Automation Update - July 2022

Page 1



Should Pharma distribution move to Automation?

Issue 90

Cleanroom tray handling system gently handles medical-use glass cartridges

Connecting EV Technology With Ultrasonic Welding

Simply done. VARIO-X is the decisive step towards the future! Agile manufacturing, sustainability or Industry 4.0 – thanks to 100 percent automation without control cabinets. Modular, flexible and future-proof, Vario-X brings your machines and systems into the future with decentralized installation technology. future. It‘s that simple.


AUTOMATION UPDATE Publication Director Kane Weller 01843 580 460 Editor Leigh Little 01843 267 690 Publishing Director Jodie Little 01843 595818 Editorial Assistant Laura Sharpe 01843 448 443

Automation Update is an engaging, editorially led publication & directory giving the reader news and updates on new products and services to our ever Progressing industry. Publishing House Jet Digital Media Ltd The Forge, Spratling Court Offices, Manston, Kent CT12 5AN

Forerunner Yesterday. Today. Tomorrow. The Sensor People have been setting technological standards in industrial automation for more than 50 years. In the field of safety at work, we convince right from the start with trend-setting inventions, such as the development of the first protective sensor ever, to our latest safety innovation, “Smart Process Gating” – the space-saving solution for access guarding on conveyor lines. This is how we ensure the success of our customers in an industry that is ever evolving. Automation Update - 3

CLEANROOM TRAY HANDLING SYSTEM GENTLY HANDLES MEDICAL-USE GLASS CARTRIDGES Gerresheimer Medical Systems Division produces over one billion high quality, medical grade, glass cartridges every year and central to its new post-production inspection and packaging system is the IEF Werner varioSTACK CF (Clean Factory) tray palletiser. Chosen for its ability to handle the cartridges quickly, gently and with high precision the varioSTACK CF is also supplied in the UK by RARUK Automation.


s primary packaging, the cartridges are most often used for insulin delivery when combined with a pen system for patients to self-administer doses. In a cleanroom environment, the varioSTACK CF is required to sort the cartridges into different containers to cost-effectively replace operators who previously had to pick cartridges from a tube and place them into polypropylene (PP) boxes. The investment now means operators are free to perform other, more valuable and rewarding tasks. The sorting process required the varioSTACK CF to be integrated with Gerresheimer’s own camera inspection system and a pallet buffer with full and empty trays to facilitate highly accurate automated control. Working with Gerresheimer’s own Technical Competence Centre, IEF Werner delivered a flexible concept that includes the use of auxiliary boxes to clamp the PP boxes as well as the matrix trays. The production line consists of the automatic pick-up of cartridges from the oven conveyor, where they relax at about 600°C after forming, a measuring section and finally to the varioSTACK CF; where the last two operations are performed in an ISO Class 8 clean room. Once in the clean room a product gripper picks up 30 cartridges simultaneously and places 15 onto each of two measuring sections.

the defective part and places it on a slide, which leads to a waste chute. Additionally, it is possible to interrupt the process and remove cartridges as test samples in order to monitor the measuring system. The cartridges, which are free from defects, are then transported to the final packaging area. An employee puts the empty container stacks on a conveyor belt. This feeds the varioSTACK CF automatically. A gripper picks up the parts out of the compressor track and places them automatically in the corresponding container. On the opposing side a further gripper picks the full containers up and places them on the pallet buffer. The IEF-Werner tray handling system is able to use two types of packaging: matrix trays with a capacity of 22 x 15 cartridges and auxiliary containers made of plastic, within which PP boxes may be placed. Each box is able to store 380 cartridges. At the end of the line a staff member removes the container, folds the front flap, and places the lid on. As illustrated in this application, IEF-Werner tray palletisers are aligned with flexible factory automation and demandoriented material flow and the autonomous, modular systems are suitable for a diverse range of applications, including the automotive component sector as well as the pharmaceutical and health and beauty industry.

These work synchronously in a reciprocating manner so that no glass cartridge touches another. In order to reach the high pass standard, a G3 camera system, including lifter, are integrated in every measuring section.

