09 | APRIL 2017
industry THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA
RIFTEK’S LASER TRIANGULATION SENSOR MEASURES CYLINDER THICKNESS AND DIAMETER
5 BIGHEAD SUPPORTS UNIVERSITY CHALLENGES
8 NSK OPTIMISING BEARING SEALS FOR AGRICULTURAL APPLICATIONS
FAULHABER NEW DC-MICROMOTORS WITH PRECIOUS-METAL COMMUTATION
09 | Industry EMEA | April 2017
THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA
FLUKE PROCESS INSTRUMENTS
ADVERTISERS: SIRAI 4
TYCO GAS & FLAME DETECTION
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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 donâ€™t need.
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RIFTEK’S LASER TRIANGULATION SENSOR MEASURES CYLINDER THICKNESS AND DIAMETER
RIFTEK, represented exclusively in the UK & Ireland by Ixthus Instrumentation, recently designed and suppled a customised scanning system that automatically measures and records geometric parameters for welded cylindrical laminated foil tubes.
he RF092 machine employs three RIFTEK laser triangulation sensors that are rotated around the sample tube and combine to measure the multilayered foil thickness as well as the weld overlap and depth, in addition to the tube length and its diameter. Manufactured using ABL or PBL (aluminium or plastic barrier laminates), these types of tubes are extensively used for packaging pastes or gels such as cosmetics, toothpaste and more aggressive materials where leakage of any kind cannot be tolerated. The tubes are typically formed and sealed by an axial weld and the machine was commissioned by RIFTEK’s customer as part of a quality control procedure that helps ensure they meet the appropriate EN 13461:2009 manufacturing standard.
The measured parameter specifications for the RF902 include diameter from 13 to 50 mm with accuracy to +/10 µm, foil thickness range from 0.05 to 0.5 mm with foil and weld thickness accuracy to +/- 5 µm, as well as length accuracy to /- 0.1 mm. MORE INFORMATION
The rotating laser scanning principle developed by RIFTEK builds upon other systems for the measurement of inner diameter and tube parameters using triangulation sensors that are more commonly associated with linear distance measurement - but are nevertheless proving to be a competitive alternative to other forms of cylindrical geometry and thickness measurement.
The automated machine is supplied complete with motorised linear and rotary positioners that present and align the sensor head so that the tube axis centreline coincides with rotation axis. The machine includes calibration cylinders for three tube diameters to suit the customer’s current production programme although more sizes could easily be included. On completion of an automatic cycle to measure and record the data the results displayed on a GUI with a PC connection via Ethernet to upload information for storage or further analysis.
A complete specification sheet is available for the RF902 is available on request from Ixthus Instrumentation and a video showing the machine is also available at www.ixthus. co.uk/videos/index.php (note embed in Ixthus website – link to YouTube… www.youtube.com/watch?v=Mw_T0BwwoE&feature=youtu.be) 09 | Industry EMEA | April 2017
High Speed Diagnostics, automatically Error-Free.
Drive solutions for laboratory automation Countless samples are tested daily in analytical laboratories. The benefits of automation in this area is obvious: They make it possible to achieve faster results, higher throughput, fewer errors and lower personnel costs. In order to ensure smooth operation, high dynamics and precision are extremely important for the drive systems. We spoke to Dr. Aihua Hong about the requirements and developments in this market segment, for which she is responsible at FAULHABER.
