Engineering Update - April 2020

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Instruments Ltd

DC UPS

CBI Series Input 90-305 V AC Output 12/24/48 V DC upto 20 A MODbus / CANbus Comms Remote Monitoring via ethernet Status Relay

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Multifunction Meters | CTs, VTs and Shunts | Transducers | Energy Meters - MID Bargraphs | Earth Leakage Relays | Protection Relays | Battery Chargers | Power Supplies DC UPS | Generator Controllers | Remote Monitoring | Ventilation Control

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TVR Instruments Limited 143 Butt Road, Colchester CO3 3DP Essex United Kingdom

Tel: +44 (0) 1206 575755 Email: sales@tvri.co.uk www.tvri.co.uk

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ENGINEERING PDATE

April 2020

CONTENTS Editor

Wendy McManus 01843 267 690 wendy@engineering-update.co.uk

April 2020

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April 2020

ENGINEERING UPDATE

CHELL Produce Smallest Ever 16 Channel Smart Pressure Scanner World-renowned gas measurement and control experts, Chell Instruments, have increased their range of leading performance pressure scanners with the launch of the smallest intelligent pressure scanner available anywhere. The new nanoDAQ-LTC-16 measures only 50 x 23 x 9mm but has the same advanced calibration and thermal compensation as the rest of the nanoDAQ-LT range. Designed for applications where small size and light weight are a priority, the LTC retains all the features and market-leading performance of its contemporaries. Fully configurable, the nanoDAQ-LTC-16 will output pressure data in engineering units over CAN and makes use of 16 absolute transducers, which are thermally compensated and conditioned. Its size and rugged construction means the pressure scanner is perfect for use in harsh environments. Reconfiguration of the port outlets allows measurements to be made more conveniently in tight spaces. Nick Broadley, Managing Director at Chell Instruments, said: “Pressure scanning applications are an area we’ve been heavily focused on. In particular, the aerodynamic testing of Formula 1 cars where we have supplied highend pressure scanners for over 30 years.

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“Our team of engineers have been working hard to design an affordable miniature scanner that replicates all the advanced diagnostics and precision of the nanoDAQ-LT range but in an even smaller package.” “Many of our engineering solutions come directly from a customer enquiry looking for help with a specific problem,” continued Nick. “Chell has a reputation for undertaking solid research as part of our new product development process so our customers know that we come up with a quality engineering solution.” Contained within a miniature package sealed to IP67 standard, the nanoDAQ-LTC-16 can be used in harsh environments, making it ideal for many potential users from motorsport teams to motorcycle designers, trains and wind turbines. Established in 1976, Chell Instruments supply and manufacture pressure and gas flow measurement and control instrumentation. They design and build test and calibration systems for many of the most demanding and mission-critical applications. For more information on the nanoDAQ-LTC-16 and other Chell instruments capabilities, please visit www.chell.co.uk.


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Monitoring the world


April 2020

ENGINEERING UPDATE

Muller Coax are the original designers and manufacturers of coaxial valves having established the company and product range in 1960 and are established in many industry sectors supplying valves to many diversified blue chip companies and organizations worldwide including Siemens, Rolls Royce, BNFL and many automotive plants where the valves are specified for use.

From their head office and main manufacturing plant in Germany, Coax have wholly owned companies in the USA,UK, Spain, Italy and China and distributors worldwide to support our customers wherever they may be. Muller Coax product range includes products for many industry sectors including power generation , automotive plants, nuclear industry, military, pumping application and machine tools to name but a few. Valve range have valves for medias and pressures up to 500 bar, 2/2 and 3/2 functions, Atex compliant , fast reaction times, various body materials, position indication all are SIL2 rated as standard with SIL3 certified available on many types.

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Due to the design of the valve the media passes unimpeded through the valves in a “coaxial” manner, there is no pressure loss across the valve, and this design also allows the valves to handle and pass contaminated media where many conventional valves would fail due to ingress of dirt. The size of the valves vary but are all known for their fast reaction time with the smaller MK10 valves able to do a complete open / closed cycle in 60 milliseconds. Muller Coax are an ISO9001: 2015 accredited company. For further information contact John Osborn on 01908 067583 or on e mail john.osborn@coaxvalves.co.uk Web address is www.co-ax.com


PRODUCT SHOWCASE – ON THE SHELF Stock items available immediately

Tempmaster PRO Precision Thermometer The Tempmaster PRO from Labfacility provides very high precision temperature measurement with Pt100 sensors. www.labfacility.com

L300 8 Zone Temperature Alarm / Controller with Pt or TC inputs The Labfacility L300 Pt100 and TC temperature alarm / on-off controller can be used in conjunction with a PC to provide accurate monitoring and alarm or on-off control of up to 8- zones simultaneously www.labfacility.com

L60 Thermocouple & Fine Wire Welder The Thermocouple Welder, manufactured by Labfacility, is a compact, simple-to-use instrument designed for thermocouple and fine wire welding. www.labfacility.com

Labcal PRO Precision Thermometer The Labcal PRO from Labfacility is fully characterised for Pt100 sensors and all major thermocouples. www.labfacility.com

Bognor Regis 01243 871280 | Sheffield 01909 569446 sales@labfacility.com

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April 2020

ENGINEERING UPDATE

Compact Proportional Solenoid Valve Enables Precise Air Flow Regulation in Medical and Industrial Applications. The UK’s leading authority on electric actuators and solenoid subassemblies, Magnet Schultz Ltd (MSL), is highlighting the availability of its compact proportional solenoid-controlled pneumatic valve range designed for the efficient regulation of air flows in medical ventilators as well as gas flow regulation across a broad range of other applications and industry sectors. Available in 16mm and 20mm

energy generation, among others.

flow rates from 30 to 200 litres per minute. All variants feature fast

diameter variants, the compact VPRM solenoid valve allows

The 16mm diameter VPRM unit is

response times, high linearity and

precise proportional control of

available in pressure supported

low hysteresis, and a switching

air, and the mixing of air and

open, closed and pressure

service life of 50 million cycles.

gas, in respirators and medical

balanced configuration. The

The standard specification VPRM

equipment. The 16mm model is

20mm diameter VPRM unit offers

valves in stock at Magnet Schultz

already being used in paediatric

pressure supported open and

Ltd operate from a 12V DC supply,

ventilators, where the advantages

pressure balanced configurations.

with voltages from 6V to 24V DC also available.

of fully proportional, direct-acting air flow control are ideally suited to

The compact VPRM units handle

the critical and delicate application.

