and thereby avoid expensive damage and downtime to high value equipment. Wear limits have an important place in health monitoring of machines. For example, if a
diagnosis is made on the health of a component based on oil analysis and a trend is used, then a minimum of three samples is required to establish that trend (the cycle is set by analysis and the resulting maintenance programme schedule).
Contamination and wear metals Contamination ﬂuids are very common and can cause numerous problems: • Water contamination is very common. Water is detrimental because it does not lubricate as well as oil and can cause wear. In some cases, it also can react with the additive system to form acids that can cause yellow metal corrosion. Water in the presence of air leads to rust of component surfaces and can increase the rate of corrosion, decreasing the ﬂuid life. Metal particles then can accelerate the oxidation process, and the contaminants can in turn cause abrasion, pitting or surface fatigue on machine surfaces. • Fuel contamination introduces several changes, including lower ﬂash point, lower viscosity, and increased vapor pressure. The viscosity change alone creates lower ﬁlm strength, hampering lubrication eﬃciency. • Two potential corrosion problems must be considered: system rusting and acidic chemical corrosion. System rusting occurs when water carried by the ﬂuid attacks ferrous metal parts. Low ﬂuids or ﬂuids that have reduced protective additive protection may have reduced coverage of the active surfaces, resulting in oxidation and wear. The corrosion can
Wear limits are useful in these situations because they provide a guideline of how the average machine should behave under normal conditions. Regular trending of the wear metal results is expected under normal operations. A smooth trend up is to be expected. For example, if the unit shows signs of being critical, with upward spikes of data typically of 10% or more change in the cycle, then an alert can help to identify that the machine’s performance is not optimal and the causes needed to be looked into. Once a diagnosis is made, corrective action can take place. Without the alert provided by monitoring, potential failure could result. Early detection of wear metals in lubricants and greases improves machinery reliability and minimises costs, especially if done as part of a professional oil condition monitoring programme. While there are many ways to ﬁlter out metals, monitoring their level will assist in deciding when to change the ﬂuids, or when there is a potential maintenance need that requires attention. On site testing is an easy low-cost way to provide timely results. Lab monitoring is typically time consuming, inconvenient, time delaying and expensive. Other qualitative tests leave out quantitative evaluation of the wear metals, thus requiring Acustrip Metals Test #70003 When used regularly, Acustrip Metals Test® #70003 allows technicians and operators to trend wear on engines and equipment component parts. Any abnormal presence of the metals allows for immediate corrective action. The results are lower maintenance costs, higher operating eﬃciencies and increased engine and component life.
How it works 1. Dip one test strip into the sample of the ﬂuid for 30 seconds with a gentle back
and forth motion. Remove the test strip and shake once briskly to remove the excess ﬂuid. Wait two minutes and then compare the colour to the colour chart. Complete colour matching within 30 seconds. For best colour matching, fold the white plastic handle of the test strip under the aperture so that it provides a white viewing background. All readings should be recorded on the device maintenance record for future reference.
result in brittle services gaskets, hoses, and linings. • Over time, ﬂuids oxidise and form acids, sludge, and varnish. Acids can attack system parts, particularly soft metals. Extended high-temperature operation and thermal cycling also encourage the formation of ﬂuid decomposition products. • If water is identiﬁed as an issue (can be tested with ACUSTRIP Moisture Test 40002) large quantities can be removed by draining the sump periodically. However, small amounts of water can become dissolved, particularly if the sump is small. Demulsiﬁers can be added to the ﬂuid to speed the separation of water. Filters can then physically remove any remaining water from the hydraulic ﬂuid. The water should leave the ﬂuid without taking ﬂuid or additives with it. Identiﬁcation of the presence of water and/or the presence of corrosion products is important to maintain the integrity of the machine’s components. Water breaks down oil-additive packages, forms acids that corrode metal surfaces and, in mineral-based oils, supports oxidation. For example, hydraulic oil containing just 0.1% water by volume can cut bearing life in half. non-precise interpretation of the results. Even the most expensive ﬂuids will not prevent the damage of high levels of metal ions and particles once they are present. By monitoring the level of metals at each scheduled maintenance service, keeping an eye on the trend of their levels, will assist with determining changes to schedules and help plan for preventative (predictive) maintenance. Change your ﬂuids when they need to be changed, but also perform corrective preventative maintenance as needed.
For more information on Acustrip, circle readerlink 213 NOVEMBER/DECEMBER 2017 IME 43
TOOLS, EQUIPMENT & PPE
Norbar Torque Tools has recently been accredited to perform calibrations on hand torque tools to the newly revised BS EN ISO 6789-2:2017 standard. Here, Neill Brodey, Managing Director, takes the opportunity to outline the key changes, and what they mean for manufacturers and tool users alike.