In which industries does laboratory automation play a part? Automated processes can be found in all laboratory areas, such as the chemical, pharmaceutical and food technology. The medical industry is an area in which there has been considerable growth worldwide. Automated solutions have been indispensable in this area for many years in so-called in-vitro diagnostics (IVD), i.e. the analysis of medical samples such as blood, urine and tissue. Test procedures are also becoming increasingly automated in the research laboratories of pharmaceutical companies in the development of new drugs. 09 | Industry EMEA | April 2017
What exactly is laboratory automation? The degree of automation in the different laboratories varies considerably. It ranges from carrying out individual processes using stand-alone devices up to complete sample analysis in complex systems. The latter is particularly required in areas where large numbers of samples need to be examined in accordance with a standardised protocol and little flexibility is needed â€“ such as IVD in the main laboratory of a hospital or in large laboratories for medical diagnostics. Which processes are carried out automatically in these areas? Almost the entire analysis process takes place automatically in these laboratories. It starts with the preparation of the blood samples in colour-coded sample test tubes. A scanner records the type of analysis that is required for a test tube, and ensures that it is picked out by a robot arm accordingly. Some of these samples are centrifuged in order to separate the constituents of the blood. The samples are then transported in special transport units to the actual analysis station, e.g. by conveyor belt or in a small trolley with a wheel drive.
head can usually be found in the mobile component. It must therefore be extremely light and compact. What are the advantages of FAULHABER motors? The DC-micromotors of series 1524SR and 2224SR are particularly suitable for these applications. They have no iron armatures and are therefore much lighter and smaller than other models with comparable performance. At the same time, they are characterised by having extremely high dynamics. They are mainly used in combination with a series IE3 encoder, which only increases the overall length of the unit by two millimetres. High performance is therefore achieved with an extremely compact design.
What happens in the analysis station? The sample is first identified by directing the bar code at a camera and having it read. Then the stopper is removed from the test tube, and some of the sample is removed. The test tube is then sealed again and archived for possible testing at a later date. The sample is transferred to a reaction vessel for the actual analysis, e.g. onto a test plate or petri dish. During the subsequent testing, the drive technology is mainly used for processes such as pipetting, liquid handling, mixing and stirring. Which requirements have to be met by the motors? Many different movements have to be be carried out during the entire process, and the demands made of the drive technology differ accordingly. The conveyor belts require large, powerful motors, and components that are as compact and lightweight as possible. Thanks to our comprehensive product range we can cover the entire spectrum, and can supply an extremely good solution for almost any requirement.
Are there any other reasons for opting to use FAULHABER products? It is extremely important to our customers place to have high-quality components so that their equipment will operate reliably for longer. They generate about ninety percent of their profit with the reagents that they sell with their devices for sample analysis. The service life of their equipment and the continuity of their reagent sales are therefore directly related. Furthermore, the equipment for IVD has to undergo an expensive certification process before it can be put into operation. In order to avoid repeating this process, the replacement of existing devices with other models is avoided wherever possible. The availability of replacement parts therefore plays an important part as well. If a FAULHABER component has to be replaced after a long service life, the customer can rely on the fact that it can still be obtained from us, even after many years. www.faulhaber.com/en/de/markets/medical-laboratoryequipment/laboratory-automation/ www.youtube.com/watch?v=mk3CsDRGocg www.faulhaber.com MORE INFORMATION
Can you give us some examples? Many applications require a highly dynamic system for repeated start/stop movements such as pick-and-place and pipetting processes. Both speed and extremely accurate positioning are required when doing this. Size and weight also play a part here: The drive for the upwards and downwards movement of the gripper arm or pipetting 09 | Industry EMEA | April 2017
BIGHEAD SUPPORTS UNIVERSITY CHALLENGES
Bonding fasteners for composite components in student competitions.
igHead Bonding Fasteners Ltd provides sponsorship and supplier partnerships for several college and university level competitions and projects for engineering design. The list includes race car, solar powered vehicles and even submarine design projects as far and wide as the UK, India and the USA. These student challenges are bound by a common goal that focusses strongly on design innovation factors to yield benefits such as improved performance, enhanced fuel economy and increased endurance - which can be largely attributed to adopting aerodynamic lines and lightweighting through composite materials technologies.