16-bar static pressure in the armature space with nominal gas

As well as ventilators and medical respiratory equipment, the VPRM units are ideal for heavier duty air flow applications such as air pressure and air volume control in spray painting equipment. In addition, the valves can be used with other gases, opening up precise promotional control options rather than a typical on/ off function in applications that include dosing of inert gas in welding, gas regulation in vehicle exhaust systems, and in fuel cells for building and automotive

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April 2020

ENGINEERING UPDATE

Grab – label – train – run AI with IDS NXT ocean Artificial intelligence opens up new fields of application for camera technology and image processing. It can be used, for example, to classify fruit varieties or to identify damaged parts (e.g. apples with marks or color deviations).

RIGHT: IDS NXT ocean Design-In Kit Below: IDS NXT ocean: AI for industrial applications

support come from a single company: IDS. Users only need sample images and knowledge on how to evaluate them (e.g. "good" / "bad") to create a neural network. This makes the start into AI-based image processing particularly easy.

Train neural networks without prior knowledge

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o cover all possible variances with classical image processing would be very time-consuming and costly. With artificial intelligence, however, these challenges can be solved in no time at all. With IDS NXT ocean, there is now a user-friendly complete solution for industrial applications available. Camera hardware, software, infrastructure and

With the help of the IDS NXT lighthouse cloud software, even nonexperts without prior knowledge of artificial intelligence or camera programming can train an AI classifier with their own image data. Since it is a web application all functions and the necessary infrastructure for creating the neural network are immediately available. This means that users do not have to set up their own development environment first, but can start training their own neural network right

away. This involves three basic steps: To upload sample images, to label the images and then to start the fully automatic training. The generated network can then be executed directly on the IDS NXT industrial cameras, turning them into powerful inference cameras.

Get started with the Design-In Kit IDS also offers an IDS NXT ocean design-in kit which is particularly useful for anyone who wants to test the potential of AI for individual vision tasks. It provides all the components a user needs to create, train and run a neural network in his productive environment. In addition to an IDS NXT industrial camera with 1.6 MP Sony sensor, lens and cable, the package includes six months of access to the AI training software. The use of deep learning-based image processing for individual applications can thus be realized in a short time.

More information: en.ids-imaging.com/ids-nxt-ocean.html

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ENGINEERING PDATE

April 2020

pressure sensors KELLER (UK) Ltd. Little Keep Gate, Barrack Road, Dorchester, DT1 1AH UK and Ireland: T. 0845 643 2855 F. 0845 643 2866 E-Mail: sales@keller-pressure.co.uk Web: www.keller-pressure.co.uk www.keller-druck.com

PIEZORESISTIVE OEM PRESSURE

TRANSMITTER 4 LD…9LD WITH I²C INTERFACE

AND EMBEDDED SIGNAL CONDITIONING – No external components – Ranges 0…1 bar thru to 0…200 bar – Accuracy, error band +/- 0,5%, 0…50 °C – Sizes Ø 11 m, 15 mm, 17 mm, 19 mm bar – Very low power consumption

PRECISION PRESSURE TRANSMITTER 33 X – Ranges 0…0,2 bar thru to 0…1000 bar, adjustable – Output signals: 4…20 mA, 0…10 V, RS485 Digital – Mathematical on-board error correction – Accuracy, error band 0,1 %FS, 10…40 °C – Optional enhanced precision to ± 0,01 %FS

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April 2020

ENGINEERING UPDATE

Interroll presents new HighPerformance Crossbelt Sorter Faster, more flexible and even quieter: With the global market launch of the new High-Performance Crossbelt Sorter MX 025H Crossbelt Sorter, Interroll extends its innovative portfolio of automatic sorting solutions to include a new highperformance system capable of handling up to 20,000 conveyed goods per hour. This new solution also allows much heavier and larger goods to be sorted. As a result, even the most demanding users can now enjoy the performanceand availability benefits offered by mechanically driven horizontal crossbelt sorters from Interroll. The new High-Performance Crossbelt Sorter MX 025H, offers an increased conveying speed of up to 2.5 m/s (8.2 ft/s) compared to 1.8 m/s (5.9 ft/s) for the still available Interroll Crossbelt Sorter ST 6160. The new sorter thus enables throughput rates of up to 20,000 conveyed goods per hour. At the same time, the High-Performance Crossbelt Sorter MX 025H is able to transport goods weighing up to 50 kg. In addition, the width of the carriers has been increased by an impressive 50 percent. This means an enormous gain in flexibility when sorting goods of different dimensions. Maintenance for the HPCS is extremely easy and inexpensive. This is true for many reasons. First of all, the drive chain has been replaced with a rubber belt. This means there is no need for lubrication. Secondly, it is now much easier and faster to replace the belt. However, extensive tests indicate this will not need to happen for many years, even in the case of 24/7 operations. The carriers

can also be replaced much faster, and wear parts are also less expensive; all this contributes to significantly lower maintenance costs – around 50% less than with a conventional Crossbelt Sorter. Thanks to the mechanical drive concept, the sorter operates extremely quietly—below 67 dB(A)—even at the highest throughput rates. In addition to extensive load and endurance tests in the in-house test center, the new sorter has already been in use for almost a year at selected customers’ sites.