Available in the UK through RARUK Automation Ltd, customers also benefit from the technical and commercial guidance and expertise of RARUK Automation when specifying and integrating equipment into existing or new production lines.

The system examines the cartridges for cosmetic errors. If the camera determines an error, the gripper removes

4 - Automation Update

Features Include:        

PLC Web Browser OPC UA Server WebView In Excess of 300 Communication Drivers Event Bar Chart Database Server SQL Query Energy Demand Display/Setting +44 (0)20 3026 2670

Lamonde Automation Limited Quality Products: Expert Advice

New Schwank Solar Air Collectors offer Climate Neutral Heating To meet rising energy costs and decarbonisation requirements for industry and logistics, Schwank has introduced Solar Air Collectors for renewable heat generation. See

The Solar Air Collectors are available in fresh air and recirculating mode.


hile solar power generation is generally associated with capturing the sun’s energy via solar arrays for conversion into electricity, Schwank’s new Solar Air Collectors work in a very different way. In fact, there is no conversion process involved in creating the heat that they produce. These solarSchwank facade-mounted systems are made of durable, perforated, light-weight aluminium with a solar active surface coating (absorber). This selective coating ensures a highly efficient conversion of solar energy into thermal energy. When the sun’s rays meet the solar active surface, they are converted into thermal energy and released into the air layer below the absorber. The heated air cushion is then fed directly into the building assisted by a fan. This is carried out without

Blue equals green! The new solarSchwank systems use the power of the sun and provide climate-neutral heating. The solar-active, selective surface shines in the typical blue colour

any conversion processes or use of a heat exchanger. Thanks to this efficient method, heating costs can be reduced, for instance, by 50% and CO2 emissions can likewise be lowered. solarSchwank systems are available with or without fresh air supply and can be easily and quickly installed in new or existing buildings, significantly reducing heating costs and CO2 emission. Schwank is a leading manufacturer and supplier of industrial and commercial heating, climate, ventilation, and HVAC solutions. The Schwank Group, established for over 80 years and headquartered in Cologne, Germany, distributes its innovative energy efficient products in over 40 countries and is the global market leader in the field of gas infrared heaters and has recently developed a tube heater that can be powered by 100% hydrogen gas.

Further information from 6 - Automation Update

Independent Pump Training from E-learning Classroom based “Live” webinars On-site courses Tailored options For more information call

0121 601 6691

scan code for the training guide or email:

Automation Update - 7

An Engineered Approach to Executive Search? Imagine an Engineer finding you your next Head of Engineering, or a seasoned Senior Commercial Leader finding you your next high performing Sales or Marketing Directors. Imagine working with people that have actually done the jobs they are recruiting for!


hat’s exactly what The Clay Partnership has bought to the sector, in a fresh and inspiring approach to help Manufacturing and Engineering Companies to find and secure the best senior talent in the market.

Dan further explained: “My own 25 years of sector relevant experience allows us to speak with Companies on their level and truly understand their succession challenges, actually translating the real requirements of the roles, using my knowledge to help shape the job specification.”

Dan Martin – The Clay Partnership’s Founder explained: “During my career, having being in various leadership positions myself in Manufacturing Organisations, I had found it could be very challenging trying to explain the nuances of a Senior level Job specification to someone that had no real-world experience in a Manufacturing and Engineering environment, or who hadn’t themselves worked at a senior level.”

Dans real-world experience also means he has the experience to work with Candidates to ensure a smooth and “no surprises” experience, having himself being placed multiple times by Executive Search Companies.

Being a qualified Engineer who transitioned over his 25 year career into global commercial roles, in 2020, Dan decided to provide a service which addressed this gap.

8 - Automation Update

The Clay Partnership typically provides Executive Search services for roles in the £50k - £150k Salary range, meaning they offer a true search and selection process, aiming to uncover the best passive candidates in the market. Get in touch with Dan to see how he can help you find the best individuals at or on 01785 450154, or visit our website

T +49 2961 7405-0

Made in Germany

Your Specialist for



© REMBE® | All rights reserved

Consulting. Engineering. Products. Service.

Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 |

Should Pharma distribution move to Automation? Global Pharma wholesale and Distribution Market projected to grow at a rate of CAGR 5.7% by 2031. Visiongain Research Inc.


he Pharma industr y is changing and more specifically regarding Pharma distribution . Rapid growth over the past few years has meant a need to look at new tools and solutions that will enable them to adapt and update their supply chain automation. With 4 main distribution channels within Pharma wholesale: direct s al e s , ret ail , w h ol e s al er o r Agent means there is a growing requirement to adopt automation, to not only win new business but also to retain existing customers. The technologies and emerging trends such as robotics, AI, 3D printing, precision medicine or patent design will impact not only manufacturing but also the distribution of pharmaceuticals. Larger organisations are creating e f f i c i e n t s u p p li e r n e t w o r k s that leverage digitalisation and automation to connect data and continues on page 10...

10 - Automation Update

...continued from page 8.

operations seamlessly along their supply chains and shed light on any areas of risk. In this process, they need to look not only at the larger tier 1 suppliers but also at the SMEs in tiers 2 and 3. These lower-tier firms also need to adopt digitalisation and automation to keep pace with their customers. The good news for Pharma distribution is that there are many scalable solutions on the market, along with more creative financing options, meaning they can reap the rewards of intralogistics automation and digitalisation. One such company experiencing fast growth was Church Pharmacy with branches in Central London and the Midlands, Church Pharmacy are one of the largest pharmacy’s in the UK fulfilling patient needs. The company found it was facing a plateau in the number of orders it was able to process. With a manual picking process in place, they required a lot of space, so working areas were tight and a considerable amount of staff energy was spent on locating and identifying products. Management considered moving premises to secure more space, and so to better understand the issue Church Pharmacy appointed two of their technical team from UpSTEAM. uk, who recognised that Innovation was required for them to stay in their current premises and manage continued growth and future-proof the business.

Kardex Remstar’s Vertical Buffer Module (VBM) (effectively a small miniload in a box) combined accuracy, fast picking, and enhanced security. The VBM delivered the exact product to the picker for a good ergonomic experience. The VBM stores the bulk of their stock in a small footprint, which meant that Church Pharmacy were able to stay in their current premises enabling enough space for 5x more order volume growth. Kardex Frame Pick was added to provide a high level of flexibility, especially when additional labour was required during higher order volumes. Frame Pick enables a batch of 36 orders to be picked simultaneously and includes optical indicators that direct the picker to the exact location of the order for the product to be picked into and out of. Digitalisation is a major benefit with Kardex Power Pick software integrating with a flexible batching and fulfilment tool designed by which helps increase picking speeds and efficiency by added 35-40%. This ensures all stocked items are delivered on-time for efficient picking whilst delivering a tailored solution based on material process and fulfilment flow.

12 - Automation Update

It’s amazing when we look at what we have achieved in a relatively short time. We have increased their accuracy, and productivity. The staff are happier and more productive, and their customers can be assured of continued great service. - Joseph Stephen - Head Software Architect – A u to m a t i o n d eli v e re d g re a te r productivity for Church Pharmacy with time spent picking reduced from 24 man-hours a day to just six. Picking accuracy – a critical factor in the pharmaceutical sector – has increased to 99.9%. With a 70% increase in picking speed, the solution for Church Pharmacy has a predicted ROI of less than two years. To learn more about how automation can assist in distribution read more at Smart Pharmaceuticals guide for warehouse distribution which delivers insights, tips and processes that will assist in your process.

moneo – simply made for you! Software to assist your industrial evolution - Nothing more. Nothing less. One platform for all digitization requirements Experience the ease of IT-supported process optimization with moneo. moneo is the all-in-one platform for everyone who wants to interact with their system in a predictive manner, evaluate information and adjust parameters. All in one software. Take the next step in digitization. Without detours, without technical hurdles, very simple and straightforward. Are you ready for industrial evolution? It's already happening, with moneo.

moneo|configure SA (SA: Stand-Alone) supports you with the parameterization of your IO-Link devices and ifm IO-Link masters. The visualized representation in the cockpit simplifies setup and error diagnosis. The simple management of parameter data sets accelerates the integration of new sensors and is supplemented by the integrated online connection to the IODD finder. Ready for more? Then start your digital evolution now with moneo, the new, open and industry-independent IIoT platform from ifm.