The design and manufacture of the composite components and provision for their efficient assembly are often closely comparable to those real-world applications that bigHead encounter on a daily basis - and bigHead is very pleased to help young students solve these challenges. bigHead’s prominent role for discreet fastening in automotive manufacturing and other industries, and its shared work with research programmes such as the KTP funded project with Cranfield University’s Composites Centre makes it an ideal partner to help students; not just with products but with full technical support. This support is very much in line with bigHead’s philosophy to work closely with designers from their first ideas and concepts in shared engineer-to-engineer processes.
Projects include the Formula Student and Formula SAE competitions where teams are challenged to build and race a single-seat formula car with marks awarded for a number of different event areas including design, economy and endurance as well as racing and handling. In this area, bigHead supports teams from universities in Estonia, Spain, UK and the USA. Another interesting area is 09 | Industry EMEA | April 2017
solar powered vehicles. The Punch Powertrain Solar Team from the KU Leuven in Belgium and the KJ Somaiya College of Engineering in Mumbai, India are both working towards innovative weight-saving strategies in competitions judged on efficiency and endurance. A project challenge to build and race a one-man human powered submarine at the 2016 European International Submarine Race competition in Gosport, England involved a high degree of composite materials construction helped with bigHead bonding fasteners.
pins and other fixings in a choice of BZP mild steel or 316 stainless steel. For further details, please visit the website at www.bighead.co.uk call + 44 1202 583696 or email email@example.com
bigHead works closely with composite components manufacturers in automotive, construction, marine, rail and many other industries where carbon fibre, plastics and other formed or moulded structures and components require invisible fixing and where secondary operations such as drilling are to be avoided.
Automotive applications include carbon fibre panel fixing solutions in specialist and luxury car production as well as higher volume car production with the use of robotics and dry adhesive techniques. Other areas include marine & boatbuilding, building & construction, and rail & leisure vehicles where both adhesive bonding and directly embedding bigHeads into other types of high volume composite material components is widely used. bigHeads are available for small- to largescale production as male studs, female collars and nuts, or 09 | Industry EMEA | April 2017
NEW FAULHABER SUBSIDIARY IN PENANG, MALAYSIA
Stronger presence in Malaysia.
rom 1 Jan 2017, the products and services of the FAULHABER Drive System will be distributed in Malaysia by FAULHABER Malaysia Sdn Bhd. The newlyestablished distribution company is based in Penang. FAULHABER was previously represented in the country by Aims Motion Technology Sdn Bhd.
“The market in Malaysia has become more and more important for FAULHABER.” declared Marcus Remmel, Head of Sales at FAULHABER Drive Systems and Managing Director of FAULHABER Malaysia. “On the one side we see business transfers to Malaysia, on the other side we see more and more demand for our products from domestic companies. The new own office brings us closer to our customers. We are excited about being able to exchange ideas with them and discuss in depth about joint development of customerspecific products. Our local presence will be a milestone in the further development of Malaysia market.”
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FAULHABER specializes in the development, production and deployment of high-precision small and miniaturized drive systems, servo components and drive electronics with output power of up to 200 watts. The product range includes brushless motors, DC micro-motors, encoders and motion controllers. In addition to this, FAULHABER also provides customer-specific and even complete solutions for medical and laboratory applications, automation technology and robotics, precision optics, aerospace and other industries. FAULHABER has more than 1,700 employees worldwide. The address of the new FAULHABER subsidiary: FAULHABER Malaysia Sdn Bhd 1A-2-01 & 02 · One Precinct · Lengkok Mayang Pasir Bayan Baru 11950 Penang · Malaysia T +60 4 619 2570 · F +60 4 619 2670. Email: firstname.lastname@example.org www.faulhaber.my
HIGH-SPEED, DIRECT-DRIVE ROTARY STAGE WITH COLLET CHUCK The ASR1300 high-speed, direct-drive rotary stage achieves accelerations of up to 8000 rad/s2 and reaches speeds greater than 1500 rpm in only 90° of travel, making it perfect for the most demanding tube-handling applications and high-throughput manufacturing processes.