Over 400 Interroll automatic sorting systems already in use worldwide "With our entry into absolute highperformance sorting, system integrators can now offer users an innovative and at the same time proven technology range," explains Jens Strüwing, Executive Vice President and Head of Products & Technology at Interroll. "Our unique, mechanical drive concept enables us to process an increasing number and variety of goods according to demand—with TOP: Interroll's new High-Performance Crossbelt Sorter can process up to 20,000 conveyed goods per hour.

LEFT: The modular sorter platform also includes innovative infeed conveyors.

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the highest reliability and economic advantages that are unparalleled in the world market." One important reason for this global success is the basic mechanical principle of Interroll's sorter platform. Today, more than 400 sorters are already in use worldwide by industry leaders such as Amazon, DHL, FedEx, UPS, Hugo Boss, Inditex (ZARA), Zalando, Swiss Post, Austrian Post and China Post. Unlike competing products, the number of electronic components in these sorters has been kept as low as possible. The unique design principle ensures maximum availability, very long lifetime, minimum operating costs as well as short payback periods.

Energy savings of up to 50 percent Interroll Crossbelt Sorters operate on a direct drive principle, in which the drive units can be positioned flexibly. The entire drive system offers power efficiency rates of over 85 percent. It is designed redundantly so that if one drive unit fails, the sorting operation continues uninterrupted. Compared to electrical sorting systems operated with traditional linear motors, energy savings of up to 50 percent can be achieved. At the heart of the sorter are the crossbelt carriers with patented mechanical drives. The modular sorter platform also includes innovative infeed conveyors and terminals that can be customized to meet the needs of each user.

www.interroll.co.uk


Power Security & Back-Up

Instruments Ltd

DC UPS

CBI Series Input 90-305 V AC Output 12/24/48 V DC upto 20 A MODbus / CANbus Comms Remote Monitoring via ethernet Status Relay

Battery Chargers CB Series Input 90-305 V AC Output 12/24/48 V DC upto 20 A MODbus / CANbus Comms Remote Monitoring via ethernet Status Relay

Power Supplies

FLEX Series Input 90-500 V AC Output 12/24/48 V DC upto 25 A Single / Dual or 3 Phase inputs

A H

h r A

Multifunction Meters | CTs, VTs and Shunts | Transducers | Energy Meters - MID Bargraphs | Earth Leakage Relays | Protection Relays | Battery Chargers | Power Supplies DC UPS | Generator Controllers | Remote Monitoring | Ventilation Control

S

Instruments Ltd

TVR Instruments Limited 143 Butt Road, Colchester CO3 3DP Essex United Kingdom

Tel: +44 (0) 1206 575755 Email: sales@tvri.co.uk www.tvri.co.uk

Ala


April 2020

ENGINEERING UPDATE

AC MICRO-DRIVES OFFER OUTSTANDING CONNECTIVITY AND FLEXIBILITY When machine builders are looking for a range of variable speed drives to ensure an easy, problem-free connection to a preferred Ethernet or Fieldbus network, YASKAWA GA500 & 700 Variable Speed Drives offer the highest standards of performance. In many control applications today there is a growing appetite for data-rich connectivity with all major industrial networks as part of the drive toward the Industrial IoT and Yaskawa is helping to satisfy this demand. From drive selection, through design, installation, start-up, or trouble shooting, the design brief for GA500 and GA700 Drives has been clearly focused on making life easier. These AC Micro-drives have been developed for the widest range of industrial applications which combine valuable functions and features to provide important benefits through the whole lifecycle of a machine or installation. With 100 years of experience in driving electric motors and over 27 million produced AC drives, Yaskawa’s pedigree is unmatched in developing products which combine technical superiority with easy handling. The latest GA Series of Variable Speed Drives are compact in size, incredibly flexible in terms of connectivity and designed to handle nearly any application enabling users to

run any motor type from 0.2 up to 315Kw. The key features and benefits include; integrated EMC filters, embedded dual channel safety (STO SIL3/PLe), one field-bus card for up to 5 network drives, the ability to meet all global standards along with safe, convenient set-up and monitoring, with apps for all mobile devices. Other features include, a robust design enabling the drives to operate up to 4000m altitude and in hot environments up to 60ºC. Coated PCB’s protect against dust and mist, while Integral temperature controlled fans run only when needed, so any potential for contamination is minimised while service intervals can be prolonged. The bright LED display and tactile keypad ensures easy and intuitive

navigation through menus, while the common menus and parameters are arranged and named as any other Yaskawa drive minimizing the need for re-training. Also, an embedded programming environment for customising drive functions means scalability and the potential to replace the need for external controllers. The USB port means easy connection to a PC or mobile device for programming, monitoring or trouble-shooting while easy-access terminals ensure quick and convenient connection of mains and motor cables without the need to remove any cover. Also screwless control terminals create long lasting, reliable connections without the need for re-tightening. In conclusion, GA500 & GA700 Drives offer simple system integration, combining network support, application focused features, with outstanding customizability, fast installation and set-up without the need for peripherals. Ends More information at: https://ga500.eu/ Further details available from Paul Seale: salesuk@yaskawa.eu.com Tel: +44 (0) 1295 272755 www.yaskawa.eu.com

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20201 ENGINEERING PDATE DS-OCT12-BLACKFAST_Layout 1 20/09/2012 April 16:28 Page

Tel: 0208 339 7370

Fax: 0208 339 7371 Unit 5 Russell House, Molesey Road Email: sales@blackfast.com Walton-on-Thames, Surrey KT12 3PE www.blackfast.com

we make ideas come to life

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

Cutting We can cut and shape perforated sheet to meet the needs of your final application. Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements. Rolling and forming We can roll, bend and form perforated sheets to match your design. Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.

