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industry THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA

PCVUE 11.2 INTEGRATES SMART BUILDINGS AND DISTRIBUTED ENERGY RESOURCES

9 ESPRIT CYCLE TIME REDUCED FROM 41 SECONDS TO 27 SECONDS

20 ASCO SPECIAL SOLUTIONS FOR ANALYTICAL AND MEDICAL APPLICATIONS

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DELTA CFP2000 DRIVE FOR HVAC AND WATER TREATMENT PLANTS

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08 | Industry EMEA | January 2017

THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA

DELTA ELECTRONICS

DELTA ELECTRONICS

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6 ARC INFORMATIQUE

9 FEINTOOL

BALLUFF

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STEUTE

8 ASCO

BAUMER

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13 HMS INDUSTRIAL NETWORKS

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EPLAN

ESPRIT

NORD

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SECO TOOLS

ADVANTECH

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29 DELTA ELECTRONICS

DELTA ELECTRONICS

30 VERLINDE

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32 ADVERTISERS: SIRAI 12

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Contact: Todd MARSHALL Editor in Chief: editor@industryemea.com Send your press releases to: editor@industryemea.com

To receive Industry EMEA magazine free of charge, please subscribe online at www.industryemea.com Industry EMEA is the English-language magazine for engineers, published by IPM (Industrial Portal Media) It contains the latest product and company news for industrial markets.

Industry EMEA edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used.

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DELTA’S PHOTOVOLTAIC (PV) INVERTERS BRING HIGH ENERGY EFFICIENCY TO A CLUSTER OF SOLAR PV PLANTS IN DENMARK WITH A TOTAL CAPACITY OF 50.4MW

Delta, a global leader in power and thermal management solutions, announced today its state-of-the-art PV inverter technology has been successfully integrated into a conglomerate of 126 solar PV power plants located in Vandel, Denmark totalling 50.4MW in AC output capacity.

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total of 1,008 units of Delta’s M50A series solar PV inverters, featuring leading efficiency of up to 98.6% and IP65-rated enclosure, support the cluster of power plants, which is expected to generate more than 71.7 million kWh of clean electricity per year, enough to power 21,500 Danish households and equivalent to an annual reduction in carbon dioxide emissions of approximately 30,940 tonnes.

Mr. Victor Cheng, vice president and general manager of Delta’s Power System Business Group (PSBG), highlighted, “As a world-class provider of energy-saving solutions, we are delighted to have our high-performance PV inverters being an integral part of such a significant renewable energy footprint project in Denmark. In line with our corporate mission, ‘To provide innovative, clean and energy-efficient solutions for a better tomorrow’, we provide smarter and greener technologies to empower the low-carbon economy.

From 2010 to 2015, Delta’s green products and solutions have enabled energy savings for our customers of up to 17.3 billion kWh and a reduction of close to 9.2 million tonnes in carbon emissions.”

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Delta’s president and general manager for the Europe, Middle East and Africa (EMEA) region, Mr. Jackie Chang, mentioned, “This is the largest success case our PV inverters have ever achieved in the entire EMEA region, a major milestone within the remarkable track record we’ve built in the residential, commercial and utility-scale segments. The integration expertise of Delta’s service team has also been crucially beneficial for the commissioning of this project given the colossal size of this PV power plant conglomerate.”

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The Danish customer recognized the outstanding features of Delta’s M50A series solar PV inverters, such as their impressive energy conversion efficiency of up to 98.6%, their ability to have a very high DC/AC ratio to enable superior performance of the PV plant as well as their watertight IP65rated protection given Denmark’s harsh climate conditions.

String inverters offer further advantages for industrial-size PV plants due to their easy installation right under the PV panels compared to large central inverters and their integrated DC-side components to avoid costly external DC connection boxes.

The 126 solar PV plants, each with 400kW capacity, were built at a former NATO military airbase located in Vandel, Denmark. The property covers 108 hectares (over 1 square kilometre), roughly equivalent to 150 football fields. This conglomerate of PV installations will provide an expected annual generation of 71.7 million kWh of renewable energy, enough to suffice the annual power needs of approximately 21,500 local homes.

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www.deltaww.com

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DELTA ELECTRONICS SUBSIDIARY LOYTEC WINS THE LUX AWARDS 2016 WITH INTELLIGENT LIGHTING SYSTEM

Delta Electronics’ subsidiary LOYTEC electronics GmbH (hereinafter referred to as LOYTEC) has won the LUX Awards 2016 in the category “Industrial and Transport Lighting Project of the Year” from over 200 nominations with its DALI Lighting System (L-DALI) at Manchester Airport in the United Kingdom.

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he international jury awarded LOYTEC’s Manchester Airport project, which implements a modern DALI lighting system with constant light control, presence detection and monitoring of energy consumption.

Combining the replacement of existing luminaires to a full LED solution, with energy reduction of up to 89%, LOYTEC demonstrated what intelligent building management systems can achieve in terms of energy efficiency.

Mr. Mark Ko, vice chairman of Delta Electronics, stated, “In recent years, Delta has spared no effort to promote building energy efficiency and actively develop the global building automation market. Our milestone projects not only include those in the European and American regions, such as the installations at the Manchester Airport, but also largescaled integration cases in China, like the Ningbo Hontai Plaza, Zhaoqing Intercity Railway Station, and others. This award confirms the technical strength of Delta's energy conservation in buildings, and also encourages us to move towards a smarter and more energy-efficient future.”

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The project included the installation of DALI occupancy/ daylight sensors in all areas, coupled with field intelligent processors that shed lighting loads when areas were unoccupied. By introducing this level of automation further energy reductions are achieved by utilizing natural daylight.

LOYTEC’s lighting control solution provides not only a fully dynamic lighting control solution, but also a full system monitoring of energy consumption. The web-based system is designed with open protocol solutions BACnet and DALI, 08 | Industry EMEA | January 2017

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and also incorporates complete flexibility for any future expansion. The results are impressive. After replacing the existing luminaires with a full LED solution & L-DALI control system, Manchester Airport reduced energy use by up to 89%, the equivalent of 7 GWh of electricity a year.

Since 2013, the LOYTEC Competence Center Calon in cooperation with the company Building Environment Controls has integrated a modern DALI lighting system with constant light control and occupancy detection at Manchester Airport’s Terminal 2. The lighting control solution in subsequent project stages has been extended to the public areas of the airport terminals T1 and T3.

In 2014 following successful trials, the BMS system was linked to Manchester Airport’s CHROMA flight information system, which provides further energy savings with the use of dynamic scheduling. Lighting setpoint levels are now adjusted based on real time flight movements, which further maximize lighting savings.