• Optimized system design for maximum acceleration. • High-speed operation (up to 3000 rpm). • Integral captive pneumatic collet-chuck for minimal part motion during clamping. • Type-D collet accepts 0.1 mm to 2 mm O.D. tubing. • Clear aperture and guide system for product feed-through. • Direct-drive brushless motor with optional water cooling for performance stability. • Maintenance-free, frictionless rotary union.
he ASR1300’s maximum speed of 3000 rpm and its outstanding acceleration capability result from a full system-level optimization of the torque-to-inertia ratio. Supremely agile, the ASR1300 facilitates higher throughput levels on supporting motion equipment and ultimately lower part manufacturing costs and increased production capacity.
Compact and Lightweight The ASR1300 is the smallest and most dynamic member of Aerotech’s ASR-series rotary stage family. Weighing a mere 2.8 kg, the ASR1300 is nearly 50% lighter than the ASR1200. Multi-axis systems accelerate faster, with less dynamic error, due to the ASR1300’s minimized weight and package size resulting in impressive process optimization and improvement. Superior Material Handling Capability The ASR1300 features an integral Type-D (Louis Levin & Sons™) collet chuck. Collets are readily available in multiple sizes supporting tube diameters from 0.1 mm to 2.0 mm. These collets provide outstanding runout characteristics for applications requiring high-precision gripping of tubular material. Applying air pressure adjusts the collet from fully open to fully closed. Air is delivered to the rotating collet assembly through a custom-engineered, noncontact rotary union that ensures a lifetime of maintenance-free operation.
For further information, please contact Steve McLane at 412967-6854 (direct), or via e-mail at email@example.com. In addition, the ASR1300 series data sheet is available at: www.aerotech.com/product-catalog/stages/rotary-stage/ asr1300.aspx
09 | Industry EMEA | April 2017
NEW HEXAPOD TARGETS MEDIUM-LOAD, ULTRA-PRECISION APPLICATIONS
Six-degree-of-freedom positioning with linear travels to 60 mm, angular travels to 30°, and payloads up to 45 kg. • Ultra-precision design with guaranteed positioning accuracy specifications. • Minimum incremental motion to 20 nm in XYZ and 0.02 μrad in θxθyθz. • Powerful controls and software with visualization of work and tool coordinate systems.
erotech’s HexGen™ hexapods represent a significant advance in six-degree-of-freedom positioning performance. The newest member of the HexGen family, the HEX300-230HL, is targeted at medium-load, ultra-precision applications ranging from sensor testing to synchrotron sample manipulation. Aerotech’s HexGen hexapods are the only hexapods on the market today that provide guaranteed positioning accuracy specifications below 5 μm.
Superior Structural Design The HEX300-230HL is actuated with six high-accuracy struts built with precision preloaded bearings, ball screws, and drive components. Unlike competitive hexapods driven by DC brush servomotors, the HEX300-230HL is driven by Aerotech’s AC brushless, slotless servomotors that maximize its performance and longevity. Directly coupling the AC brushless servomotors to the ball screw results in increased drive stiffness, higher positioning accuracy, and better minimum incremental motion (20 nm in XYZ and 0.2 μrad for θxθyθz), compared to competitive designs using belts, gearheads, or compliant couplings. Specially-engineered strut pivot-joints provide low friction and high stiffness, enhancing the hexapod’s overall performance. The HEX30009 | Industry EMEA | April 2017
230HL’s superior structural design offers the user a generous load capacity of up to 45 kg.
interface permits selection of the active coordinate system for easy virtual pivot-point programming and motion.
Design Flexibility The HEX300-230HL’s platform and base can be easily modified with user-specific features or mounting patterns. It features a 100 mm diameter clear aperture in the platform, while a 60 mm diameter clear aperture in the base allows workpiece access from the bottom. The base mounting holes adapt directly to English and metric optical tables. Vacuum Options Aerotech hexapods can be vacuum-prepared for demanding applications such as synchrotron sample or optics manipulation, semiconductor manufacturing and inspection, or satellite sensor testing.