Over a dozen online MRP software educational events to be hosted online over the summer months Free events show what manufacturing software should be delivering for your business or that are unhappy with their existing manufacturing software and considering replacing it. The INFO Exchange is a one-to-many webinarstyle event, while the number of attendees of the Evaluation Workshop is capped to allow all attendees time to participate in the Q&A session.

123 Insight are to host over a dozen online manufacturing software events until the end of September, allowing companies to get a better understanding of how MRP/ERP can improve overall business efficiency. There are two event types; the INFO Exchange gives a 50-minute brief taster of the MRP process, while the more indepth 3-hour Evaluation Workshop goes into much more detail and has a Q&A session at the end, allowing attendees to ask any questions. Both event types are free to attend. The event dates are as follows: • Tue 5th July 10am – INFO Exchange • Tue 19th Jul 10am – INFO Exchange • Wed 20th Jul 9.30am – Evaluation Workshop • Wed 27th Jul 9.30am – Evaluation Workshop • Tue 2nd Aug 10am – INFO Exchange • Wed 10th Aug 9.30am – Evaluation Workshop • Tue 16th Aug 10am – INFO Exchange • Wed 24th Aug 9.30am – Evaluation Workshop • Wed 31st Aug 10am – INFO Exchange 14 - Automation Update

• Wed 6th Sep 9.30am – Evaluation Workshop • Thu 15th Sep 10am – INFO Exchange • Wed 21st Sep 9.30am – Evaluation Workshop • Tue 27th Sept 10am – INFO Exchange The events are suitable either for companies that are looking to move away from paper-based processes or home-grown Excel/database systems,

All attendees at both events also receive a free paperback copy of ‘How to implement a manufacturing system’ by 123 Insight’s Marketing Manager Martin Bailey. The book acts as a template for implementing any manufacturing system, not just 123insight, and also highlights the best practices and pitfalls of each stage of the evaluation and implementation process; from initial selection and choosing your implementation team, through to data migration, down-stream training, going live and measuring success. Simon Badger, Managing Director, said; “With the cost of raw materials and energy increasing everywhere, companies are looking to be more efficient than ever. A well-implemented MRP system can deliver business efficiency across every department, not just manufacturing. In these educational events we aim to dispel many of the myths and complexities that often surround MRP, making it accessible to more businesses.” To book to attend any event visit


Manufacturing so�ware for any industry

Are you struggling with: Stock issues

Errors and mistakes

Produc on management

Inability to grow

Financial planning

Wasted me

Our educa onal approach allows you to understand the benefits of MRP, learn the so�ware and helps us to understand your business needs in a relaxed, informal atmosphere, with no hard sell.

Risk-free selec on process Assess




Go live

With 123insight, you won’t commit anything financially un l you are fully trained on the so�ware and are 100% sure that it will work for you. Find out more by a ending one of our free online events, and receive a free paperback book that explains how to implement any MRP system, not just our own.

01489 860851

Be Inspired by Innovation at Advanced Engineering Book your stand today to avoid disappointment


he 13th edition of Advanced Engineering will celebrate innovation, development and growth within the UK’s manufacturing industry. There 18/02/2022 06:30:08 will be seven show zones this year — aerospace, composites, automotive, advanced metals, connected manufacturing, space and satellite and a new product testing and quality control zone. In the space and satellite zone, the ExoMars Rover, Bruno will return following huge interest at the 2021 exhibition. This year, Advanced Engineering will once again be colocated with sister show, Lab Innovations, giving visitors and exhibitors more opportunities to collaborate across sectors. It is also offering more networking opportunities with a new composites networking area and drinks reception, which will be sponsored by PRF Composites. “Over the last two years, our whole industry has learned the value of in-person interaction, both personally and professionally,” explained Alison Willis, Director at Easyfairs, the organiser of Advanced Engineering and Lab Innovations. “At last year’s event, we found that more visitors and exhibitors were attending with a purpose — whether that was to connect with a new supplier or purchase a particular piece of equipment. AE Connect, our digital platform that helps exhibitors and visitors connect and arrange meetings in advance of the show, really helped facilitate this.”