For more information please contact us tel: 01925 839610 | email: info.uk@rmig.com | www.rmig.com

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April 2020

ENGINEERING UPDATE

Metering Flow in Larger Diameter Pipes Titan Enterprises offers a range of highly reliable insertion turbine flowmeters for accurately metering flow in larger diameter pipelines (40 - 900mm). Insertion turbine flowmeters from Titan combine proven technology with modern materials and innovative design. The durable PVDF turbine rotates freely on a 316 stainless steel shaft and has special aerofoil shaped blades to extend the dynamic range of the meter. Specially contoured housing further improves the meter linearity particularly at lower fluid velocities. Installation from the side of

the flow line is made via a 1.5" BSP or NPT fitting, and versions are available for 'hot-tap' insertion into pressurised lines. Each Titan insertion turbine flowmeter contains two sensors, one self-powered (for battery operated equipment) and the other an open collector transistor. A reed switch may be specified for hazardous

areas were simple apparatus is acceptable. The body of Titan insertion turbine flowmeters is manufactured from AISI316 stainless steel and as standard is supplied with three meters of five core screened instrument cable. This insertion turbine flowmeter can be provided with a directly mounted battery and powered display which will give Flow Rate and Total as well as digital and analogue outputs. For further information please visit www.flowmeters.co.uk/insertionturbine-flowmeters-for-large-40900mm-pipes/ or contact Titan Enterprises on +44-1935-812790 / sales@flowmeters.com.

High Pressure Hastelloy C Flowmeters for Hazardous Areas Based upon a proprietary oval gear design, Titan Enterprises OG Series flowmeters are designed to give reliable, high performance in a wide range of applications. For more challenging applications, Hastelloy® Cis the material of choice for OG Series flowmeters. Inherently Hastelloy C has outstanding resistance to both highly oxidizing and reducing agents, making it an ideal choice for moderate to severe corrosive fluid handling and environments. Titan Hastelloy C OG flowmeters can withstand high temperatures, high pressures and can be fitted with a suitable sensor for Hazardous areas. The chamber sealing on these meters is designed for the required pressure rating and it can be a fluid compatible ‘O’ ring such as Kalrez. When constructed from Hastelloy C and PEEK™ - Titan Enterprises compact OG flowmeters are perfect for measuring flow at pressures up to 700 Bar and 150°C. Designed to be IP-67 / NEMA 4 compliant, Titan's Hastelloy C OG Series high

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pressure flowmeters are available in standard and customer specified configurations. Unlike other types of flowmeter, the measurement accuracy of these oval gear flowmeters improves as liquid viscosity increases, from a nominal one per cent towards 0.1 per cent of flow rate at higher viscosities. To operate - Titan OG Series flowmeters employ oval-shaped, gear-toothed rotors that rotate within a chamber of specified geometry. As these rotors turn, they sweep out and trap a very precise volume of fluid between the outer oval shape of the gears and the inner chamber walls, with none of the fluid actually passing through the gear teeth. Ceramic or Teflon® coated magnets are embedded in the rotors, which then actuate a reed switch, Hall effect sensor or ATEX approved sensor to

provide a pulse output. Each pulse or switch closure then represents a precise liquid volume that passes through the meter. The result is highly accurate flow measurement almost immune from the effects of varying fluid viscosity, density and temperature. For further information please visit https://bit.ly/3ap9761 or contact Titan Enterprises on +44-1935-812790 / sales@flowmeters.co.uk.


ENGINEERING PDATE

April 2020

New Liquiphant ready for Industry 4.0 Endress+Hauser’s vibronic level instrument FTL51B reliably detects the level of liquids in storage tanks, containers and pipes – but it also provides proof test, verification and IIoT functionality.

T

he Liquiphant FTL51B can be used in all types of liquids as its vibronic sensor is not affected by changing media properties, flow, turbulence, gas bubbles, foam, vibration or build-up. It works in process temperatures of -58 to 302°F (-50 to 150°C) and pressures up to 1450 psi (100 bar). It can be used in SIL2 and SIL3 hazardous locations and has built-in automatic maintenance and verification functions. The device can perform its own proof test, which can be activated remotely at a control system or locally via the device. The proof test diagnoses the sensor for corrosion and build-up, and ensures the entire instrument is operating properly. Verification can be activated either manually or automatically via Endress+Hauser’s Heartbeat Technology, providing a verification report required by various regulatory agencies. Access via Bluetooth technology and a mobile device – such as a smartphone – allows the user to identify each device, commission it, check the status, start a proof test and download verification documentation. Bluetooth has a range of 33 ft, allowing a technician to access Liquiphant instruments installed in hard-toreach locations, such as at the top of tanks. For more information visit www.uk.endress.com/FTL51B or call 0161 286 5050. |17


ENGINEERING UPDATE

April 2020

Unique Innovations from UK Drives & Motor Supplier, 5 years running Quantum Controls have been awarded the prestigious Business Excellence Drives & Motor Supplier of the Year for 5 years running, we provide our customers with unique innovations that keep their site running 24/7. Weatherproof Rental Drives We have over 1500+ Weatherproof Rental Units available, up to 1.5MW in size, market leading Variable Speed Drives from ABB and Schneider Electric. Perfect for any indoor and outdoor applications. Our Rental Fleet also includes Wireless Remote-Control Boxes for our Rental VSDs, Motors, generators and critical components for your applications, everything you need to get you up and running. Available Any Time, Any Place, Any Weather using our 24/7 Emergency Support Line – 0330 9000 247.

Emergency Drive Breakdown Our First Site Visit Fix guarantee gets you back up and running with one

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call in emergency situations, we have a massive stock of suitcase spares, rental drives and new drive stock which our Engineers have access to. Covering all your VSDs on site regardless of make, size or type. We provide service, maintenance, repair and rental to get you back up and running 24/7/365.