For further information, please contact Steve McLane at 412967-6854 (direct), or via e-mail at firstname.lastname@example.org. In addition, the HEX300-230HL series data sheet is available at: www.aerotech.com/product-catalog/hexapods/hexgenhex300-230hl.aspx
Powerful Controls and Software Driving the HEX300-230HL is Aerotech’s award-winning A3200 motion control software. Built on years of experience with difficult kinematics applications, the A3200 controller allows easy programming and control of the hexapod in any user-defined coordinate system. Aerotech’s HexSim™ software gives users the ability to easily visualize and simulate the available workspace. Tight integration between HexSim™ and the A3200 motion controller provides real-time motion visualization in any user-defined coordinate system. An intuitive graphical 09 | Industry EMEA | April 2017
AN EXCELLENT PRESS MAILING SERVICE DECENTRALIZING THE SYSTEM TO REDUCE SPACE AND MATERIALS
Machine CMC 400 for printing and sending promotional material as direct mail.
Promotional postcards and flyers, membership cards, coupons and other info materials fill up our mail boxes daily and encourage shopping tailored to you. Do we ever ask ourselves where all this comes from? The answer is probably from creative minds based in marketing companies. That’s true, when it’s about the idea. However, who produces and makes all of this? A mailing house. Cor-rect! But how? The answer is provided by engineers and planners at C.M.C. srl with the support of Kollmorgen’s decentralized solutions.
.M.C. srl is an Italian company based in Città di Castello (Perugia) since 1980. They are leaders in de-veloping solutions and innovative systems in the fields of mailing, graphics and packaging on demand.
The company is able to offer high-speed machines for managing envelope inserts which are completely integrated within the production line,reading and printing systems. C.M.C. is a proud pioneer in automated mailing: C.M.C. machines can process up to 30,000 envelopes per hour with detailed digital printing tailored to your needs. Thanks to our strong engineering and informatics department, the company is able to promptly deliver on clients’ needs and can speed up the variable packaging program when sending out the materials and in the finishing process. One of the last challenges this company took on was that of creating a customized plant which could an-swer to the needs of a major enterprise at European and international 09 | Industry EMEA | April 2017
level. It consisted in printing and sending out publicity materials which needed to print promotional coupons in a short frame of time] and at the highest quality as well as being custom made. A head start we had on this project was consolidated technology that is market proven. Its strength, however, was the winning idea: the machine was revolutionized and tailored to the needs of the client, thanks to our own research and development department, strong communication with the client on the one hand and the support of Kollmorgen on the other. The challenge was to produce high quality print on fine coated paper, customize, pack and send the materials with the maximum precision, quality and possible speed. “For years we tried to reduce the switchboard dimensions” said Enrico Martinelli – Production Manager Mailing Department, and Maurizio Giacchi, Sales Manager. Thanks to Kollmorgen’s solutions – we were able to decentralize each drive along the three production lines that are part of the plant”.
Centralized versus Decentralized. Advantage of Decentralized Solution, less cabeling and smaller cabinet.
Every line is made up of three machines equipped with 24 stations matching the number of coupons, some which were customized, whilst others were standardized. The objective was achieved by removing the control panel drives used previously and therefore drastically reducing the size of the switchboard, number and length of cables involved: from a four-frame stand-alone one built on alongside the machine and two meters wide, we moved to an integrated electric switchboard, saving in the process some external space. The AKD-N series drives, installed close to the motor only have one connection cable. The client also benefits from this since they are able to save space for the materials: this transformed the machine to improve efficiency at reduced cost (Total Cost of Ownership).