The UK’s largest gathering of OEMs and engineering and manufacturing supply chain professionals, Advanced Engineering, will return to the NEC, Birmingham on November 2 and 3, 2022. The event is shaping up to be a huge success, with 80 per cent of exhibitor space already sold. Last year saw over 7,000 people attend across the two days, including representatives from Airbus, Jaguar Land Rover, Alpine F1, Ford, BAE Systems, RollsRoyce, and the Ministry of Defence. “Our industry is always innovating and releasing new technologies that are even more impressive when you see them in person. Take Advanced Engineering’s Enabling Innovation competition as an example — inperson events give start-ups like those involved in this the chance to showcase their ground-breaking products to the rest of the engineering community.” In 2022, Advanced Engineering’s smart badge system will return, meaning that attendees scan a personalised badge to receive digital literature and exchange virtual business cards with suppliers. As well as reducing the amount of paper being used, the smart badge technology also helps decrease the spread of COVID-19. Over 75 per cent of last year’s exhibitors rebooked for 2022, including Qimtek, a business that helps industry buyers and designers find new subcontract manufacturing partners. At the exhibition, marketing manager, Dean Munkley said, “The show’s been really good — far busier than I expected. We’ve probably taken more leads than we have at any show over the last three years. There was a lovely mix of people and it was great speaking to anyone from students to directors. There’s such a good variety of suppliers here too — we’ll definitely be returning.”

Exhibitor space is selling out fast. To book your stand, visit and make an enquiry. Alternatively, you can contact our Head of Sales, Ali Farr on +44 (0)20 3196 4244. 16 - Automation Update

2 & 3 November 2022 | NEC Birmingham

The UK’s LEADING annual gathering of OEMs and engineering and manufacturing supply chain professionals An absolutely outstanding event! We’ve met many great people who we will be looking to work with in the future, and overall it has been a very successful couple of days. Matt Travis, Engineering Manager, JCB

Scan the QR code to discover the event

Association partners Composites


Trade Association | +44 (0)20 3196 4300

Co-located with

Success of TCT 3Sixty 2022 Promises Bright Future Ahead for UK 3D Printing and Additive Manufacturing Sector The UK additive manufacturing and 3D printing community gathered on 8-9th June at the NEC, Birmingham for two incredible days of innovation and collaboration. Thousands of visitors and 160 exhibitors met at the NEC to share and witness mind-blowing demonstrations of the latest developments and practical applications of 3D printing and additive manufacturing.

TCT 3Sixty’s ongoing partnership with The CREATE Education Project saw Inspired Minds return for the first time since the pandemic. Over 100 secondary school students attended TCT 3Sixty to undertake 3D printing workshops, lead by industry experts, in a purpose-built classroom on the show floor. They also had the opportunity to explore the show further and discover the many live tech demonstrations in the hall. Well-loved 3D printing content creators, Sam Prentice and Joel Telling (3D Printing Nerd) joined the thousands of visitors at the show. Telling was more than happy to share his thoughts on the latest 3D printing and additive manufacturing technology, and delighted his many fans on the show floor with his infectious energy and passion for the sector and tech on show.