• • •

Instant Motor Availability With one phone call, you as an engineer can have a market leading, high efficiency ABB WIMES motor in transit within 30 minutes, with a known delivery time to your site, any time day or night, 365 days a year. Our partnership with logistics specialist, OSE, has allowed us to offer this unique service:

24/7 access to the UK’s largest stock of WIMES Specification ABB Motors 2 and 4 pole motors available foot mounted, flange mounted and up to 250kW All motor stock held is suitable for use with all forms of motor starters, including Variable Speed Drives Order placed direct to logistics company, no need to wait until offices are open Motor will be in transit within 30 minutes of receiving your call, ‘guaranteed’

To access these unique innovations, all you need to do is call us on 0330 9000 247 or email us at onecall@quantum-controls.co.uk. For more information go to www.quantum-controls.co.uk.


0330 9000 247 Quantum offer 24/7 support, simply call us.

COVID-19 Drives & Motors Resilience Plan During these difficult times, we understand that your current engineering teams may be reduced due to a requirement of self-isolation. This will undoubtedly put extra stress onto you and your colleagues to keep vital production lines running. To keep your site running through these testing times, we are offering our customers a free resilience plan to cover your critical assets if they fail over the next 3 months and, of course, a plan to ensure if this does happen, we can get you back up and running with minimum fuss. We know site visits may not be an available option to you right now so we can create this plan on a conference call, a safe environment for everyone. However, if you are still happy for us to visit site, a self-certification document will be issued before we arrive. Our qualified engineers and yourselves will go through your critical drive & motor assets and any specific technical applications that are required, as well as assessing the life cycle position of the asset. We will then draw up a contingency plan based on replacement options, spares, available hire units or direct replacement availability that we can put in place to keep your site running if one of these critical assets were to breakdown.

To book your FREE Drives & Motors resilience plan, contact us:

assets@quantum-controls.co.uk | 01661 835 566


April 2020

ENGINEERING UPDATE

DESIGN FOR SUCCESS IN MICRO MOLDING Aaron Johnson, VP of Marketing and Customer Strategy, Accumold If you are undertaking a micro injection molding project, there is enormous value in working alongside a specialist sub-contract manufacturer that under one roof has control of all aspects of the product development process from design to high volume manufacturing. Micro molding projects are by their very nature complicated, and the fact that many require the repeatable attainment of extremely high tolerances demands that there is a collective focus on accuracy when looking at micro tool fabrication, molding, validation, and automation processes. However, material selection and design for micro molding are also hugely important, and must be a primary consideration as time, cost, and the frustration of creating a design that needs to be radically altered before it can be manufactured need to be eliminated as much as possible. It is because of this that it is especially important that manufacturers work with micro molders as close to the beginning of the product development process as possible, as accessing expert micro molding design insight early is the key to cost-effective, timely, and right-first-time manufacturing. When looking at the design for micro molding rule book, it is worth taking on board a few things that will help you even at the product inception stage, and this article will cover these points. However, the advice again needs to be emphasised, speak to the micro molding expert as soon as you can, as then you will access the precise application-specific advice you will need. THE DESIGN CONUNDRUM Many OEMs view the likes of Accumold and other micro molding practitioners as manufacturers. While this is in itself self-evident, we very often view ourselves as consultants. Those micro molding experts that are truly vertically integrated with all stages of the product development process under one roof, as already mentioned, have expertise

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in design, tooling, molding, validation, and automation. What this gives them the ability to do is pool this expertise, and the best time to do this is at the conceptual design stage of any product development program. There is no better time for the tooling manager to put his hand up and advise as to the best design for seamless molding than early in the design stage. Likewise, a judicious word from the assembly manager will potentially save a customer from weeks of delay and spiralling costs if problems are detected early. As manufacturers begin to conceive a micro molding project, it is important to bear in mind some key issues from the get go. Every project as with so much in life should start with the end in mind. You need to understand the basic design approach, really bottom out what you can and cannot do, as when micro molding, even the smallest design change can be catastrophic and completely derail a project. Let’s take a look at what is meant by this. If a manufacturer is considering an application with a 0.005” (0.127 mm) wall thickness, a 5%-dimension change can be the difference between whether a part will fill or not. A material change can also have a profound effect on a part with this level of detail. Any design

engineer will be used to considering stack tolerances and stack dimensions, but when parts get smaller and smaller, the amount of change becomes more of a limiting factor. Design for Manufacture (DfM) is a fundamental consideration when micro molding. In fact there should be a subset of DfM, basically DfMM (design for micro manufacturing), as the rules of the game are so different when designing miniature parts or parts with very precise elements and tight tolerances. Design engineers have all the computer power and expertise to create the most astoundingly innovative products on screen, but they can be utterly impossible to make. Sometimes the reason for this is simple to deduce, other times less so. Size is often part of the problem. It is possible to blow up a particular part of a design to fill the screen and nuance aspects of it that are tinkering and adding functionality at the scale of fractions of an inch or a few microns. Theoretically, this can be the difference between perfectly optimised design or a slightly better than average design, but it is impossible to mold. Any design at the micro scale requires careful attention to what might otherwise not be a big deal for larger parts.


ENGINEERING PDATE

Each micro molding project is unique in terms of geometric complexity, shape, and can be made in a wide range of materials, all of which will ultimately affect the ability to manufacture. DESIGN FOR MICRO MOLDING So what constitutes a micro molded part? Typically if you are looking to manufacture a part or component that weighs less than a gram, you are micro molding. However, it’s one thing to mold something small, and it’s another thing to mold it efficiently and precisely time and time again. Micro molding must be capable of producing thousands, millions, even billions of parts with the same precision. As a general rule of thumb when looking at the DfMM, dimensionally at Accumold we can accommodate parts up to ½ “ (13 mm) in the largest dimension, and to date the smallest we have molded is 0.031” x 0.012” x 0.015” (800 x 300 x 380 microns). General guidelines for design engineers to consider are as follows. Thin wall sections need to be 0.004“ (0.1 mm) or thicker and there needs to be an especially focus on thick- to thin-wall transitions, as well as on wall thickness uniformity. Feature aspect ratios around 6:1 (although this is highly material dependent), gates can get as small as 0.1 mm, and ejector pins can be a small as 0.25 mm. It is also vital to have an understanding of how shrink rates will affect the part, and to be cognizant of parting line mismatch. Taking all this together, you can see that there are numerous variables, and