LOYTEC was founded in Austria in 1999. In April of 2016, LOYTEC became a subsidiary of Delta Electronics, a leading power and thermal management provider. LOYTEC currently ranks among the leading European providers of highly innovative building management and control solutions integrating HVAC control, room automation, lighting control, sunblind control and energy monitoring. Recent large-scale integration cases include the Ningbo Hontai Plaza and Zhaoqing Intercity Railway Station in China, and commercial buildings in Europe such as the ParkLake Shopping Center and OBI Market in Nuremberg, Germany. www.deltaww.com

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The LUX Awards is hosted by Lux magazine, which recognizes the best lighting products, projects and companies leading innovation and change. With over 10,000 readers in Europe, Lux magazine, the official publication of the Lighting Industry Association, is authoritative and accessible, keeping the lighting industry up to date and helping lighting users get the best results.

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FOR TEMPERATURES DOWN TO - 60°C Explosion-protected, robust and resistant to cold: new series of Ex position switches.

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ffshore industry knows no fewer than four factors which make extreme demands on switchgear.

There is a risk of explosions; switches are exposed to high levels of mechanical wear and tear; the environment is corrosive; and it can be very cold.

The steute business unit “Extreme” has developed the position switches in its Ex 97 series for precisely this requirement profile – and will be presenting them at the SPS IPC Drives.

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These position switches, with dimensions to DIN EN 50047, have been tested and approved according to ATEX and IECEx for use in gas Ex zones 1 and 2, as well as dust Ex zones 21 and 22. They can be used in temperatures as low as - 60°C, which is very demanding on housing construction and sealing. For example, it must be guaranteed that the switchgear's high protection class (IP 66) will be maintained in these subzero conditions at all times, even after a 7-Joule impact test.

For this reason, the stable housing is manufactured from high-quality fibreglass-reinforced plastic. The sealing of the housing cover is completely vulcanised, while the sealing of the plunger features a redundant sealing system, comprising an external sealing cuff able to withstand low temperatures and an internal Teflon sealing ring.

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The sealing materials have been cleared by their manufacturers for temperatures down to - 95°C, and the lubricants down to - 75°C. There is therefore a sufficient “tolerance” to the steute-approved temperature of - 60°C. This gives users the certainty that the new position switches will work reliably even in truly extreme ambient conditions.

Due to a comprehensive range of actuators (plunger, roller plunger, roller lever, parallel lever, turning lever, adjustable turning lever, push button…) and their compact dimensions, the Ex norm switches are very versatile and easy to integrate in a surrounding construction. They are available with slowaction or snap-action and, as an added bonus, earthing and potential equalisation are superfluous because of the protection-insulated plastic.

This set of features in the Ex 97 series makes it a good example of the “Extreme” switchgear developed by steute.

It is suited not only to applications in the chemicals industry and energy technology, but also e.g. for position monitoring of flaps and valves in plants of the oil and gas industry (offshore and onshore), as well as on ships travelling through the Arctic. www.steute.co.uk

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PCVUE 11.2 INTEGRATES SMART BUILDINGS AND DISTRIBUTED ENERGY RESOURCES

PcVue 11.2 has been released, a premier platform for Supervisory Control and Data Acquisition (SCADA), Building Management Systems (BMS) and Human-Machine Interface (HMI) solutions.

Consolidation of Building Automation, Energy Management and Industrial Equipment with Enhanced Cybersecurity Features.

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ACnet Testing Laboratories awarded PcVue 11.2 its highest level listing, BACnet Advanced Work Station (B-AWS). It offers full integration to BACnet equipment with enhancements for developer efficiency and ease of use.

Advancements in building equipment communications also include native KNX and COMMEND SA ICX driver (for Intercom monitoring and control) along with the established LonWorks and Modbus drivers. New BMS libraries include GEZE objects for door, window and safety technology.

PcVue 11.2 offers the consolidation and integration to support convergence of SMART Buildings, Distributed Energy Resources (DER), Infrastructure, Transportation, and Industrial Automation. The release includes built-in drivers for Energy Management and SMART Grid interoperability including IEC 61850, 61400-25, 60870-5-104 & DNP3.

PcVue mobility solutions are expanded with HTML5 scalable clients augmenting WebVue and TouchVue, a mobile app for alarm and event notification with trending and browsing of variables that requires no mobile device configuration.

PcVue continues its strategic policy of maintaining backward compatibility while enhancing and expanding features. PcVue technology is proven “future proof” ensuring the sustainability of customers’ investments for more than 30 years. PcVue 11.2 is qualified for Microsoft Windows® Server 2008-2014 and Microsoft Windows® 7 – 10 operating systems with continued support for virtualization with Hyper-V and VM-Ware.

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Deployment, IT & Cybersecurity Cybersecurity is a primary design goal with additional protection of server components including PcVue as a service with clients deployed as desktop applications. There are comprehensive tools for configuration and diagnostics applicable to both local and remote sessions. PcVue is securely delivered with installation signature and binary

file signature. It is fully integrated with Microsoft Windows® Active Directory and supports secure HTTP (HTTPS).

www.pcvuesolutions.com

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SPECIAL SOLUTIONS FOR ANALYTICAL AND MEDICAL APPLICATIONS

Through a series of recent application examples, ASCO is proving time after time its competence and professionalism in being able to offer customers bespoke solenoid valves in line with the exacting requirements of the medical and analytical sectors. The ASCO range of valves suitable for these industries include a broad portfolio of miniature solenoid valve products, including isolation valves – where the fluid is isolated from the mechanical parts of the valve, proportional valves and complete customised solutions.

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n excess of 80% of ASCO’s miniature solenoid valves sold into the medical and analytical sectors are customised.

All of these ‘specials’ are created based on years of knowledge accumulation relating to the specialist demands of these industries. For the medical technology market, this might concern the supply of custom valves for use in dialysis machines, anaesthesia machines, ventilator systems (Emergency/ Home care and Hospital) or air mattresses for “pressure relieving” hospital beds. While bespoke valves for analytical technology applications could involve machines that analyse blood or gas samples, for instance.

Producing a special valve means taking different parts (standard or special) in order to meet perfectly the customer requirement. Customising a valve means to offer a valve with special body, electrical connection or special technical characteristics (pressure, flow…) ASCO can recount numerous recent requests for specials, such as special plastic

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injection blocks with several valves incorporating pressure sensors, fittings and filters.

In short, ASCO can custom-engineer just about any valve; whether the requirement is for a complex manifold interface assembly or simply a choice of solenoid valve terminations.

To provide complete peace of mind, the company manufactures under clean room conditions, and tests every assembly before shipment. One part number is provided for one function (assembled and tested).