The two day show saw a huge number of attendees create an electric atmosphere whilst discussing the latest industry developments, networking and building longterm business partnerships. The palpable buzz of excitement in the hall suggests a bright future for the growing 3D printing and additive manufacturing sector in the UK, over the next 12 months and beyond. Highlights of TCT 3Sixty 2022 included a CPD accredited conference programme with over 60 world-class presentations from Boston Consulting, US Air Force, Deutsche Bahn, MTC, Callum, Vital Auto, Progressive Technology and the University of Birmingham alongside panels and debates covering sustainability, quality assurance and supply chain. 18 - Automation Update

Feedback from exhibitors on the show floor was excellent. The huge popularity of the show has already seen a record re-book rate, with many exhibitors keen to secure their place on the show floor for next year as early as possible.

show for TCT, we come back every year. For us, TCT is the only UK show dedicated to AM, we’d be stupid not to be here. All our customers come here, all our prospects come here and it’s nice to see other people from the industry as well. Next year, we’re looking forward to being back here again.” Feedback from visitors on the show floor was also extremely positive.

Yves Jamers, Sales Manager UK&I at HP Printing said: “The show is really brilliant, TCT is a show where we absolutely need to be as HP. Brilliant conversations so far, we’ve already met a couple of really interesting prospects and it’s really living up to our expectations. Our main objective is to show people how HP can make a difference in additive manufacturing. This is my second time at TCT, I really love the show here and the venue. We’re coming back next year!” Catherine Aspinall, Marketing Manager at Tri-Tech 3D said: “TCT is THE show for us, it’s the leading additive manufacturing show in the UK...this is the one to go to so we had to be here. The show so far has been really busy, quite shocking really as we didn’t know how it was going to go, but we’ve had queues outside the door, the guys have been busy all morning – we can’t complain. It’s innovative, fun and exciting. It’s our 6th

Alex Ball, Head of Imaging and Analysis at The Natural History Museum said: “TCT is important to the industry because you can get a really good snapshot of all the industries in one place – so 3D printing, 3D scanning and the software that supports all of that – to see it all in one place is unusual, and I haven’t seen it anywhere else. It’s a good melting pot for all of the different technologies that are important to the industry.” Adam Thickett, Development Engineer at Siemens Energy said: “This was a great opportunity to engage directly with the additive manufacturing industry experts all in one place and so easily and quickly compare what is currently available.” TCT 3Sixty will return to the NEC on 7-8th June 2023.

For more information visit

Automation Update - 19


12-13 October 2022

Coventry Building Society Arena

Celebrating 10 yea r s

@EngDesignShow #EngDesignShow

Interested in exhibiting?

Get in touch with for more information on our exhibiting and sponsorship opportunities.



Connecting EV Technology With Ultrasonic Welding Global targets driving forward the introduction of all electric vehicles (EV’s) have created multiple considerations for EV battery development. These include a range of factors such as average journey distances, charging times, charging infrastructure, and as a consequence, optimisation of battery range. The weight, size and compactness are the main considerations within the battery technology itself, that is, the energy density of the battery cells. With such high volumes projected of batteries with multiple sub cells, the combined performance of connections within the battery construction, battery management and sensing are vital areas for consideration. Additional key factors include any manufacturing process effects on the battery components, the speed and cost of production, and of future importance, end of life recyclability. As a technology which has been widely used for joining plastics, wire splicing and metal connector welding within the automotive, and other industries for decades, it is a natural progression that ultrasonic welding is fast becoming a process for many joining applications on components being manufactured for Hybrid and full Electric Vehicles. Historically, this fast, efficient, measurable, and environmentally friendly process has delivered joint quality and commercial advantages for many manufacturers. The advent of Electromobility has now opened up a wide range of new opportunities for ultrasonic welding on components such as high voltage interconnectors tabs and foils as part of the battery, together with battery management components and sensing harnesses.