CHANGES TO ISO 6789-2:2017 BS EN ISO 6789:2003 divided requirements into three sections: design conformance testing; quality conformance testing and recalibration. The intention was to allow different groups of users to identify the relevant clauses for their needs. Coming into play earlier this year, the 2017 edition takes this logic even further and divides the standard intotwo distinct parts. As a result, the type of documentation supplied with tools has changed. 44 IME NOVEMBER/DECEMBER 2017
With new requirements for design and quality control, Part 1 relates to the manufacturer and conformance, whereas Part 2 focuses more closely on the calibration of torque tools. In essence, the key changes have been made to protect the word ‘calibration’, which is often used too casually. Calibration is deﬁned by ISO as: “a set of operations that establish, under speciﬁed conditions, the relationship between values of quantities indicated by a measuring instrument or measuring system… and the corresponding values realised by the standards.” While most of the requirements from the 2003 edition are carried into Part 1, there are new design requirements at work of which engineering teams need to be aware when purchasing future tools. These include the
introduction of new maximum torque values for hexagonal output drives, which is of particular interest for torque screwdriver manufacturers. Additionally, changes have been made to certain quality conformance requirements. For example, the time to attain the last 20% of the torque application during testing has now been more tightly deﬁned according to the size of the
torque tool. Manufacturers will also now need to state that the tools adhere to the new requirements of Part 1 by supplying a “Declaration of Conformance” with the tool, as opposed to a “Calibration Certiﬁcate” – so be aware of this when making any purchasing decisions. Part 2 of the standard now covers the traceable calibration of the tool, and the requirements of the calibration equipment. This includes highlighting the steps that need to be taken to distinguish uncertainty factors that may cause the calibration values to vary from calibration to calibration for that particular torque tool. Therefore, should a manufacturer also wish to produce a certiﬁcate of calibration, they must issue it in accordance with Part 2 of the new ISO 6789 standard. For a new torque tool model that has not yet been seen by the laboratory, calibration to this standard takes around 60 minutes. However, the good news is that what this all means for the tool user is quite simple. Those who were previously content with buying a new torque tool and putting it into service on the basis of the “Calibration Certiﬁcate” supplied by the manufacturer, can still do so. However in its place, there will be a “Declaration of Conformance”. The declaration does come with a date of issue, but retesting should take place within 12 months, or 5,000 cycles of the tool being put into use, rather than the date of the Declaration of Conformance. However, for those working in environments with stricter quality control processes that require a traceable “Calibration Certiﬁcate” issued by an accredited laboratory, it will be necessary to request that the tool be tested to Part 2 of the standard as well. This will provide the tool user with both a “Declaration of Conformance” and a “Calibration Certiﬁcate”. While the change may take a little getting used to, the update to ISO 6789 will help to provide more clarity in the long run, with two distinct parts and separate documentation to match. The 2017 edition is now published and should be used in place of the old 2003 edition, which has been withdrawn. However, in Europe the Euro Norm or EN version has a 12-month period of overlap (February 2017 – February 2018) where either edition can be used.
For more information on the new ISO standards from Norbar Torque Tools, circle readerlink 214
TOOLS, EQUIPMENT & PPE
ABRASIVES TRAINING To help companies comply with Provision and Use of Work Equipment Regulations (PUWER) regarding machines and hand-held power tools, Master Abrasives oﬀers a solution to training employees with its safe use of abrasives training course accredited by the British Abrasives Federation (BAF).
When used correctly, abrasives have an excellent safety record. Whilst reputable manufacturers follow precise manufacturing standards (EN 12413) to ensure products are fit for purpose, problems are likely to arise when products are used incorrectly or for materials and applications for which they were not intended. Abrasive wheel breakage is the largest risk for incidents, as grinding tools have operating speeds up to 180mph and can accelerate and decelerate faster than a Formula 1 racing car. Personal injuries resulting from wheel breakages are usually a result of using hand held machines, and unfortunately the single largest reason for a wheel breakage is operator error. For this reason, it is a requirement of the PUWER legislation that all people who use, supervise or manage the use of work equipment have received adequate training. Master Abrasives oﬀers a training course to ensure this legal requirement is covered for employers. All who attend and pass the safe use of abrasives training course, accredited by the BAF, are issued with a certiﬁcate, giving employers peace of mind that they are helping to keep their workforce safe. The course familiarises abrasive users with basic but vitally important facts about abrasives, the use of them and
how, when used correctly, they have an excellent safety record. Although hand-held tools pose possibly the greatest risk to life and limb, even machines that are fully enclosed require training for operators and other employees involved to prevent costly accidents. Training provides the knowledge needed to select the appropriate product to match the machine and the material being ground, ensuring that it is not damaged with methods such as the ring test, as well as teaching required for mounting wheels to the machine correctly. As simple as it sounds, these basic operations are a major source of accidents when carried out incorrectly in the workplace every year. Paul Batson, Managing Director of Master Abrasives, explains: “Ian Meredith, our certiﬁed trainer, carries out the safe use of abrasives course accredited by the BAF. Ian is our Applications Engineering Manager, with vast experience in various engineering industries, making him the ideal trainer for this course.”
The training course oﬀered not only helps to fulﬁl legal requirements and reduce the propensity for accidents, it can seriously improve operator and programmer knowledge to further cut scrap rates and improve output. The programme can be tailored to customers speciﬁc needs and can even be expanded to include application recommendations for abrasives to improve performance and output.