ASCO’s knowledge of the medical and analytical sectors ensure it is able to meet the high requirements for accuracy, reliability and purity demanded in these specialist fields. In addition, extensive international safety accreditations and certifications are applied to ensure the quality and safety of special products and their suitability for applications in various regions of the world.

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Image 1: In a further multi-function module example, this time involving fluid isolation valves with a flapper mechanism on a blood analyser, a valve module with several fluid isolation valves and a pressure sensor was mounted on a customised acrylic manifold. Distinctive features of the innovative flapper mechanism were the low number of moving parts and corrosion-resistant fluid isolation from the solenoid operator. This design provided a high level of operational and process safety. In comparison with valves offering similar characteristics, it was possible to further improve selfdraining and flushing capabilities. What’s more, due to the valves’ low power consumption of 4W (only 1.5W with optional battery operation), the temperature rise of the fluid could be reduced further.

With regard to analytical technology, special valves must not only exhibit precision and functionality, but be resistant to aggressive fluids and gases. Further requirements include a low internal volume and an easy-to-flush design, while valves with low power consumption will reduce heat transfer into the fluid. Typical applications include systems for chromatography, haematology, immunology, cytology, DNA synthesis, emissions analysis, water analysis and leak measurement.

Concerning special valves for medical technologies, the clear emphasis is on patient safety. Here, valves come partly into direct contact with fluids introduced into, or taken from patients, be it in handling medical gases in respirators, or liquids in dialysis. This field of application requires the use of inert materials, a low internal volume and low power consumption, as well as easy-to-flush internal valve or system cavities. Typical applications include equipment and devices for artificial respiration, anaesthesia, oxygen concentration, dialysis, dentistry, clinical sterilisation, minimally invasive surgery, cryosurgery and cellulitis treatment (massage).

The success story is similar with regards to multi-function modules. For instance, ASCO has recently created special assemblies involving an injection-moulded manifold with a bellows seal valve used in equipment designed to handle ultra-pure laboratory water.

Yet another recent customer example involved solenoid valves for fluid isolation in a dental application. Here, an injection moulded modular valve manifold was mounted with proportional and miniature fluid isolation valves. These had to shut off or proportionally control liquids and gaseous fluids.

The success story is similar with regards to multi-function modules. For instance, ASCO has recently created special assemblies involving an injection-moulded manifold with a bellows seal valve used in equipment designed to handle ultra-pure laboratory water.

www.asco.com

Ultimately, products for analytical and medical technology must meet very specific requirements. ASCO has proven that it can offer a variety of valve solutions that are specially adapted to gas and fluid handling in medicine, biomedicine and industrial analytics – in fact wherever standard products have shown to be unsuitable.

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Recent examples of ASCO expertise in special solutions include fluid isolation valves with a diaphragm mechanism for chemical analysis. Here, six solenoid-operated diaphragm valves were assembled in a star-like configuration on a manifold. In a similar application, this time for a bioanalytical system, Fluid isolation solenoid valves with low internal volume were mounted on a PMMA (acrylic) manifold.

Another application with a PMMA manifold saw a rocker type fluid isolation valve with a power saving circuit board used with a cell analyser machine.

You get more than a valve when you buy

You get the peace of mind that comes with purchasing from a long established supplier with the backing of one of the largest global technology companies.

You get the support that you need throughout the whole purchasing cycle thanks to an extensive local and international network of sales staff and distributors.

You get a product that optimises the performance you need from your machine or process, without paying for functionality or performance that you don’t need.

1946 2016

Simply what you need

Sirai - Bussero (MI) Italy - Tel. +39 02950371 - sirai.com TM

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NEW CLEVERLEVEL LBFS MODELS WITH MORE INTERFACES FOR OPTIMIZED COMMUNICATIONS

Thanks to their flexible integration properties and ease of use, the CleverLevel LBFH and LBFI are the ideal solution from planning to maintenance for all systems.

Baumer has expanded the successful CleverLevel series with two new variants – the LBFH and LBFI. They are available with two switching outputs, qTeach and a 360° output status indicator. In the same way as their predecessors the level switches are based on frequency deviation technology and are suitable for both hygiene and industrial applications.

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he level switches offer various programming options to suit different requirements. The convenient qTeach procedure is of great advantage especially for small installations with simple control systems. The sensors can be easily adjusted with any ferromagnetic tool, thus making it possible to quickly adapt to changing process requirements on site.

The multicolored switching status indicator provides reliable feedback on all parameterization steps to support effective process control.

The two switching outputs make it possible to set two trigger thresholds. This means two different process steps, such as production and cleaning, or two media groups, such as water and oil, can be monitored with one sensor. This saves on storage and costs. The two switching outputs facilitate a plausibility check of the sensor. Complementary trigger point setting ensures sensor faults and wire breaks are reliably detected, thus guaranteeing effective monitoring of all processes.

www.baumer.com/CleverLevel

Both variants are suitable for use in temperatures up to 135°C while the variant for hygiene applications has SIP capabilities.

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NEW XFT 2500SPEED FOR HIGHEST FINEBLANKING REQUIREMENTS

The new version of the XFT 2500speed from Feintool offers new possibilities for fineblanking production.

The reinforced model of the XFT 2500speed press offers an effective solution for the special challenges in fineblanking production and sets new standards.

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his model is equipped with stronger knuckle joints.

This increases the press force at the tip to 3000 kN (time-limited). For the user of the XFT 2500speed, this modification means new possibilities in fineblanking production. Due to the additional reinforcement, this model is also suitable for parts made of high-tensile materials with thicknesses of up to 8 mm at more than 100 strokes per minute. This means a lower load on the press during operation with conventional tools and greater flexibility due to the occasional use of tools with higher power requirements.

In addition, Feintool has equipped the new XFT 2500speed with a lot of innovations that ensure the highest productivity and perfect quality of the fineblanking parts. This includes increased stiffness and a quick-change system for tools.

The latest control technology and innovative energy management are also part of the new press model. In addition, the new XFT 2500 speed is equipped with FEINmonitoring, the intelligent analysis and maintenance tool and Feintool's contribution to industry 4.0 A video of the XFT 2500speed (English version) in practice is available at www.feintool.com/powerpackage

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www.tekinfo.link/r2dd6091316

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COMPACT BIDIRECTIONAL DATA MEMORY MODULE IO-LINK MEMORY MODULE

Balluff offers a compact, bidirectional data memory module for tight mounting spaces. The compact memory module with IP 67 protection is just 34 x 16 x 8 mm in size and can be used as a memory storage device on interchangeable units such as milling heads on gantry type machining centers.

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his means the assemblies can carry their actual operating data along with them. With the following advantage: When a machine is changed, all the data such as the number of use cycles, shock and vibration values or lubrication and oil change intervals are directly loaded.