April 2020

numerous “rules”, but it is important to discuss ideas for micro plastic parts and components with an expert micro molder before you abandon an idea as being too complicated. Micro molding pushes the boundaries of what is possible in manufacturing every day, and challenges from manufacturers help push the envelope. A good micro molder will relish the opportunity to work to innovate, and only if the objective is truly impossible will they advise manufacturers make design changes. MATERIALS AND DESIGN Material selection is an area that can have a dramatic influence of successful design for micro molding. Micro molding materials come in almost as many forms as there are ideas in the mind of a design engineer. In the world of micro molding, missioncritical components often require exotic or highly engineered compounds. Materials like PEEK, PEI (Ultem®), carbon-filled LCP, or glass-filled nylons are commonplace. Soft durometer or elastomeric resins are also prominent. Direct experience with these materials in the context of micro molding is another part of valuable know-how needed to maximize the performance of the resin/part design combination. Even in macro product design scenarios material selection can be complicated as it is a trade-off between what is best for the functionality of the part or component being designed, and if it is possible to mold it into the shape required. When looking at micro molding applications, however, where limits are often extreme, the issue becomes more complicated.

The typical route to material selection is to match the functional part requirements with material datasheets. However, most datasheets are based on the manufacture of much larger parts, and this will reflect on recommended gate size and flow properties etc… So manufacturers looking to micro mold follow datasheets, and then see sub-optimal results when the parts are molded. This can lead to premature design iterations, or in extreme cases the abandonment of projects all together. The central issue is that datasheets, advice from resin suppliers, and part design criteria are all at odds at the micro scale. It is because of this that it is vital to engage with expert micro molders early in the conceptual design phase of product development, as they are best equipped to advise based on years of experience navigating material selection issues, and are best placed to indicate whether a chosen material could be an issue in part production. SUMMARY Design for micro molding is complicated as the “norm” in terms of geometric complexity and material performance are different from molding lager scale products. Working with micro molding experts early in the product development cycle and at design reviews is important as they can offer vital insight into issues such as design for tolerance achievement, optimal gate locations, accounting for flash and mismatch, advice on prioritising and limiting critical dimensions, and material selection for optimal outcomes. www.accu-mold.com

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ENGINEERING UPDATE

April 2020

DIXON LAUNCHES NEW COUPLINGS & ACCESSORIES CATALOGUE Dixon are excited to be launching their new full colour comprehensive Couplings and Accessories catalogue which will be available from January 2020. The company's global reach includes a wide range of products for numerous industries, including petroleum exploration, refining, transportation, chemical processing, food & beverage, steel, fire protection, construction, mining and manufacturing. The new 400 page catalogue comprises of Dixon’s traditional hose fittings and couplings including Cam & Groove couplers, quick disconnects, valves and clamps; with the addition of some new products such as the Arctic Steel range of marine water strainers and accessories, ADS outalarm liquid level measuring probes, split flange swivel joints and a brand new loading arm. The newly enriched technical section serves as an excellent information reference point to procurement,

engineering and maintenance teams alike. New innovations featured within the latest catalogue include evolutions in the design of traditional Cam & Groove fittings; the Vent-Lock safety release Cam and Groove couplings permit the release of static pressure when disconnecting hose assemblies whilst the armless EZ Link Cam & Groove couplers feature a push-toconnect positive locking system and low-profile design perfect for space is restricted. At Dixon™ we are committed to providing ‘the right connection’ for your fluid handling applications. Our world-class customer service backed by over 100 years of manufacturing expertise and BSI ISO 9001 approval ensures you will receive accurate hose coupling and

assembly recommendations for your application requirements. We are proud to design and manufacture fully tested and certified customised solutions to your fluid and air handling challenges. For additional information, products and technical support Dixon’s evolving website plays host to the full product range and keeps you in touch with all of the latest product developments, technical information and literature. To request a copy of the new catalogue in hard copy contact Dixon’s customer Service Team on: 01772 323529 or email: sales@dixoneurope.co.uk. Alternatively download your own PDF version direct from the website www.dixoneurope.co.uk

Dixon Hose & Coupling Products The Right Connection for your fluid transfer application Products:

• Hose assemblies • Fittings & accessories • Clamps • Quick release fittings • Blow-Out prevention couplings

• Valves • Loading arms • Liquid level sensing • Marine Accessories • Bespoke Fabrications

New Couplings & Accessories Catalogue Now Available

+44 (0)1772 323 529 • dixoneurope.co.uk •

©2019 Dixon Group Europe Limited

• T E CHN IC A L E X P E RT IS E • U N C O M M ON E X C E L L E N C E • D E S I G N • CU STO M ER SERVI C E • I N N O VATI O N • M AN U FAC TU R I N G • Q U ALI TY • TEC H N I C AL EXPERTISE •

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ENGINEERING PDATE

April 2020

NEW MAGNET DRIVE MICROPUMPS For high system pressure duty applications

T

he unrivalled MICROPUMP range of magnet drive gear pumps has recently been extended to include new options which provide exceptional pumping performance for high system pressure applications. The GLH Series compact, magnetically driven external gear pumps are designed for fluids handling applications with system pressures up to 103 Bar (1500 psi) and maximum differential pressures to 8.5 Bar. They can deliver flows from 2 lit/min up to 22.0 lit/min (at 2850 rpm) on liquids with a maximum viscosity range up to 2500 cp, at temperatures up to 121ºC. GLH Series pumps are designed to deliver a rugged, reliable and leak-free performance for any high-precision pumping application and, thanks to their compact, miniature size, can be easily incorporated into the design of highprecision fluids handling systems. Typical applications include sampling from crude oil pipelines and on sub-sea vessels, refrigerant recovery duties involving transferring

pressurised liquids from cooling systems and mechanical seal flushing to cool or clean seal faces. The external gear design provides the benefit of a smooth, pulse-free and highly accurate output, so the distribution of the pumped fluid is even and constant, compared to the more unpredictable pulsed flows from other types of pump. Also, the cavity style gear design is easy to service, the incorporation of a magnet coupling removes the need for a shaft seal and so provides safe, leak-free pumping whilst the wide range of wetted materials ensure exceptional chemical resistance. The GLH Series can be coupled with multiple drive and motor options while a choice of configurations means they can meet the most challenging applications. For example; three standard gear sizes, multiple gear, body and ‘O’-ring materials, optional high-torque magnets and NEMA and IEC drive mounts.