Additional safety training Complementing the abrasives training, the Master Tool Services department oﬀers an IOSH accredited Hand Arm Vibration (HAV) Toolbox Talk to help attendees to understand, control, and reduce the risks involved. It covers the types of tools which are high risk, the causes and health eﬀects of Hand Arm Vibration Syndrome, the measurement and assessment of HAV, the Health and Safety Executive (HSE) points system and many more points which operators should be aware of. This option can be a solution to the HSE legislation which requires employers to provide information, instruction and training to employees on the risk and the actions being taken to control the risk of HAV. For more information on abrasives training, circle readerlink 215
NOVEMBER/DECEMBER 2017 IME 47
TOOLS, EQUIPMENT & PPE
INTEGRATED DUST EXTRACTION Bosch’s new active integrated dust extractor is designed to allow for dust-free rotary hammer drilling. IME reports.
Look after your health – it’s your greatest asset,’ is the message from Bosch as it launches the GDE 18 V-16 Professional Dust Extractor. Designed as an active integrated attachment for all Bosch GBH 18 V26 (F) Professional Rotary Hammer Drills, its development is part of a continuing drive by the manufacturer to minimise dust-related illness.
Don’t underestimate the danger While asbestos is perhaps the most infamous dust hazard, workers regularly come into contact with many other substances which can irreversibly damage their health and shorten their life. They include silica dust, for example. Crucially, Bosch warns, you must never assume that any kind of dust in the workplace is harmless. Estimates from a Health and Safety Executive (HSE) report in 2016 suggested 48 IME NOVEMBER/DECEMBER 2017
around 12,000 deaths in Britain each year resulted from respiratory diseases caused by past working conditions. These included chronic bronchitis, emphysema and other types of chronic obstructive pulmonary disease (COPD), as well as lung cancer, mesothelioma and pneumoconiosis. Various allergic illnesses took smaller numbers of lives but nevertheless greatly aﬀected workers’ quality of life. About 14,000 new cases were reported annually of breathing or lung problems caused or made worse by work. In total, around 141,000 people who had ever worked were now suﬀering in this way. Inhalable dust, which is relatively easy to see, can damage your nose, mouth, throat and windpipe. Respirable dust, whose small particles are invisible to the naked eye, goes deeper into your lungs, and even beyond, to cause harm. Some dust trapped in the mucus of your respiratory system ﬁnds its way to your mouth, is swallowed, and may aﬀect your gut
or reach other organs through your bloodstream. Skin and eye contact with dust is another source of health problems.
Protect yourself Where generation of dust is unavoidable, it should be extracted close to its source of emission. Normally this is achieved by placing a vacuum cleaner hose end next to the drilling or cutting point – or, better still, attaching it to the power tool. Bosch has improved the convenience and eﬀectiveness of dust extraction by making its new GDE 18 V-16 Professional Dust Extractor an integral part of the hammer drill in use. It simply slots into place on the tool whenever needed. Driven by its own motor, which is powered by the drill’s battery, the active integrated dust extractor has an automatic power on/oﬀ function. When the drill trigger is pulled, the unit automatically activates. When it is released, extraction continues for a
further two seconds, to ensure optimal dust removal, before coming to a stop. The unit’s dust container features a HEPA ﬁlter which removes 99.97% of all dust particles larger than 0.3 micrometres. An inspection window shows how much dust has been collected, and both the container and ﬁlter are quick and easy to remove, clean and replace.
Taking dust extraction seriously While economic considerations might seem trivial compared with life and health, they do add weight to the argument for taking dust extraction seriously. A clear, dust-free view of the job is important for precise and eﬃcient work. A clean and tidy workplace keeps customers happy, and extracting the dust at source saves time on cleaning up afterwards. What’s more, the
tool, its motor and its accessories will have a longer service life if they are not covered in damaging dust. But above all, says Bosch, don’t forget that your health is your capital – so make sure you protect it. Bosch already oﬀers dust extraction in a wide variety of applications through its Click & Clean system, with which most Bosch power tools are compatible. This allows
simple and fast connection between the tool and any one of a range of freestanding Bosch dust extractors. Its new active integrated dust extractor provides an alternative approach particularly suited to hammer drilling.
For more information on the Bosch GDE 18 V-16 Professional Dust Extractor, circle readerlink 216
TOOLS, EQUIPMENT & PPE
GETTING STARTED WITH THERMOGRAPHY With the latest developments and the advent of low cost spot thermal cameras, thermography is now accessible to all for the fast troubleshooting of electrical and mechanical installations. IME speaks to Martindale Electric to ﬁnd out more. It’s now possible to purchase entry level spot thermal cameras for as little as £200 to £300. At this level, the benefits of being able to identify faulty installations and equipment early, and prevent serious disruption to production processes and systems, easily justify the costs. The latest designs combine real time thermal imaging with spot infrared temperature measurement and come packaged in rugged pistol shaped designs, ideal for maintenance teams needing fast onsite diagnostics. The cameras show hot and cold spots at a glance and accurately measure spot temperatures of hot and hard to reach surfaces. The question is, what do you need to know to get started? The latest entry level products 50 IME NOVEMBER/DECEMBER 2017
are point and shoot in nature, so they are easy to use and it’s fast to get up and running. To get the most out of the cameras and understand where they can be used for troubleshooting, it’s important to understand some basics about how they work and what to look out for. Troubleshooting with thermography relies on the fact that most components in a system show an increase in temperature when
malfunctioning. The increase in temperature in an electrical circuit could be due to loose connections causing increased resistance or, in the case of mechanical equipment, it could be the result of a worn bearing. By observing the infrared heat maps of components in working systems and equipment, faults can be located and their signiﬁcance and root causes evaluated. As contact with the system is not required, inspections can be made under full operational conditions resulting in no loss of production or downtime. Heated objects radiate infrared energy, which can’t be seen by the human eye but can be detected by a thermal camera and displayed as a series of colour gradients or heat map on the screen of the camera. The heat map shown by spot thermal cameras can be used to show relative surface temperature and identify hot
Choosing the right feature set Generally, spot thermal cameras avoid the need for complicated menus to be set up before getting started, but there are a range of features available on different models to choose from. Here are some key considerations to ensure the right tool for the job:
“With the new generation of point and shoot spot cameras and a basic understanding of the dos and don’ts, it’s fast, easy and affordable to add thermal imaging to your troubleshooting toolkit.”