The work required to install and parameterize the module is minimal. Only a single standard cable is required for stable, fault-free, bidirectional data transmission between the milling head and controller. The cable is connected to the milling head interface in the system ring. Data transmission is noise-immune as well as resistant to EMC effects. The module can hold a total of 14 segments of 64 bytes each.

Machine operators will profit from the fact that when a milling head is switched from one machine to another, all the identifying and usage data will be automatically copied and loaded from the milling head memory into the NC controller through a cable. When maintenance or repair work is needed, the service personnel can read out all the data from the memory chip on a PC or laptop and update it as needed. This gives the plant operator continual and transparent information about the current status of the milling head.

Once again IO-Link proves to be a key technology for highperformance, space-saving Industry 4.0 concepts. www.balluff.co.uk MORE INFORMATION 08 | Industry EMEA | January 2017

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IXXAT INPACT PCIE MINI CARD ENABLES PCS TO COMMUNICATE ON PROFINET IRT FIBER OPTIC

HMS Industrial Networks expands the IXXAT INpact multi-protocol card series with a PCIe mini variant for PROFINET IRT Fiber Optic.

Designed for secure data transmission in harsh environments The IXXAT INpact enables easy implementation of a PROFINET IRT Fiber Optic Slave interface and can be used in compact industrial PCs as well as in mobile devices. Typical use cases are coupling of subsystems with superordinate networks, visualization of process data on human machine interfaces (HMIs) as well as data acquisition in PC-based process devices. IXXAT INpact is fully compliant with the requirements of the AIDA (Automation initiative of German automobile manufacturers) for a PROFINET interface.

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PROFINET IRT via fiber optic meets the highest requirements for interference immunity and data transmission. It is often used in critical areas in the automotive field, e.g. in robotic cells for car body construction, in automated welding systems and other areas with high electromagnetic interferences.

Hardware concept of the IXXAT INpact multi-protocol card series The new PROFINET IRT Fiber Optic card is the newest member of the IXXAT INpact series which supports a variety of Industrial Ethernet and fieldbus protocols, such as PROFINET, EtherCAT, EtherNet/IP, Powerlink, ModbusTCP and PROFIBUS. The multi-network capability of INpact is based on the proven Anybus CompactCom technology from HMS – used within millions of devices globally.

The FPGA-based Anybus NP40 network processor includes all functions required to handle the communication between the Industrial Ethernet or fieldbus network and the PC-based customer application. The FPGA has a low latency and a deterministic real-time behavior, making it ideal for demanding industrial applications. The PROFINET IRT FO connection is made via SC-RJ connectors. Other network standards are supported by corresponding Sub-D9 or RJ45 Ethernet interfaces.

The IXXAT INpact is offered as a dedicated version for each network with pre-installed network protocol. Furthermore, INpact is also available as a Common Ethernet version, a highly flexible and open version in which the desired industrial Ethernet protocol can be flashed by the user.

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Connection to the customer application The IXXAT INpact is supplied with a comprehensive driver package for Windows and Linux, which allows a fast and easy development of customer-specific applications, regardless of the used card type or protocol. Thanks to a universal programming interface, users can change between INpact cards and protocols without changing the customer software, which leads to increased flexibility and a significant reduction of the development costs. Support for real-time operating systems such as RTX, Intime, VxWorks and QNX is available on request.

Further information on the IXXAT INpact can be found at www.ixxat.com/inpact

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EPLAN HARNESS PROD 2.6 COMPREHENSIVELY CAREFREE THROUGH TO MANUFACTURING

Wires with predefined length can now easily be routed in Eplan Harness proD in an intuitive fashion. During the design process, the current as well as the targeted length are exactly depicted and users can recognise at a glance how the wires can optimally be routed.

Efficiency ranks first, but the joy of designing doesn’t get short shrift: the new Eplan Harness proD version 2.6 is an intuitive 3D/2D software that covers all of today’s requirements for wiring and wire harness engineering.

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ew features include enhancements to production specifications, which include cable drawings in addition to the nail board. Cable dimensioning is now automatic. If desired, cables with predefined length can easily be routed in an intuitive fashion. Cooperation between mechanical and electrical engineering becomes true team-work with open interfaces.

The new Eplan Harness proD version 2.6 software from Eplan for convenient cabling and wire harness engineering is ready for release. Based on the 3D model of the mechanics and electrical schematics, the wire harness can be designed in an intuitive manner. The next step is the handover of this data to manufacturing, and there have been major updates in this area as well: integrating 2D cable drawings, which are automatically derived from the 2D/3D design environment and that specify both dimension points and connection points. This allows for automatic dimensioning, saving valuable time and ensuring correct results. Stripping lengths and wire coatings can now also be defined in the design phase, and professionally depicted in the manufacturing drawings. This provides users with a quick and comprehensive overview of their projects.

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Determining lengths Wiring harness software normally offers the suitable tools of the trade to easily calculate cable lengths. In Eplan Harness proD 2.6, this now also works the other way around: users may predefine a fixed length – for antenna cables (as an example). During the design process, the current as well as the targeted length are exactly depicted and users can recognise at a glance how the wires can optimally be routed.

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2D wire drawings are now integrated, which are automatically derived from the 2D/3D design environment and specify both dimension points and terminal points.

This simultaneously allows for the reduction of variations, resulting in cost savings in warehousing and manufacturing.

Additional functions for the creation of cable units allow elements to be grouped together as well as the assignment of component numbers to cable units, thereby providing a more comprehensive project overview.

wire harness prefabrication, machinery manufacturers and company divisions where interdisciplinary cooperation is required. www.eplan.me

Optimally integrated The connection to Eplan Platform and system openness to MCAD and ECAD ensure a continuous workflow between electrical engineering and mechanical engineering. Another new feature is that Eplan projects can be transferred directly into the wire harness software with version 2.6. Not only that, but Eplan Platform’s central parts management supports integrated data storage as users must only maintain master data in one system. This allows for integrated working processes for wire harness engineering from the schematics to manufacturing. The ease of use and integrated data in every phase of design through to manufacturing thereby lay the groundwork for quick and efficient results.

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Individual fields of application Numerous functional enhancements in the system contribute to making cabling design and wire harness projects more efficient and to accelerating customers’ workflows. Eplan Harness proD supports all industries in which cables and wire harnesses must be routed, for instance special vehicles, equipment manufacturers, wiring/ 08 | Industry EMEA | January 2017

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CYCLE TIME REDUCED FROM 41 SECONDS TO 27 SECONDS ProfitTurning™ – The cutting edge of tomorrow’s CAD/CAM software.