More details at: https://www.michael-smith-engineers.co.uk/products/micropump/magnetically-coupled-gear-pumps

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April 2020

ENGINEERING UPDATE

The EL-SIE Range Softwarefree, next generation data logging from Lascar Electronics

A

lthough Lascar Electronics has been manufacturing data loggers for over 25 years, even for the original inventors of the USB data logger the launch of the new EL-SIE range is a major event. The EL-SIE is the first in a new generation of EasyLog products that takes data logging to another level. Capable of measuring ambient temperature, humidity and pressure, each can store over 1 million readings inside the sleek metal housing. The bright and clear display shows readings and device status at a glance, and the coloured LED indicators and sounder mean the EL-SIE can grab your attention when it needs to. Each logger is supplied with batteries (two standard AAAs), a USB cable and a wall bracket so it’s ready to use right away, and one set of batteries will typically last over a year. But the biggest innovation is hidden away inside the EL-SIE itself: all the software needed to configure your logger and view, analyse and download the data. There is nothing to install, simply connect the logger to any PC or Mac and use your existing web browser. You don’t even need internet access, it couldn’t be easier. Of course, the EL-SIE also comes with all the powerful features expected from EasyLog. These include high, low, cumulative and pre-alarms, and also start modes including delayed start at a pre-set time, or a triggered start based on any selected measurement parameter. In another breakthrough, the EL-SIE is the first USB logger that can be used with the EasyLog Cloud, giving total peace of mind about the

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security of your data. Once on the Cloud the readings can be accessed from any internet-connected computer or mobile device, and also used with EasyLog’s powerful online graphing, analysis and report generation tools. The EL-SIE is intelligent and adaptable enough to be perfect for use in a number of markets including facilities and building management, logistics, warehouses and storage, and clean rooms and other pressure sensitive environments. The new EL-SIE range: data logging has evolved. Lascar Electronics www.lascarelectronics.com +44 (0)1794 884567



April 2020

ENGINEERING UPDATE

Gentle, Calm, Steady: the new KNF FP 150 pump KNF launches the new FP 150 multi-diaphragm liquid pump. The FP 150 offers linear flow adjustment from 0.2 to 1.5 l/min, low pulsation and continuous duty up to 2 bar pressure.

L

ow pulsation is a key feature of the new FP 150. By using five diaphragms to provide smooth laminar flow, pulsation values are typically below 150 mbar (at the pump outlet) at nominal flow rate and lower still depending on system configuration and running speed. The benefits include greater pumping efficiency, greater flow through your system at lower pressure and no vibration of the pump and tubing – resulting in less stress on system components. In this respect, the new FP 150 fares just as well as gear pumps whilst offering the additional advantages of a diaphragm pump: self-priming, the ability to run dry, chemical and abrasion resistance, no contamination of media, gentle (low-shear) transfer of delicate media, stability with changing viscosity, no cavitation, long service life, etc. Linear adjustment of the flow rate is another strong feature of the new FP 150. The pump is driven by a 5-wire brushless DC motor with integrated electronics offering linear speed control via either a 0 to 5V control voltage or an inverse PWM signal. Thanks to the stability of the pump and the laminar flow it produces, the flow rate can be adjusted between 10% and 100% of the nominal flow rate with outstanding linearity. The FP 150 is stable against back pressure (up to 2 bar) and, with a PTFE-coated diaphragm as standard (FFKM is an option on request) and a choice of FFKM or EPDM valves available, it can pump a wide range of challenging fluids.

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During its development, the FP 150 has been intensively tested at several original equipment manufacturers in the USA, UK, Italy and Israel and has already aroused broad interest. The FP 150 is suitable for a wide range of applications including medical devices, diagnostic instruments, laboratory equipment, industrial inkjet printing, semiconductor, fuels cell and cleaning & disinfection applications. More information is available at: www.knf.com/FP150


ENGINEERING PDATE

April 2020

APPLICATION NOTE FLIR GF346 Gas Detection Camera Used at Tata Steel Ltd. to Detect Carbon Monoxide Gas Indian multinational steel-making company, Tata Steel Limited, is one of the largest steel producers in the world. With an annual crude steel capacity of 23.88 million tonnes, Tata Steel has manufacturing operations in 26 countries and employs about 80,500 people. The company’s largest plant, located in Jamshedpur, Jharkhand, is a 10 MTPA crude steel production facility that produces hot and cold rolled coils, sheets, galvanized sheets, tubes, wire rods, construction rebars, and bearings. PROTECTING WORKERS AND CONSERVING CARBON MONOXIDE WITH OPTICAL GAS IMAGING Ensuring environment and worker safety in all production units is a top priority for Tata Steel. The plant uses blast furnace, coke oven, and Linz-Donawitz (LD) gases in the production process. The primary component of these gases is carbon monoxide, so leakage is not only harmful to the environment but can be life-threatening to workers. In addition, these gases are reused for power generation and reheating furnaces, so leaks cost the company a substantial amount in both money and energy conservation. Identifying a gas leak source can be difficult, not only because these gases are invisible to

the naked eye. The effect of leaks is often very gradual and can be masked by changes in airflow, making fugitive gases difficult to detect with more traditional methods. In an effort to find a better solution, Tata Steel researched and eventually purchased a FLIR GF346 optical gas imaging (OGI) camera.