Blended images A blended thermal and optical image makes it easier to identify components Rugged design Tough enough to survive a toolbox for on-site use Fixed or adjustable emissivity for a wide range of surfaces Laser pointers and built-in torches for easy targeting in low light environments Selectable colour palettes for enhanced analysis Screen capture or image storage and download for reporting
spots. The temperature of the hot spots is measured at the same time with the built-in infrared thermometer. Thermal imagers that measure and record the temperature of each pixel on the screen are also available but come with a hefty price tag and many features that are not needed for initial troubleshooting. As with conventional cameras, thermal cameras cannot see through the surface of the component and can only see line of sight. With the new generation of point and shoot spot cameras and a basic understanding of the dos and don’ts, it’s fast, easy and aﬀordable to add thermal imaging to your troubleshooting toolkit. The range of applications is extensive, from non-contact electrical and mechanical fault ﬁnding through to identifying sources of heat loss and checking the correct functioning of heating and ventilation systems. The latest cameras provide an aﬀordable solution for busy maintenance teams to troubleshoot problems quickly and identify potential maintenance issues early.
For more information on products from Martindale Electric, circle readerlink 217
What to look out for when using thermal cameras Beware of reflections. Just as with a normal camera, thermal cameras are susceptible to reflections, but of course you can’t see infrared with the naked eye. For example, when measuring the temperature of a window you may see a hotspot which is in fact purely a reflection of heat from the camera operator. Surface Emissivity makes a difference. Emissivity is the capacity of a surface to emit heat. It is a relative quantity between 0 and 1 and expressed in terms of an ε value. Thermal and electrical insulators are excellent emitters, but metals are unlikely to have emissivity above 0.25 unless they are heavily oxidised. If you are inspecting different material surfaces and making quantitative temperature measurements, you’ll get the best results with a camera on which you can easily adjust the emissivity for the application. For purely qualitative inspections it’s less important.
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TOOLS, EQUIPMENT & PPE
ADVANCES IN WEARABLE TECHNOLOGY David Clark, Managing Director of Snickers Workwear, part of the Hultafors Group UK, talks to IME about the advancements in wearable technology and high-tech fabrics. With Google and Levi’s joint initiative Project Jaquard being typical of how ‘Smart Clothes’ are driving the development of the wearable technology industry, we’re now seeing weird and wonderful performance enhancing initiatives like yoga pants, powered sports bras, smart bikinis (and even smart socks), compression shirts and posture-tracking shorts. It’s certainly a long way from boiler suits and jock straps, but indicative of how high-tech fabrics and wearable technology are becoming the norm in performance clothing. As Snickers Workwear leads the way with the trial of its Tracker-1 device and the patented KneeGuard system, wearable technology is here to stay in the working lives of professional users. In fact, the results of a recent survey by research organisation Oﬃce Genie show the extent to which people are mindful of the role that wearable technology plays at work. While the beneﬁts to personal wellbeing are now widely accepted, a key question remains: are wearables the answer to productivity? In the survey of over 1,000 employees, more than a third (36%) of employee respondents cite increased productivity as a beneﬁt of using wearable technology in the workplace. 43% of respondents cite employee wellness, while 41% also cite health beneﬁts. 52 IME NOVEMBER/DECEMBER 2017
Furthermore, 69% of respondents aged 18 to 24 believe that wearable technology is beneﬁcial in the workplace. “We have shown that wearable technology is certainly a major factor in helping to ensure personal wellbeing,” says David Clark, Managing Director of Snickers Workwear. “Our R&D goes on to show that the integration of wearables and high-tech fabrics in working clothes does have a major inﬂuence on productivity.”
Performance, comfort and productivity As any athlete will tell you, when it comes to clothing, performance and comfort are closely linked. “In fact, an athlete’s performance can improve by up to 26% through the use of the advanced 37.5 Technology fabric,” says Clark. Snickers Workwear continues to bring advanced workwear with 37.5 Technology to the UK market.
37.5 Technology The name 37.5 comes from the ideal relative humidity of the microclimate close to the skin – and the average person’s ideal core body temperature. It’s a technology that cools when
it's warm, but warms when it's cold. Its developers discovered that embedding activated carbon in fabrics speeds up the conversion of liquid to vapour, cooling you down when it is hot and warming you up when it is cold. Unlike conventional moisture management fabrics, 37.5 Technology is all about preventing sweating in the ﬁrst place. “The problem with fabrics that absorb moisture is that they solve the problem after it has arisen. You sweat, and then they start to work,” Clark says. “That’s too late. A fabric that knows what your body needs in advance is the solution. “37.5 Technology started in outdoor clothing, expanded into lifestyle and sportswear, and now it’s embedded into Snickers Workwear. The more comfortable our users are, the more productive they are likely to be, reducing the risk of mistakes and accidents.”