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rofitTurning™, releases in the latest version of the ESPRIT CAM software, represents years of ground-breaking research. A lathe roughing strategy that significantly reduces machine cycle time, ProfitTurning™ has hurdled a grueling series of tests, delivering a performance that promises to take machinists, engineers and industrialists to greater levels of precision, quality control and productivity.

ProfitTurning™ is a high-speed lathe roughing strategy developed by DP Technology Corp. for OD/ID/face cutting and other tasks. Fast, secure and efficient, it also extends tool life by significantly minimizing wear. Compared to conventional ramping methods, ProfitTurning™ reduces machine cycle time as well as the frequency tooling inserts need to be replaced.

DP Technology’s R&D Director of Product and Engineering Ivan Kristic reveals the science behind ProfitTurning™’s performance:

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“ESPRIT 2016’s ProfitTurning™ toolpath maintains consistent cutting forces and chip loads, allowing cutting speeds to be significantly increased. By employing trochoidal turning and controlled engagement techniques, the ProfitTurning™ toolpath also reduces vibration and residual stresses, which in turn makes it particularly well-suited to thin walls or hard materials, especially super alloys. The net result is significantly reduced cycle times and maximized productivity.”

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Physics-Based Cutting Engine ESPRIT 2016 uses a physics-based cutting engine which provides the foundation for the technologies such as ProfitTurning™.

While traditional cutting strategies consider only the geometry of materials, ESPRIT 2016 taps deeper into the science of how different industrial materials can be cut in the most efficient ways possible. Its new toolpath technology uses the principles of physics to formulate unique strategies for each cutting challenge.

To do that, ESPRIT 2016 inputs all relevant factors in the toolpath algorithm such as tool material, tool shape, workpiece material, tool speed, feed rate, chip deforming, chip load, machine tool power, acceleration and deceleration. This helps establish complete control of the cutting environment, allowing for optimal cutting everywhere along the toolpath.

For more details about this new technology, please read the ESPRIT 2016 ProfitTurning™ White Paper available at www.espritcam.com/products/profit-turning

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SMART DRIVE ASSUMES LOCAL CONTROL

In case of an intentional or accidental disconnection of the central control system, the inverter PLC can execute preprogrammed procedures to keep the application running or bring it to a defined standstill.

Enabling centralized as well as autonomous operation.

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requency inverters from NORD DRIVESYSTEMS can react flexibly in case of disrupted communication with a central control system.

The on-board, pre-programmed PLC can take control, initiate a defined state for halting operations, or keep the application running. In process plants this can help avoid costs, for instance by preventing spoiled batches. In manufacturing facilities, material flow can be maintained.

As NORD intelligent drives feature various interfaces and are able to evaluate sensor and actuator data, optimal integration in the application is ensured. Autonomous control capability obviously has other uses beyond fallback

scenarios. In some instances, users may wish to deliberately switch the smart drive over to local control. For set-up, testing, or maintenance, the distributed frequency inverter can additionally be equipped with switches for manual drive direction and speed control.

The integrated PLC functions are programmed using IEC 61131-3 “Structured Text” or “Instruction List” text-based languages. For straightforward, user-friendly application development, NORD CON software is provided without any charge or license fees. www.nord.com

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TEN SIMPLE STEPS TO PEAK PERFORMANCE AND PRODUCTIVITY

Figure 1: NEXT STEP – total integrated production model

All machining shops face the same task: converting raw material into finished workpieces. The products must be machined to the specified level of quality, completed in the required quantity and delivered within the desired amount of time. Sustainability considerations and environmental issues must be resolved as well. To remain competitive and profitable, shops continually seek the most economical and productive ways to accomplish their work.

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he ultimate example of those process improvement efforts today is what is called in Europe “Industry 4.0” – strategy and tactics that integrate state-ofthe-art data acquisition, storage and sharing technologies into the manufacturing process. Industry 4.0 is presently the top level of manufacturing evolution, requiring strong management commitment, specialised personnel and significant investment.

Figure 1: NEXT STEP – total integrated production model MORE INFORMATION

Unfortunately, shops that lack the extensive resources of global industrial giants such as General Electric or General Motors may feel that productivity improvements are out of reach. However, simple, cost-effective analyses and actions can have a large positive effect on the productivity of small to medium-size operations. In fact, before investing in new computers, robots or personnel, any shop, large or small, should perform basic process analysis and organise current 08 | Industry EMEA | January 2017

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equipment and practices. The truth is that computerisation of disorganised shop operations results only in computerised disorder.

Three phases and ten simple steps Organisation of shop practices begins by viewing the production process as three phases. First is a selection phase, involving choices of cutting strategy, tools and cutting conditions. The next phase is collection, in which the selected tools and strategies are grouped together in a machining process. Realisation is the third phase and puts the process into action.

In a large number of cases, the results of phase three fails to meet expectations, and certain steps are needed to bring reality in line with preparation. The steps can be technical in nature, such as seeking ways to moderate cutting forces, or economic, including actions to reduce costs. Fortunately, there are ten simple steps that will enable a shop to analyse

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Figure 2: Different selection criteria for tooling

Figure 3: The two-step model for cutting condition selection

and improve its metalworking operations. They are as follows.

Intelligent budget control A common approach to budgeting in metalworking operations is to acquire every element of the process at the lowest price possible. However, it is best not to base tool selection on price alone. Before discussing prices, a shop should consider the desired end results. If a tight-tolerance, top quality part is the goal, more-expensive precision tooling will be required to machine it.

Figure 2: Different selection criteria for tooling The cost of struggling with bargain tools to achieve high part quality and producing unacceptable parts will exceed the expense of higher-priced tooling. On the other hand, when quality demands are less stringent, a portion of the capabilities of high-precision tools will be wasted.

Recognising the ultimate goal of the process is the first step in cost-effective purchasing decisions.

Figure 3: The two-step model for cutting condition selection Nonetheless, simply reducing cutting parameters overall is not an intelligent way to deal with process constraints. For example, changes in depth of cut have a greater effect on the consumption of machine power than changes in feed rate. The combination of decreasing depths of cut and increasing feed rate can improve productivity within the constraint of limited machine power.

Tool application rationalisation Considering the massive number of tool geometries, sizes and materials available, the possible configurations of metalcutting tools are practically endless. Machine shops typically make tool application choices one operation at a time, choosing a specific tool to create a certain feature on a part and then picking another tool to machine another different feature.

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Intelligent handling of constraints Real-world metalworking operations, as opposed to theoretical discussions of metalworking theory, are bound by practical constraints that include machine power and stability and customer demands regarding dimensions and surface finish quality. Cutting conditions can be varied over a wide range, but the effects of different combinations of

parameters on cutting forces and surface finish may limit some choices.