necessary for new generation machines without losing out on the simplicity. Power supply as well as safety (STO) and EtherCAT fieldbus are combined in one single hybrid cable of only 11mm diameter. On the motor side there is also only one cable needed for power, brake control and feedback. This leads to more than 80% of machine cable savings. AKD-N Servo Amplifier – Benefits • More compact machines. • Smaller and lighter integrated switchboards. • Servo amplifier placed closer to the machines. • Robust structure made of protection class IP67, no need for protective casing. • Easy to clean and service for hygienic environments. • High operating security – thanks to the robust structure. • Faster machine debug and test thanks to less cabling. • Higher flexibility in machine design (modularity and scalability). >>>
AKD-N Multiaxis Servo Amplifier System: the winning input The keystone to this project was the use of the AKD-N Multiaxis Servo Amplifier System, an innovative technology with excellent performance that comes in extremely compact size. Thanks to the robust structure and the IP67 protection class, the new decentralized AKD-N Kollmorgen servo drives can be placed close to the motor. Plug-in connections, freedom of choice of motor , most suitable mounting point , and wide range of functions: these decentralized AKD-N servo drives can offer complex Motion Control systems with EtherCAT fieldbus and/or other automated interfaces such as ProfiNet, EtherNet I/P and Modbus TCP/IP. The system offers everything that’s
AKD-N decentralized Multiaxis Servo System is perfectly compatible with any type of motor and allows you to utilize non-stop all the advantages of systems with single power cable.
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AKD-N in CMC Machine Decentralized Servosolution inside the machine and close to the motors.
AKM Servomotors from Kollmorgen available in 8 Sizes – a perfect match.
C.M.C. has attained the highest benchmark through Kollmorgen components and in choosing a decentralized solution. Kollmorgen is a specialist in Motion Control solutions offering a wide range of servo drives, servo amplifiers, pre-wired cabling and technical support with the highest level of experience, providing step-by-step support to the client during the entire project development. The global scale of the Kollmorgen brand has enabled C.M.C. to venture in the US and to tap into established markets.
AKM Servomotors, a step further In terms of motors, even the wide range of AKM™ Servo Motors contributed to C.M.C. choosing Kollmorgen as their partner in this project: AKM™ practically has an unlimited number of configurations and therefore allows for unprecedented choice and flexibility as well as top-level performance and an ex-cellent power density. It is worth noting that the AKD™ servo drives are easy to set up and use thanks to their plug-and-play motor recognition and self-adjustment.
Conclusion “I’m really pleased to be working with the C.M.C. team, it’s a dynamic company, full of innovative ideas, with young and talented staffs – concludes Fabio Massari, Senior Sales & Key Account Manager at Koll-morgen. Working closely from the start with the management team and being able to share our respective needs has allowed us to provide a solution, which in this specific case has brought about a reduction in the amount of cabling used; from the old system which required 1,500 meters down to 240 meters. We were able to save on more than one entire kilometer of cabling. I hope that we will be able to undertake new challenges ahead together, with the added value that has allowed us to stand out to date”. www.kollmorgen.com/en-gb/products/drives/servo/akd-n/ akd-n-decentralized-servo-drive/ www.kollmorgen.com/en-gb/products/motors/servo/ akm-series/akm-series-ac-synchronous-motors/akmsynchronous-servo-motors/ www.kollmorgen.com
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Author: Fabio Massari Senior Sales & Key Account Manager, KOLLMORGEN Italia
LINE OF HIGH-TEMPERATURE RATIO PYROMETERS EXPANDED
New high-precision ratio pyrometers enable continuous visual process monitoring in the harshest industrial environments.
Wider temperature range, new application areas.
luke Process Instruments has added four new singlecolor and two-color pyrometers to the Endurance series. The series now covers measured temperatures from 50 °C to 3,200 °C. The manufacturer has enhanced the maximum optical resolution from 150:1 to 300:1, enabling measuring of even smaller targets from a distance. A new low-temp ratio pyrometer for demanding applications measures temperatures from 250 °C. The sensors feature galvanically isolated inputs/outputs and a stainless steel IP65 housing.