Telsonic PowerWheel ®

22 - Automation Update

One of the key attributes of direct ultrasonic welding is that it is an “on demand” process, delivering optimised weld energy at high efficiency levels into the joint. Involving only the joint materials themselves, the process supports and of life recyclability. The process is fast, easily automatable for high volume welding, and can join dissimilar materials. It also delivers excellent results with highly conductive materials, and it is particularly good with thin copper and aluminium, thin wires, and also multi-layer sheets. The larger conductor / termination sizes and cross sections involved in EV applications require high power ultrasonic oscillations using Telsonic’s Torsional technology to deliver high levels of energy within very short process times to produce the weld. Over the last decade Telsonic has kept pace with the growing e-mobility market, developing and perfecting the techniques and machines required for these applications based upon their Linear, SONIQTWIST ® and patented PowerWheel ® technology. Another important factor in Telsonic’s success in these applications is their high-power MAG based generator capability which allows large cross section single point welding.


Battery cell construction and Interconnectors Energy storage systems for EVs have a modular design and consist of single battery cells that are joined into modules which are then grouped to form a battery pack. The cells may be secured using metal or plastic support structures to leave space for state-of-charge related swelling. The joining application opportunities include individual battery construction and the interconnection of the cell arrays. The commonly employed Li-ion battery has three different cell types which are solid cylindrical cells, soft pouch or polymer cells, and solid prismatic structure types. The pouch type battery construction is an especially good fit for the ultrasonic weld process where typically, thin copper, nickel plated copper, and aluminium materials are required to be joined.

Typical EV Pouch Cells

The various battery structure types generally involve Busbar interconnections for series or parallel connections, and the materials used for wire conductors or their rigid connections are mainly copper and aluminium. Ultrasonic technology can be employed as the joining method used on a variety of tasks in battery cell construction and their subsequent interconnection. This involves busbars, prismatic foil and tab welding. These operations are ideally suited to Telsonic’s Linear Technology MPX range, which has been developed for wire terminations braided connectors and pouch tabs, with the capability to deliver low or high-power joining as required for the specific application.

MPX applications include Low & High Power joining tasks for wire cross-sections of 4mm2 to 50mm2 - Copper -and 70mm2 -Aluminium

MPX module ready for automation integration for battery pouch applications

Automation Update - 23

High Power Ultrasonic Joining A particular “fit” for the Ultrasonic joining process is higher power conductor to terminal joining for EV motive systems. In these applications it can be difficult to maintain process control and quality levels, with the larger cross section conductor cables and their associated connectors, using alternative methods. In these applications, Telsonic’s new PowerWheel ® Technology, integrated within the Telso ® Terminal TT7 system, delivers torsional ultrasonic energy which enables large cross section area wires to be bonded, with narrow bonding areas, and importantly, good part accessibility with directly applied weld force. Telsonic technology can conform to the automotive performance and design validation specification standards which have been developed by Industry OEM’s and their Tier one suppliers for ultrasonically welded wire terminations.

Telso ® Terminal TT7

Wire Splicing and Wire End Consolidation Using ultrasonic technology to weld wire harness assemblies has become recognised as the process of choice for sequential splicing for the many different wire cross sections required for the various power distribution supply aspects of any high-volume production vehicle type.

Telso ® Terminal TT7 machine fixturing and tooling

Ultrasonic cable splicing machines from Telsonic are used to splice or end consolidate cables ranging from 0.26mm2 up to 75mm2 with a process capable of integration with real time Manufacturing Execution Systems (MES). Again, Telsonic’s wire splicing technology can conform to industry design standards for wire splicing.

High Voltage charging connector Welded usingTelsonic’s Power-Wheel ® technology

Aluminium cable welded into Nickel plated tubular lug with PowerWheel ® technology

24 - Automation Update

Wire splicing and consolidating in the wire cross sectional area range 0f 0.26mm2 to 75mm2 in Copper, Aluminium and Copper / Aluminium combinations.

Vertical Ultrasonic Torsional Welding for EV Applications - TSP Range Historically this ultrasonic process has been used for hardto-reach applications at a range of different power settings, and for welding within recesses and welding onto ceramics (IGBT). The main reasons for and advantages of using the torsional process over conventional ultrasonic welding is the “reach,” plus the process is gentler on sensitive or delicate product assemblies. Low force / power torsional machines are ideal for foils, flat conductors, battery end cap tabs and delicate sensing components. Applications include collector tab welding on cylindrical cell electrode foils and collector tabs to end caps. Conversely, the same technology can be used with higher force and power to weld round stud type high power connectors requiring direct force over the joint and encapsulation of the stud male features. Telsonic’s TSP range are supplied as standalone machines, or modules for integration Into automated systems for the production of connectors and battery cells.