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Figure 4: The total offer for tooling is enormous – rationalisation is the key

Figure 4: The total offer for tooling is enormous – rationalisation is the key In an example case, two separate tools would be used to turn a shaft and produce a wide groove with two square shoulders. Specifically, one tool turns the shaft to the desired diameter and cuts one shoulder and the width of the groove, followed by a second tool that cuts the other shoulder. Each tool is programmed and optimised separately, representing separate programming and administrative costs.

A contrasting tool selection strategy is to develop a highlyspecialised custom tool that can create multiple features in one machining pass. The strategy is convenient but the design and manufacturing of special tools is expensive.

Between the two extremes is an approach that utilises a standard tool engineered to perform more than one operation (multi-directional tooling). A perfect example of this approach is a Seco’s MDT tooling.

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The tool’s features enable it to turn the diameter, plunge in to create one shoulder, move across the shaft to cut the groove, then withdraw to form the second shoulder. Even if such a multidirectional tool does not operate at the optimised cutting parameters of the two separate tools, the savings in tooling, programming, tool change time and inventory costs make the multidirectional tool the preferred choice.

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Complex workpiece approach (group technology) Comparable to the technique of applying tools that combine two or more operations, a shop can choose tools that are capable of creating similar features across a range of workpieces. A shop may machine a wide range of different workpieces, but the workpieces will share common features such as holes, slots and milled surfaces.

To expedite the machining of complex parts, a shop can view similar features as a group and choose a tool optimised for a certain operation, such as holemaking, that is repeated on different parts. The optimised tool maximises productivity and also reduces cost when considering the engineering time that goes into repetitively programming tools for each separate part. The group technology approach also helps reduce tool inventory.

Achieving minimal functional workpiece quality Although the concept initially may seem strange, shops must realise that it is necessary to achieve only the lowest possible workpiece quality that meets customer specifications and functional requirements. There is no need to exceed those requirements. If a part tolerance is 5 microns, achieving 3 microns is a waste of time and money. Higher quality tooling and more precise operating processes will be required to achieve the tighter tolerance. But customers will refuse to pay for such unrequested higher quality, and the job will be a money-losing proposition for the shop.

NEWS Figure 5: Total quality of a finished workpiece is influenced by a big number of elements

Figure 6: Cutting tools wear out due to different phenomena

Figure 5: Total quality of a finished workpiece is influenced by a big number of elements Some quality issues, such as burrs, obviously must be resolved. And there are situations where minor cost considerations are irrelevant – tool cost differences of a few Euros or cents are meaningless when compared to the value of a large titanium aerospace component the tool will machine. To maximise cost efficiency, a shop should tailor production quality to the functional and quality requirements of the workpiece.

Predictive tool maintenance Traditional tool maintenance is reactive. When a tool wears out or breaks, it is replaced. That approach, however, generates costs beyond those of the tool itself, including manufacturing process downtime and possible damage to the workpiece. Preventive tool maintenance is a step beyond reactive maintenance.

Figure 6: Cutting tools wear out due to different phenomena

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The useful lives of even identical tools usually vary above and below an average length of time. Preventive tool maintenance is based on replacing the tool before it reaches its shortest expected working life to be sure that the change is made before the tool wears out too much or breaks. That approach, however, wastes tools with a tool life that is at or above average.

A relatively new approach, based on tool life modeling, uses computer calculation and simulation to provide predictive data on tool deterioration and to indicate when replacement is due. At a somewhat greater expense, use of sensors can further fine-tune the results by tracking tool wear in real time. Use of predictive tool maintenance has the potential to reduce tooling costs by 15 percent, 20 percent or more. >>> 08 | Industry EMEA | January 2017

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Figure 7: Productivity and cost efficiency can be achieved through different roads

Tool inventory control When dealing with the second – collection – phase of metalworking production, it is important to note that tool inventory control is different than tool management.

Tool management refers to organising an existing tool inventory and making it available for production. For that task, a variety of automated tool management systems is available. Tool inventory control, on the other hand, is an effort to rationalise and consolidate the number of tools a shop possesses to focus on what is really needed. If tools are not rationalised before being loaded into an automated tool dispenser, the result is simply automated disarray.

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Practical work analysis In his 1907 book “On the Art of Cutting Metals” American engineer and work analysis pioneer Fredrick Winslow Taylor noted that some of the activities in a workshop, such as milling a surface, clearly add value to a workpiece. On the other hand, he noted that many activities that are necessary for the production of a finished workpiece do not directly add value. These include e.g. fixturing the workpiece on the machine or writing the machining program.

Taylor said that non-value-adding tasks should be completed as fast as possible and in a way that minimise their effects on the total costs of production. Automation can accomplish tasks such as part loading and fixturing and save time and money.

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Figure 7: Productivity and cost efficiency can be achieved through different roads Manufacturers typically believe that the best way to reduce processing time is to increase machining parameters.

Most shops do not fully recognise the time consumed by activities such as engineering. A task that can represent as much as 40 percent of the total time for a part to travel from

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Figure 8: Developments in machining processes

drawing to delivery. Unplanned downtime caused by tool failure, quality issues or chip control problems also may be overlooked. When analysing work activities and costs, it is essential to consider all the contributors to part production time.

(See sidebar next page) Practical application of optimisation The third phase of metalworking part production, the realization phase, puts into action the tools and strategies selected in phase one and collected in phase two. Rarely if ever does a process work exactly as planned, and it is at this point where optimisation of the operations in terms of speed, reliability and other factors is necessary. Additionally, most shops also seek to improve ongoing processes. After carrying out the organisation and rationalisation steps of phases one and two, practical optimisation enables a shop to find technical and economic benefits in a combination of feed, speed and depth of cut that produces the desired results.

potential effects of the fluids on the environment as well as the cost of safely disposing them. Growing use of lead-free workpiece materials is aimed at removing the harmful metals from the environment. Improving process parameters and production tooling performance will result in measureable savings in energy expenditures.

Figure 8: Developments in machining processes >>>

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Intelligent introduction of new technology Manufacturers today face a range of relatively new challenges including mandates for sustainability and environmental protection. Intelligent introduction of new technologies and processes enables shops to fulfill the challenges. Dry machining, for example, permits a facility to reduce the use of coolants, which in turn reduces the 08 | Industry EMEA | January 2017

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Figure 9: Total STEP offer

TRACKING ELUSIVE COSTS

Conclusion: phase 4 and STEP education As manufacturers of any size utilise the ten simple steps to improve their operations, a fourth phase of the production process involves ongoing internal education. The goal of that education is to ensure shop personnel realize solutions to productivity issues do not always necessitate huge investments, high technology and expanded workforces.