Perfect tech for workwear It’s all about improving comfort and enabling a better work experience,” Clark continues. “This technology suits our workwear perfectly with its superior absorption capabilities. We tested several similar technologies available on the market, but none of them were as responsive as 37.5.”
User feedback Snickers Workwear did both lab tests and live user tests on 37.5 before including the
technology in its product range. “We have had very positive feedback from users, highlighting the improved comfort of the fabric,” Clark explains. “This ground-breaking, state-of-the-art technology ﬁts nicely into our strategy of oﬀering the best workwear on the market, aimed at improving the user’s eﬃciency, comfort and productivity. It has unique features, and it feels great to be the ﬁrst workwear manufacturer to launch it in the UK.” 37.5 active particle technology captures and releases moisture vapour to maintain the optimum relative humidity in your body’s microclimate.
the heat is on or warm and comfortable when the temperature drops. Interweaving 37.5 Technology fabric into its latest LITEWork and ALLROUND garments means that you can wear clothes that excel at ventilation and moisture transportation to keep you working comfortably wherever you are on site. There’s a new range of shirts, jackets, trousers and accessories to ensure a balanced work temperature for your wellbeing, eﬃciency and job safety. So, to make sure you get the right protection, ﬂexibility, durability and ventilation, check out the newest LITEWork and ALLROUND workwear for the right garments to ﬁt your workday.
Climate control workwear A change of temperature means a change of focus on what you wear, so Snickers Workwear ensures you keep your cool when
For more information on Snickers workwear with 37.5 Technology, circle readerlink 218
TOOLS, EQUIPMENT & PPE
TOOLS TO INCREASE EFFICIENCY
IME takes a look at how some of Wiha’s latest products work together to improve eﬃciency for engineers whilst on the job.
Improving efficiency is key to any job, and having tools at hand that can make life easier is vitally important to supporting the process. Tool selection and visibility should be easy – no engineer wants to be in the midst of a repair to find they are unable to identify the correct tool or device for the job, with poor visibility only adding to the issue. On this note, Wiha has recently released products that can provide solutions to these problems. Perhaps a crucial point is that the latest range of bits have been coated in UV, whilst the new torch can usefully detect UV light. If, for example, the bits are dropped whilst working, they can be easily relocated with a ﬂick of a switch, suggesting there has been collaborative thought behind the additions.
Easier selection Bit selection has never been easier, faster, more intuitive and “impact perfect” for users, Wiha says. All its bits are now perfectly suitable both for normal screwdriving tasks and impact screwdrivers, while the subdivision of coloured bits ensure engineers can quickly and correctly identify the necessary item. A glance at the screw, another at the concept’s new colour and symbol code, and the bit is located in seconds. If the user has screws with a 90˚ angle at the screw head, which tend to lie ﬂat against the material, the new blue T bits are the ones to go for. 54 IME NOVEMBER/DECEMBER 2017
For screws with angles of more than 90˚, in other words with more of a countersunk shape, the yellow Y bits are the answer. If the user wants to fasten both types of screws, the red all-rounders, the TY bits are the right choice. Thanks to the extended torsion zones of the new bits, there is also an improved lifespan – 120 times longer – compared to previous standard bits, for instance. This saves time and money and allows for smoother workﬂows and task changes. As previously mentioned, for better detection, special UV coatings on the bits’ blue, yellow and red colours illuminate ﬂuorescently when an appropriate light, such as the Wiha torch, is shone upon them. Ronny Lindskog, Sales and Marketing Manager at Wiha, comments: “Professionals should be able to use their valuable time for their work – not searching around, choosing and constantly changing bits.”
Visibility is key when working on machinery and production lines, and darkness can creep up out of nowhere. To combat this, Wiha has introduced its new hand torch to the market. Equipped with practical functions – laser, UV light and a strong LED lamp – the torch provides a variety of usage options. The tool contains special features such as a retaining clip, magnetic positioning mechanism, and easy positioning and transmission of measurements thanks to the swivelling light head and permanent laser function. With a very strong LED lamp, this light is suitable for diﬀerent work situations and light conditions due to the two LED lighting levels at 280 lm and 100 lm, since dazzling light often reduces vision outside the light beam. The integrated laser function with a press of a button will also likely prove useful, providing detailed positioning and easy transmission of measurements. Meanwhile, the integrated UV light works in collaboration with the new bits, and is also useful when carrying out technical inspection work. With these latest releases, Wiha believes it can oﬀer a rounded selection of tools to MRO professionals. Working collaboratively with each other, they can increase eﬃciency and ultimately make life easier - speeding up repair and maintenance processes.