They withstand ambient temperatures up to 65 °C or up to 315 °C using cooling accessories. Application areas include primary and secondary metals manufacturing, carbon processing, silicon production, and now also foundries and welding, as well as rubber and thick plastics. The Endurance series offers a versatile range of models with wide temperature ranges and different wavelengths for precise process data that will help manufacturers reduce reject rates, improve product quality and uniformity, maximize throughput, and minimize energy costs. The sensors operate with Power over Ethernet or DC power and interface to Ethernet, ProfiNet, and RS-485. A backlit rear-panel with tactile feedback allows for easy, intuitive
navigation. The PC-based Endurance software simplifies configuration and deployment, and a built-in web server enables archiving of historical data for traceability, process troubleshooting and remote viewing. Various lens, sighting, and focus options are available, for example, an on-board camera for video sighting via Ethernet. A dirty lens alarm helps avoid unneeded periodic lens cleaning checks. All Endurance series pyrometers are offered with a best-in-class four-year warranty.
09 | Industry EMEA | April 2017
OPTIMISING BEARING SEALS FOR AGRICULTURAL APPLICATIONS On purpose-built test rigs, rolling bearings were subjected to loads that simulate agricultural machinery use over a whole season.
NSK’s Agri Disc Hubs are characterised by their considerably longer service life under harsh environmental conditions.
The seals of rolling bearings used in agricultural machines have to withstand extremely arduous operating conditions. This is why NSK has developed new seals for deep groove ball bearings that deliver a highly effective balance between the conflicting goals of sealing capability and low friction. Indeed, the performance of the seals has been ably demonstrated in a series of demanding test simulations.
he Neuweg factory in Munderkingen, Germany is part of the NSK manufacturing group. It was established in 1954 by a manufacturer of agricultural machinery to produce rolling bearings for its own requirements. NSK took over the factory in 1990, and today ‘Agri Disc Hubs’ are among its specialities in worldwide demand. These readyto-install bearing units are typically fitted to soil tillage machines such as compact disc harrows.
Disc harrows loosen the soil using disc-shaped, separately mounted and spring-loaded tools. The tools need to keep rotating and run smoothly, regardless of soil condition and working depth. Operating speeds are up to 18km/h over uneven ground, and the machine must be able to withstand impacts from stones hidden in the soil. As the tools are positioned at an angle to the direction of movement, the rolling bearings are subjected to high axial stresses, while further potential hazards include abrasive dust, moisture, dirt and corrosive fertiliser. All of these place high demands on the bearing and its seal. 09 | Industry EMEA | April 2017
Once duties using the disc harrow are complete, the machine is usually subjected to a high-pressure jet wash before being left idle for several months until the next season begins. This presents another threat to the bearing whereby the seal must be able to resist the penetration of water. With all these factors in mind, NSK’s design team at its European Technology Center (ETC) in Ratingen, Germany, set about creating a suitable high-efficiency sealing system optimised for agricultural use. Their approach was to orient their development work to a standard used by a worldleading manufacturer of agricultural machinery to qualify rolling bearings acquired from external suppliers. This manufacturer operates an accelerated test fixture that rotates the rolling bearings at a speed of 5000 rpm and a load of 900N. The test lasts 500 hours and simulates seal usage over a period of one season. Subsequently, high-pressure cleaning is simulated on a second test bench, where the bearing is sprayed from a distance of 200mm by water jet at a pressure of 11 bar and a temperature of 90°C. A total of
NEWS Even after 200 hours of water jet testing, no water penetration into the bearings could be detected.
Deep groove ball bearings with optimised DG/DDG seals are already in full production at NSK.