The lessons learned while improving an operation or a family of operations can be reapplied and expanded to include similar situations throughout an entire shop. These lessons can be supplemented with organised education such as the Seco Technical Education Program (STEP), a well-developed and practical program designed to familiarise users with the latest tooling systems and techniques. Combined with practical experience in process analysis and improvement, education is the key to establishing a culture of problemsolving and process improvement that will result in ongoing manufacturing success.

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Figure 9: Total STEP offer By: Patrick de Vos, Corporate Technical Education Manager, Seco Tools www.secotools.com

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When performing practical work analysis, costs may be obvious, hidden or overlooked. The factors affecting the total cost of converting raw materials into a finished workpieces can generally be grouped into eight categories. The categories include tools and tooling systems; workpiece materials; processes and process data; personnel and organisation; maintenance; special factors; peripheral equipment; and various random factors.

Processing time is the most obvious cost factor, and it includes machining time as well as the time spent in machine and tooling setup, work handling operations and quality inspection. It is clear that a planned amount of downtime is necessary for setup and workhandling, but a less apparent subset of processing time is unplanned work stoppages resulting from unanticipated tool deterioration, chip problems and inconsistent quality.

Unreliable machining processes that produce poor quality or rejected parts, broken tools, damaged workpieces and systems problems needlessly increase process times and expense. The factors at the forefront, such as machining time and scheduled tooling replacement, may contribute less to overall processing time than the effects of operator errors and system anomalies.

Engineering – consisting of general, geometric (programming) and technical (selection of tooling and machining parameters) activities – is often overlooked as a contributor to overall production time. Part programming represents a significant portion of engineering time, but a large amount of engineering activity is also consumed in technological issues such as tool selection and choice of machining parameters.

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ADVANTECH LAUNCHES WEBACCESS 8.2 TO ROUND OUT THE END-TO-CLOUD IOT APPLICATIONS

Advantech, a global Intelligent System leader, will launch WebAccess 8.2 in November to round out the IoT applications from the end to the cloud.

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system, WebAccess 8.2 HTML5 based Dashboard not only tuned the widgets to meet users’ demands but also improved data transmission efficiency to accelerate the data refresh speed on the mobile phone. As a result, users can view the dynamic data anytime anywhere without delay.

In response to more extensive and complicated IoT applications, Advantech WebAccess’s Super SCADA is a useful tool to link multiple nodes or projects through a simple setting, making integration quick and easy while accomplishing unified remote monitoring management.

When the network connection is interrupted, its active retransmission function can temporarily store the data on the nodes and automatically resume uploads after reconnection. Users do not need to worry about data loss as well as eliminating the trouble of manual resetting by the user.

Unlike the traditional HMI/SCADA system, Advantech WebAccess is 100% Web-based SCADA software and provides cross-platform and cross-browser functionality and compatibility such as Intelligent Dashboard, various open interfaces, ample protocols and hundreds of drivers, allowing users to conveniently develop projects and view or control automation equipments.

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ased on the previous powerful features, the latest version supports MQTT protocol and adds two new drivers (Ethernet/IP for Allen-Bradley PLC and B+B Wzzard MQTT) enabling manager/administrator/System Integrator to effortlessly integrate more on-site devices and upload the front-end data to the cloud. In order to push product performance to perfection, Advantech has enhanced Dashboard performance in this new release to ensure stable and synchronous data transmission.

Meanwhile, WebAccess provides special network architecture called Super SCADA that can collect the information of distributed nodes by its project upload tool so as to easily achieve centralized monitoring management, no matter how many layers users need to expand.

As the MQTT gradually becomes one of the major transmission protocols in the IoT field, supporting it allows WebAccess 8.2 users to save network traffic costs and reduce the required network bandwidth while getting better network security mechanism to protect the users' important data. Through its lightweight transmission mode, WebAccess 8.2 can act as a gateway and do large data collection, helping integrators or partners to successfully extend their systems to the cloud applications.

Since the dynamic data display is an important function of the SCADA (Supervisory Control And Data Acquisition)

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CFP2000 DRIVE FOR HVAC AND WATER TREATMENT PLANTS

The CFP2000 series is Delta’s brand new high reliability and industry-specific vector control drive for fan and pump applications. Featuring a built-in EMC filter, DC chokes, Real-Time Clock (RTC), and BACnet, the CFP2000 Series provides the best solution for the special needs of the HVAC industry. The IP55 model features highly effective protection against dust and water in harsh environments.

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elta's CFP2000 series is an AC motor drive specially designed for HVAC, fans & pumps, and water treatment applications. It is designed with an IP55 enclosure to provide effective protection from dust and other particles and to offer a good level of water protection.

In addition, it includes many outstanding features and builtin functions that reduce setup and tuning time in operation, and provide higher efficiency.

Various parameter groups are also included to allow simple and straightforward system setup. If a higher safety standard is required, an optional mains switch function is also available upon selection. The CFP2000 complies to STO/ SIL2. Other outstanding features include support for both induction and permanent magnet motors, a real time clock, a built-in 10k-step PLC capacity , built in BACNet & MODBUS and various optional extension cards such as MODBUS TCP , Profibus DP and EtherNet/IP .

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High reliability The CFP2000 benefits from Delta’s high range production quality systems that differentiates both for reliability and cost. With an IP55 rating, the CFP2000 series features highly effective protection against dust and water in harsh environments. Additionally, an enhanced coating protects the PCB from gases such as salt, SO2, O3 and H2S. The CFP2000 is vibration (IEC 60068-2-6) and shock (IEC / EN 60068-2-27) resistant. Operation temperature range is - 10 °C to 50 °C. The CFP2000 is equipped with a built-in EMC filter and a DC choke. This design replaces the need 08 | Industry EMEA | January 2017

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for an electrical distribution cabinet and saves space for other devices whilst providing the benefits of harmonic suppression and better power quality to the system.

Multi-pump control Delta´s Multi-Pump Solutions adopt the CFP2000 series to manage up to four pumps simultaneously. In HVAC applications, the Sensorless Vector Control (SVC) function of the CFP2000 series automatically adjusts motor output based on changing torque conditions to improve motor performance, reduce energy consumption, and extend service life. This auto-tuning capability also eliminates vibration in mechanical systems caused by sudden starts and stops, and provides protection in variable load environments where momentary power loss or variable loads are encountered.

from 0.75kW to 90kW and it integrates high speed communications such as BACnet and MODBUS. The built-in 10k-step PLC Function supports independent and distributed control when connecting to a network system for high operation flexibility. The Real Time Clock (RTC) function facilitates the PLC program writing process for ON/OFF chronology, daylight savings operation and many other settings. Interface is English, Spanish, Portuguese, French, Russian, Turkish and Polish. www.deltaww.com

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Fire Mode Application This feature is designed for ventilation of buildings, tunnels, subways and more. The drive will bypass the alarm warning in fire mode. When a fire occurs, it forces the drive to continue to operate to extract smoke or supplies water , until the drive fails or runs out of emergency power.