Telsonic’s TSP range of machines used stand-alone or integrated into automation systems

High force / power applications

TelsoSplice ® TS3 / TS6 Wire Splicer

Low Force / Low Power Applictions Automation Update - 25

SICK’s Fill Level Monitoring Keeps Packaging Machines Topped Up A digital service that gives instant visibility to filling levels in packaging machinery has been developed by SICK in collaboration with industry end-users. SICK Filling Level Monitoring avoids machine stoppages by giving real-time data to operators via smartwatch or phone, so that levels of carton blanks, adhesive or film wraps, for example, stay topped up.


nstead of having to check each magazine or film roll level in person, machine operators monitor fill levels on their watch or phone and are alerted by SICK’s Filling Level Monitoring system before levels become critical. Machine downtime is avoided and staff walking routes can be planned efficiently to ensure optimum production uptime.

Industry Collaboration The SICK Filling Level Monitoring digital service can be used with any SICK smart level sensors. Its first applications have been developed with packaging manufacturers and machine builders using SICK DT-50 laser distance

sensors to output level measurements from carton magazines and film rolls. The measurements are routed to a SICK SIM1012 edge gateway, which aggregates and forwards encrypted data via SICK’s LiveConnect digital interface, so that it can be easily accessed, managed, and processed online. The SICK Filling Level Monitoring cloudbased dashboard provides easy-tointerpret graphical information about the real-time status of machines from any internet-enabled device. Automatic push notifications on the fill levels can be set up for smart devices to alert with an acoustic signal and vibration. Meanwhile, production managers can monitor the fill levels of all machines across a packaging line, shift or entire production facility. Analysis of historic trends can be used to optimise production processes.

Unexpected Benefits Neil Sandhu, SICK’s UK Product Manager for imaging, measurement and ranging, said: “SICK worked closely with leading packaging end-users and machine builders in Europe to develop a costeffective and easy-to-implement system. “By using the smart watch alerts, our customers found that fewer operators were needed to keep cartoning machines replenished, so staff could be deployed more efficiently to other duties. What’s more, the system brought unexpected benefits to overall production control. For example, the loads on packaging machinery lines could be monitored to identify over- or under- capacity.” While initially developed for cardboard and film packaging materials, Filling Level Monitoring can also be adapted for liquids including adhesives, or granular raw materials. It is also possible to add customised services and analyses tailored to particular machinery or processes.

A SICK DT50 distance sensor measures carton fill levels

26 - Automation Update

Carton Magazine Fill Levels displayed on Smart Watch

SICK Application Filling Level Monitoring

Up to six SICK sensors can be monitored by each SICK SIM1012 gateway, and more sensors, including third-party devices, may be added by connecting over OPC-UA. Sensors are also continuously monitored by the system in case one should go offline or need a replacement. The solution can be extended to meet the needs of customers on request, e.g. to customise and display additional data on the dashboard. Integration to third party ERP and MES software systems is also possible.

Digitilisation Neil Sandhu concludes: “Cloud-based services such as Filling Level Monitoring illustrate how making reliable sensor data transparent enables digitalised machine operation as part of Industry 4.0. By combining smart sensors with intelligent software, critical processes can be visualised in real time and adapted for the needs of users. “Early adopters are noticing new and unexpected production trends when they view and interpret their historical production

data in easy-to-read graphical displays. As a result, they have been able to optimise production processes and deploy staff to achieve efficiencies never even expected.” Automation Update - 27

Features Include:        

PLC Web Browser OPC UA Server WebView In Excess of 300 Communication Drivers Event Bar Chart Database Server SQL Query Energy Demand Display/Setting +44 (0)20 3026 2670

Lamonde Automation Limited Quality Products: Expert Advice