220 test cycles are performed before a second 500-hour test is repeated on the first test fixture. The test rigs, which have been replicated at NSKâ€™s ETC at Newark in the UK, accurately simulate extreme agricultural conditions over a two-year period of use. Once testing is complete, the bearings are weighed to within 1Âľg precision to detect any grease loss. They are then inspected visually, and seal efficiency and wear are recorded. In parallel with designing the test rigs, NSK engineers completed the development of the new seal. The application clearly requires high sealing capability under extreme conditions, and the best way to achieve this is with a seal that presses firmly against the surrounding structure. However, the unwanted effects of such a configuration include higher friction and elevated heat generation, which lead to reduced energy efficiency and service life.
capability in comparison with both NSK deep groove ball bearings featuring existing DU seals, as well competitor products. The bearings completely satisfy the stringent requirements of agricultural users in terms of seal tightness/performance and low-friction torque. As a result, demand from agricultural machinery manufacturers is currently high and NSK has already commenced full production of deep groove ball bearings featuring the new DG and DDG seals (single-sided/ double-sided sealing). www.nskeurope.com
To overcome this challenge, the newly designated DG/DDG triple-lipped seal differs from existing seals in that it has a double lip made of acrylonitrile butadiene rubber with steel reinforcement. Furthermore, on the inner side of the deeper, U-shaped groove, it has an additional seal that also forms a grease barrier. The deep groove ball bearings featuring DG/DDG seals were subjected to intensive comparative testing. At the end of the tests, they were found to have significantly better sealing 09 | Industry EMEA | April 2017
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. Based 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.
I MORE INFORMATION
n 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) system, WebAccess 8.2 HTML5 based Dashboard not only tuned the widgets to meet usersâ€™ 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.
09 | Industry EMEA | April 2017
In response to more extensive and complicated IoT applications, Advantech WebAccessâ€™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.
To find out more about the WebAccess 8.2, contact your local Advantech sales representative or visit www.advantech.com
09 | Industry EMEA | April 2017
Compact DC-motor with high torque.
he new 1016…SR series from FAULHABER expands the proven motor family of compact DC motors with precious-metal commutation. Together with the already introduced 0816…SR and 1024…SR series, these drives, combinable with suitable FAULHABER gearheads and encoders, are ideally suited for applications where maximum power is required in the most compact spaces.
The new 1016…SR motor series reaches a continuous torque of 0.92 mNm with a length of only 16 mm and a diameter of 10 mm. Its Δn/ΔM characteristic curve has an especially flat slope of 5953 rpm/mNm (3 V) and therefore makes it possible to have extremely soft transitions during a load change. Further advantages of the motor are its low power consumption, high energy-efficiency and minimal vibration and low audible noise. It is therefore suited as a drive for applications with small dimensions and very high requirements, such as for precision tools, optical devices or active prostheses.
09 | Industry EMEA | April 2017
The 1016…SR DC-micromotor can be combined with a wide range of gearheads like the other motors in the SR family. It reaches a torque of up to 300 mNm with the 12/4 planetary gearhead. For applications where high-precision positioning is essential, zero backlash spur gearheads are available as a compact alternative. With these, undesirable play can be reduced or eliminated. Optical and magnetic encoders with a resolution of up to 256 pulses per motor shaft revolutions make highly precise control of the drive possible. In addition, it can be combined with numerous controllers, from the miniaturised SC 1801 speed controller up to the MC 3002 motion controller for a complete solution. www.faulhaber.com
DG-TT7-S WITH MOS SENSOR RECEIVES SIL 2 APPROVAL
Tyco Gas & Flame Detection is pleased to announce that the DG-TT7-S H2S gas detector with Metal Oxide Semiconductor (MOS) sensor underwent stringent functional safety assessments by an external certification body and is now SIL 2 approved.
he DG-TT7-S is solid-state metal oxide semiconductor (MOS) gas detectors used mainly for the detection of hydrogen sulphide (H2S) in arid locations having air present or in locations with continuous H2S background. The sensor specifies a wider continuous operating temperature range than the standard electrochemical sensors up to +65â€‰Â°C.
The device supports HART 7 protocol option for full configuration and diagnostics over non-proprietary interface. The MultiTox DG-TT7-S features on board relays, plug and play sensors and a high visible display that changes colour depending on the status mode. www.TycoGFD.com
MORE INFORMATION 09 | Industry EMEA | April 2017
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