Perfect solution for HVAC and water treatment applications The CFP2000 Series High Reliability Vector Control Drive is Delta’s brand new AC motor drive for fan and pump applications. The CFP2000 is available for all IP55 models 08 | Industry EMEA | January 2017

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DIACLOUD FOR REMOTE AND SECURED CONNECTION OF FIELD DEVICES

Network Topology

This solution enables the implementation of an easy-to-use, cost-effective and safe communication system between most field devices and a PC or a Smartphone. It includes Ethernet and wireless gateways, private cloud and secured VPN software solutions.

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elta’s Smart Factory and Cloud Solution provide a remote control and monitoring platform for realtime management of factory facilities. This solution integrates Delta’s brand new Industrial 3G Cloud Routers DX-2100 Series to collect facility operation data from PLCs and industrial controllers in factories, and upload it to Delta’s DIACloud internet cloud service platform for management. It allows managers and customers to acquire real-time facility operation and manufacturing execution information from

worldwide factories – anywhere, anytime. With high security technologies, the DIACloud ensures data safety for all users.

Currently, Delta has setup DIACloud servers in 7 locations around the globe, and will have 10 more built by 2018 to serve worldwide customers.

DIACloud is a cloud-based IoT platform developed by Delta Electronics. With this platform and the corresponding network gateways, users can communicate with field devices, collect data and push them to a cloud web portal, and push the control commands or settings to field devices at anytime and anywhere. Device status, alarms and field data will be displayed on this mobile APP, whilst control commands can be sent from the APP as well.

Innovative routers which connect all field devices to DIACloud Delta Electronics recently launched the innovative DX2100 series 3G Cloud Router and DX-2300 series Industrial Ethernet Cloud Router, which enable a built-in secure tunnel between the DIACloud cloud service and a set of

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through 6 levels of encryption. All of this helps to make Delta’s DX-2100 and DX-2300 some of the market’s most secure industrial cloud routers. Additional user advantages include networking failure diagnostics, device and PLC interlocking, and custom alarm conditions with email alerts.

A platform designed for smart manufacturing and Industry 4.0 implementation DIACloud includes without additional cost 1GB of data traffic, 10MB storage in the Cloud, and unlimited user accounts.

This makes it possible to perform remote configuration, remote firmware upgrades, scheduled tasks and remote management operations. The device is targeted at a host of remote connectivity applications that include industrial automation, smart homes, smart buildings, smart grids, surveillance and transportation monitoring. www.deltaww.com

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industrial devices such as PLCs, HMIs, AC motor drives, AC servo systems, sensors and more. Designed to support fast and reliable two-way data collection, DX-2100 is a rugged wireless router that establishes a secure ‘tunnel’ between the user and the remote networked devices or PC (via the cloud server) without the need for VPN servers.

Superior performance based on quick, strong and secure connectivity is viable with these advanced new devices.

Able to support Modbus TCP and RTU protocols, the DX2100 is downward compatible with GSM/GPRS/EDGE 2G networks. Both the DX-2100 and the DX-2300 offer HSPA+ data transmission rates of up to 21.6Mbps (downlink) and 5.76Mbps (uplink). Before purchasing any router, users are advised to determine how fast it transmits data.

For the Industrial 3G Cloud Router, further benefits include automatic APN parameter matching and connection redial, therefore minimising offline time in the event of internet drop-out. In addition, there are various peripheral interfaces that include RS-485, RS-232 and Ethernet ports to meet all user device connectivity requirements, while an integral RTC also features along with support for NTP synchronisation over a network.

Data integrity From a security perspective, the firewall offers many advanced functions, including SPI and the prevention of DoS attacks. The firewall also provides, port triggering and port mapping functionality, along with IP address, MAC address and URL filtering. Additionally, information passes

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VERLINDE HOIST HELPS WORKSHOP MANOEUVRE CANAL GATES

Underside view of the wire rope crab unit.

A VERLINDE EUROBLOC VT3 electric wire rope hoist is helping the Canal & River Trust to lift and manœuvre wooden lock gates for canals. The 10 tonne hoist is part of a crab unit that was selected for its ability to offer dual speeds and high levels of operator control. Pelloby, a company which has been working as a UK distributor of VERLINDE products for several decades, designed, manufactured and implemented the double girder crane system.

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he Canal & River Trust has been producing lock gates for the UK’s waterways since 1963. This investment in the 10 tonne double girder crane is designed to further enhance capability at the organisation’s Bradley Workshop in Bilston, West Midlands where around 180 lock gates are produced every year.

With over 1500 locks on UK canals, building new lock gates is a year-round job at the Canal & River Trust. An average lock gate lasts for about 25 years. Towards the end of their working life they will get a visit from the Trust’s carpenters, who measure it up, ready to be rebuilt back at the workshop.

Usually it takes a couple of carpenters two weeks to build a pair of lock gates, but for the biggest gates it can take over a month. Every single lock gate is unique and made in the traditional way using sustainable oak.

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Heavy design and construction is needed so that the gate holds up to the pressure of the canal water and continual wear and tear from boats that pass through the lock. This weight means that suitable cranage capacity is required to lift and transfer lock gates between workstations.

The highest capacity existing crane at the site was a 4 tonne single girder PELLOBY system. However, when the team 08 | Industry EMEA | January 2017

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The VERLINDE EUROBLOC VT3 hoist helps the Canal & River Trust manipulate heavy lock gates between workstations.

began researching a way to lift heavier loads, it was evident that a double girder system would provide the way forward.

PELLOBY was chosen to oversee the project from the early design and manufacturing phases, through to delivery, installation and final commissioning. Featuring a 12 metre span and running along the workshop’s existing gantry steelwork, the double girder electric overhead crane with VERLINDE EUROBLOC VT3 hoist has a maximum capacity of 10 tonnes. The hoist features a travelling motor type trolley, 11 mm diameter galvanised wire rope and HBC 5 V hook.

The wire rope crab unit was selected as it provided dual speeds for a high level of operator control. A further feature is that the long travelling motion also moves at two speeds, with both motions governed by a pendant handset. In addition to lifting heavier loads, the crane also offers the Canal & River Trust the functionality to easily rotate materials so that work can be carried out on the underside of the lock gates.

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“The installation and commissioning process went smoothly and our team have found the 10 tonne system extremely easy to use, allowing us to achieve exactly what we needed,” says Dave Constable, Team Leader at the Canal & River Trust workshop. www.pelloby.com www.verlinde.com 08 | Industry EMEA | January 2017

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