For more information on Wiha’s latest range of tools, circle readerlink 219
TOOLS & EQUIPMENT
PRODUCTS FUJI AIR TOOLS FA-45 SERIES Fuji Air Tools has launched a new series of compact angle grinders, sanders and a cutter designed to deliver improved productivity in industrial metal working applications. The FA-45 Series is said to offer a superior power to weight ratio and a lower profile head than previous models, making these tools ideal for deburring, weld bead removal or basic chamfering. Durability is assured, says the company, with a robust design for the body, exhaust and throttle lever, as well as air-cooled gears to extend service life. The ergonomic design also reduces noise and vibration to ensure operator comfort. There are six models of FA-45 Series 5” Angle Grinders to choose from, delivering between 870W - 1100W and weighing no more than 2.1kg. The 5” Angle Cutter and three models of 7” Angle Sanders are also in the collection. CIRCLE READERLINK 221
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SNICKERS WORKWEAR AUTUMN & WINTER CATALOGUE The latest catalogue from Snickers Workwear features products designed to keep wearers warm and dry in the coming months. Included within are the latest 37.5 undergarments – plus jackets, trousers and accessories added to the RUFFWork, FLEXIWork and ALLROUND clothing families. In addition, there’s a new range of Hi-Vis garments for maximum safety and wellbeing on site. All clothes from the brand are said to deliver functionality, comfort, protection, and are equipped for any task at hand. CIRCLE READERLINK 220
WIHA BIT CONCEPT
UNILITE PS-HDL6R Designed to support engineers on site, this SMD LED headtorch produces a wide beam spread offering a smooth flood of light, and features a silicone non-slip headband or adhesive front helmet mount, ensuring a secure fit. The six Samsung SMD LEDs produce 350 lumen of bright white light, whilst featuring two further dim settings, as well as a ﬂash mode for attracting attention. Its head rotates at a 45˚ angle for precision beam placement, and it also features an anti-dazzle retractable light shield allowing users to direct the light further down to the ﬂoor. The headtorch comes complete with a high power lithium-polymer battery as well as a battery case that holds three AAA batteries. The lithium battery has a direct-to-battery charge micro-USB point for easier charging. CIRCLE READERLINK 222
The subdivision of the Wiha bit range in three colour-coded categories is set to simplify selection for users, claims the company. Thanks to its simple classification based on the screw shape to be fastened, the new bit concept ensures the right bit can be identified. If the user has screws with a 90˚ angle at the screw head, which tend to lie ﬂat against the material, the new blue T bits are the ones to go for. For screws with angles of more than 90˚, the yellow Y bits are the answer. If the user wants to fasten both types of screws, the red TY bits are the right choice. In addition, all Wiha bits are now suitable both for normal screwdriving tasks and impact screwdrivers, whilst UV coatings will help to ﬁnd any that may be misplaced. CIRCLE READERLINK 223
FLIR BLACKFLY S FLIR Systems has released a Gigabit Ethernet-based (GigE) machine vision camera, the Blackfly S. Said to be ideal for a range of applications including display and PCB inspection, microscopy, robotics, 3D scanning, intelligent traffic systems, the camera gives engineers the tools to quickly develop solutions by combining the latest CMOS sensors, GigE Vision compatibility, and advanced on-camera features. The ﬁrst three models feature the 5MP Sony Pregius IMX264, the 1.3MP On Semiconductor PYTHON 1300, and the 3.1MP Sony Pregius IMX265 sensors. These sensors are combined with the Blackﬂy S and Spinnaker software development kit feature set, which include 240MB of frame buﬀer to maximise reliability, IEEE 1588 Precision Timing Protocol, color correction matrix, and serial I/O. With ice cube form factor and support of cable lengths up to 100 meters, the Blackﬂy S GigE POE family’s versatility allows for a varied application use. CIRCLE READERLINK 224
CHICAGO PNEUMATIC CP66 NUTRUNNER Weighing as little as 3.8kg and equipped with a sturdy stabilising arm to aid operator comfort, the CP66 nutrunner is said to be ideal for flange-related and other bolting applications. It also provides a more durable, powerful and safer alternative to an impact wrench for MRO professionals. With models capable of delivering 1300, 2600 or 4100Nm, the product is a compact and powerful nutrunner that will deliver the right amount of torque to tighten or loosen bolts, says the manufacturer. Models in the range are capable of dealing with bolts ranging from 20mm to 45mm, and maintenance is required on average every 13,000 cycles. Lightweight and easy to handle, it operates with little vibration and with lower noise levels than an impact wrench for operator safety. CIRCLE READERLINK 225
HEALTH & SAFETY
HEAD PROTECTION Having recently undergone a major rebrand, Centurion has also developed its new Nexus range of safety helmets to provide extensive protection for users working in hazardous environments. IME explores.
protection and includes a new logo, tagline – ‘When Clarity Counts’ – and website. The rebrand has been underpinned by extensive customer research to understand current brand perceptions as well as the opportunities and challenges faced by customers in today’s changing landscape. The research reaﬃrmed Centurion’s belief in the importance of its total focus on above-the-neck protection. Jeﬀ Ward, Chief Executive Oﬃcer, commented: “Above-the-neck solutions are the most vital decision any organisation’s PPE buyer can make. We will therefore focus Whether sourcing your own equipment, or purchasing for a team, the choice of head protection is vital to an engineer’s PPE wardrobe. Not only does it need to comply with the latest legislation and regulatory requirements but, simply put, it needs to provide excellent protection and be comfortable for the wearer to ensure maximum safety on site. Having started out life manufacturing helmets for miners, tanks and eventually motorbike users, Centurion believes it knows a thing or two about head protection. The company has re-launched its brand following a complete review last year, which it believes reﬂects its deep specialism in above-the-neck 58 IME NOVEMBER/DECEMBER 2017
relentlessly on making the safe even safer, solving problems encountered by customers and amplifying our unwavering, unique focus on above-the-neck.”
Nexus After carrying out extensive research into customer insights and current market trends, Centurion has also developed its head protection system, Nexus, which is said to provide greater safety on site to protect workers from falls from height and any potential falling hazards. The Nexus range received both a
“Above-the-neck solutions are the most vital decision any organisation’s PPE buyer can make.” commended award at the 2017 Safety Awards organised by The British Safety Industry Federation (BSIF), and award winner within the head protection section of the 2017 ISHN Readers’ Choice Awards in North America. In addition to these proof points, the Nexus range is tested to global industrial standards EN, ANSI, CSA and AUS/NZ. To maximise versatility, the Nexus system, including the integrated eyewear, has also just recently been further tested to the antistatic/explosive atmosphere test (IEC 600079-32). Jeﬀ Ward added: “According to Health and Safety Executive, in 2016, in the UK alone, there were over 600,000 non-fatal injuries, 37,000 caused from falls from height. Falls from height accounted for the highest percentage of fatalities at 26% yet our research has shown an increasing trend towards style in users’ purchase preferences – our Nexus range oﬀers customers style without compromising on their safety. “The ﬂexibility of the Nexus system complies with a variety of safety standards and has been developed as a system for added convenience, rather than a helmet with optional extras. The Nexus range marks an exciting stepping stone for the business and demonstrates our continued investment in solving the most relevant problems for our users.” The detachable liners and chinstraps enable the Nexus to be used both at height and ground level, making it more convenient for the user. The system also allows for easy cleaning or replacing of liners and chin straps versus existing solutions. This can save users signiﬁcant costs as they do not need to replace the whole helmet system each time.
For more information from Centurion and its above-the-neck protection range, circle readerlink 226
60 IME NOVEMBER/DECEMBER 2017
GIVEAWAYS In each issue of IME we will be working alongside manufacturers to oﬀer you the chance to win some great prizes. Entry is totally FREE, and all you have to do is circle the appropriate readerlink number on the FREEPOST Readerlink card and send it back to us.
Bahco’s new range of stainless steel screwdrivers are made from non-rusting stainless steel, renowned for its hygienic qualities and ease of cleaning, and oﬀer the added beneﬁts of being resistant to weather conditions, corrosion and antacids. According to the company, demand for stainless steel screws has risen by almost 70% over recent years. Whilst the material doesn’t rust, screws will wear when conventional steel tools are used on the surface. This can be averted by using stainless steel tools, which have been subjected to cryogenic technology for added hardness and durability.
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WIHA SLIMVARIO SET
In an eﬀort to simplify engineers’ work, Wiha is giving away ﬁve slimVario screwdriver and bit sets. The pack helps securely arrange the set in a robust and clearly laid out carrying bag, for ease of use and protection against damage or loss. Wiha slimbits allow for protected access to deep-set screws – ideal for those hard to reach pockets when working on machinery. Crucially, the products are individually tested to 10,000 V AC and approved for 1,000 V AC, ensuring they are VDE certiﬁed for safe use.
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C.K TOOLS MIGHTYRODS
C.K tools is giving away its C.K MightyRods PRO Cable Rod Standard Set 5m (T5420) to ﬁve lucky readers. Fusing a series of advanced technological features, the cable rods deliver the ultimate in performance and eﬃciency. Featuring SplinterSHIELD, the durable, splinterproof coating fully encases the inner ﬁbreglass rod to prevent harmful and painful splintering for users. The new range comes complete with a series of accessories, all oﬀering high levels of strength and durability.
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UNILITE SAFETY VEST WITH LED LIGHT
With an integrated USB rechargeable safety light, these Class 2 safety vests from Unilite are ﬁre retardant and come in a variety of sizes. The light is powered by four cool white 6500k LEDs to provide 150 lumen. The light gives up to six and a half hours of light oﬀ one charge, and can be fully charged again in four hours. When needed, the light can be easily removed from the vest and charged directly through a USB port, giving additional ﬂexibility to engineers when on site. It is placed inside a safety pocket on the inside of the vest to hold it in place, and oﬀers three intensity levels.
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PRODUCTS SILVENT PRO ONE Pro One is a robust hand tool designed for professional industrial use. The thought behind the product is to improve the work environment and minimise the amount of occupational injuries when blowing with compressed air, says Silvent. The air gun is ﬁtted with a specially designed, patented nozzle in stainless steel which provides an eﬀective blowing force and a low noise level. The nozzle creates a concentrated jet of air which reduces turbulence, thus enabling a more targeted, eﬀective blowing force. In addition, the ergonomic handle allows several diﬀerent grips to make work easier and reduce the risk of repetitive strain injuries.
SCHAEFFLER SMART ECOSYSTEM 4.0 Smart Ecosystem 4.0 is said to offer a comprehensive, cloud-based hardware and software infrastructure that includes every stage of digital added value – from components equipped with sensors through to digital services. The flexible architecture of this system gives MRO professionals a simple, application-oriented point of entry into Schaeffler’s range of digital services that can be expanded at any time. The rolling bearing, its mechatronics derivatives, and the corresponding domain expertise provide the central source of information in this field. In addition, the company’s Cloud-capable FAG SmartCheck allows a simple and ﬂexible point of entry into the digitalisation of machines and equipment based on vibration monitoring. This latest version of the FAG SmartCheck uses an MQTT interface to provide a direct link to the Schaeﬄer Cloud or to any other platform based on IBM technology. It’s also possible to communicate with other cloud technologies via a gateway or alternative gateway solutions using an OPC/UA interface.
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KTR SHAFT COUPLING KTR has developed a new backlash-free, vibration-reducing shaft coupling for drives with severely high speeds. The ROTEX GS HP achieves peripheral speeds of up to 175 metres per second and is available in three sizes, with a further three sizes being developed for introduction in the first quarter of 2018. The coupling has compact dimensions, meaning the driving and driven shafts can be pushed together to within a few millimetres. This allows the engineer to keep the mounting space short. It can also be used in machine tools, along with measurement and test bench technology.
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BOSCH REXROTH ELECTRIC DRIVES A universal inverter developed by Bosch Rexroth has been approved for use in ships and offshore equipment by two international maritime classification organisations. The electric drive series covers a power range from 110KW to 4MW, and can be used as both a power supply and a motor inverter, which makes it simple to handle, with reduced storage costs, says the company. Its capability to support a power supply from 380V to 690V, as well as its extensive drive capacity, means the series can cover many applications.
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SKF EXPLORER BEARINGS SKF's Explorer high performance, long-life bearings range now includes an improved single row angular contact ball bearing that delivers a number of benefits for engineers seeking to reduce the TCO of this equipment through improved reliability and energy efficiency. Featuring a redesigned brass cage that delivers reduced noise and vibration levels and improved robustness, the new 40˚ contact angle bearings are said to increase the limiting speed up to 30% compared to previous designs. A new contact angle of 25˚ is also oﬀered, giving the bearing a further 20% increase in speed over that of the 40˚ version, while enabling higher radial loads to be accommodated. In each case, the ball-to-cage contact arrangement allows cooler running and greater temperature stability, while noise and vibration levels are reduced. Sealed variants of these bearings are also available.
ATLAS COPCO VACUUM PUMP SYSTEM
The manufacturer is offering customers with existing ESAB cutting machines the opportunity to upgrade to newer technologies for greater efficiency, reliability and cutting quality. The options available to customers will depend on the speciﬁcation of their existing equipment and the level of performance that they desire from an upgrade. Typical projects encompass a new CNC controller and plasma system; other upgrades might include plasma or oxy-fuel cutting heads and the laser system. In some cases, customers might also replace linear bearings and guides as well as servo motors and servo drives. At the same time, customers often take the opportunity to add new dust/fume extraction equipment and up-to-date safety-related control systems.
The DZM multiple dry claw vacuum pump system is designed for use in a wide variety of dry pumping applications. Dry claw vacuum pumps use two claw-shaped rotors running in opposite directions that do not touch each other or the pump chamber – resulting in enhanced performance and efficiency. Atlas Copco asserts its sturdy, durable DZS pumps require very little maintenance, being single-stage oil-free machines with air cooling. One of the pumps in each system has a variable speed drive, allowing the vacuum to be adapted precisely to the customer’s requirements. The space-saving vacuum system is available in three sizes: 600 VSD, 900 VSD and 1200 VSD, with an intake volume flow between 112 and 1230 cubic metres per hour. The standard features of DZS pumps include stainless steel claws and a corrosion-resistant pump chamber, allowing reliable operation even under difficult conditions.
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ESAB UPGRADE OPPORTUNITIES
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AD INDEX Carl Kammerling Ltd (page 7) ...................................... 003
New Tech Lubes (loose insert) .............................................
DEB (page 55) ................................................................ 026
Norbar Torque Tools (page 49) ...................................... 017
Flir (page 46) ................................................................. 025
Optibelt (page 18) .......................................................... 007
Fluke (page 39) .............................................................. 014
Redashe (page 55) ......................................................... 019
Gates (page 22) ............................................................. 009
Renold (page 15) ........................................................... 006
IMI Precision Engineering (page 29) ............................. 012
Schaeffler (UK) Ltd (inside front cover) ........................ 001
JCS (page 46) ................................................................ 022
Siemens (page 11) ......................................................... 005
Koyo (inside back cover) ................................................ 023
SMC (page 2) ................................................................. 002
Labfacility (page 46) ...................................................... 016
Sykes Pickavant (page 36) ............................................. 013
Lodestar (page 59) ........................................................ 021
Total UK Ltd (page 25) ................................................... 010
Mann Filter (outside back cover) .................................. 024
Tsubaki (page 27) .......................................................... 011
Martindale (page 57) ..................................................... 020
Unilite International (page 45) ...................................... 004
Megger Ltd (page 21) .................................................... 008
Wiha (page 45) ............................................................... 015
Nero Pipeline Connections (page 53) ............................ 018
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Industrial Maintenance Engineer targets professionals with MRO and associated responsibilities operating across a broad spectrum of industri...
Published on Oct 31, 2017
Industrial Maintenance Engineer targets professionals with MRO and associated responsibilities operating across a broad spectrum of industri...