LD#2 caster- leakage through tundish heating line blanking joint.

The FLIR GF346 optical gas imaging camera visualizes CO and 17 additional gases.

The FLIR GF346 uses a specially filtered thermal detector to visualize carbon monoxide (CO) and other harmful gases. The camera can be used to quickly scan for gas across wide areas and from a safe distance, without the need to interrupt a plant’s production process. As CO emissions can be a significant threat to steel manufacturing operations, emissions need to be closely watched. Even the slightest leak in a vent stack or pipe can have a devastating effect. The FLIR GF346 can scan potential leak points rapidly, and allow the user to pinpoint their source in real time.

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April 2020 One of the first uses for the company’s GF346 was to find an elusive leak near the Caster #2 casting floor. Amitabha Guha, Senior Manager (inspections) at Tata Steel, said his crew was unable to detect the CO gas leak source in the casting floor area. The leak began in the late evening hours, so a lack of sunlight and the frequent change in natural air flow direction made it difficult to trace out the source of leakage. With the help of the GF346 thermal imaging camera, inspectors scanned all possible sources of the leakage point near gas pipe lines. They found no gas leak in the region around the steel-making unit (LD2&SC), so they decided to scan the gas lines outside the LD2 premises. The crew finally detected the source of the leak in a Fuel Management Department main CO line, which is 60 meters away from the casting floor. Gas was escaping from a flange joint in a line that supplies gas to the hot strip mill (HSM) reheating furnace from the gas mixing station. Inspectors closed off and secured the area, then communicated their findings HSM & FMD for immediate corrective action. Repairs began immediately, preventing an unsafe incident and closing off the source of the leak. BLAST FURNACE INSPECTION Tata Steel used the FLIR GF346 to inspect all of its blast furnaces, which produce liquid iron for steel making. Blast furnaces have tuyers for supplying hot blast to the furnace burden that are fitted to the furnace shell. Frequent leakage of CO gas from these tuyers creates an unsafe and unhealthy atmosphere at the tuyer platform and above. Inspectors used the GF346 to scan all 34 tuyers and identified the leaky tuyers from a safe distance. As before, Tata Steel took immediate corrective action and updated the tuyers with a new welded design. After changing the tuyers, they scanned with the GF346 again and found that the leaks were eliminated. As a result, operating personnel are now working in a gas-free environment. Inspectors ensuring they had proper Delta T – or temperature difference between the target and the background scene – to achieve the optimal image contrast needed to detect the lowest level of gas emissions using the GF346’s high sensitivity mode.

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ENGINEERING UPDATE PH #4 leakage through BLR flame support line

HBF tuyer #6

HBF tuyer #7

HBF leakage through GV #1


ENGINEERING PDATE

HOT STRIP MILL INSPECTION The Tata Steel hot strip mill (HSM) produces hot-rolled sheets for automobile and LPG grades. The mill is fed by three reheating furnaces which use carbon monoxide-rich blast furnace gas and coke oven gas as

April 2020

-*@!HEADING!@*HSM FCE area leakage, seen in high sensitivity mode.

through the camera, and inspectors quickly and safely found the source of the leak at three locations in the pipe joints. HSM took immediate corrective action to eliminate the presence of CO near the furnace. The FLIR GF346 OGI camera has served as an extremely important tool for Tata Steel, helping inspection crews identify problems before they become catastrophic, and conduct surveys without shutting down operations. The GF346 is ideal for

HSM pipe leakage at FCE #1

components with contact measurement tools such as gas sniffers. Inspectors can scan literally thousands of components per shift without the need to interrupt the process. Optical gas imaging also allows operators while working from a safe distance, outside the gas cloud. Tata Steel found that, through these advantages, the FLIR GF346 improved work safety, reduced environmental impact, and helped them maintain regulatory compliance. Tata Steel has achieved zero gas leakage incidents in the past year.

FLIR Systems, Inc. 27700 SW Parkway Ave, Wilsonville, OR 97070 +1.877.692.2120

This information was shared for knowledge enhancement purposes only.

|29 © FLIR 2017 All Rights Reserved 17-2420 - 08/17


April 2020

ENGINEERING UPDATE

World-class decoking and inline inspection technology from cokebusters Cokebusters is an international company specialising in the mechanical decoking and in-line inspection of process piping within fired heaters, steam generated boilers, transfer lines and pipelines. From two headquarters based in the United Kingdom and the United States, Cokebusters are able to consistently deliver high quality services to the oil and petrochemical industries worldwide.

MECHANICAL DECOKING Cokebusters industry-leading scraper pigs have been developed to ensure 360° circumferential coverage of bends and pipework, from 2½ – 12-inch internal diameter. Their unique design means that they are tough enough to effectively remove fouling, but also retain a degree of flexibility to manoeuvre short radius return bends, plug headers, mule ears, flat-back bends and avoid damage to tube walls. The S21 double pumping units are manufactured at the Cokebusters Technology Centres in the UK and the US. A team of highly skilled welders and fitters work alongside experienced site operators to ensure that each unit is manufactured to exacting standards. Each unit is self-contained and has a two-stage filtration system for on-board collection and storage of coke and scale fragments. Equipped with automatic Chalwyn and Roda Deaco emergency shutdown, and spark arresters on exhaust systems, Cokebusters DPU’s guarantee minimised risk and improved safety. Teams of highly skilled and experienced operators provide outstanding service with a focus on safety, efficiency and quality.

INTELLIGENT TUBE INSPECTION As well as decoking, Cokebusters offers Coke Removal Verification and Tube Integrity Analysis via the Merlin “Smartpig”. Merlin is a subsidiary of Cokebusters, providing inspection technology that is constantly developing in terms of capability, performance and reliability.

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The “Smartpig” was developed to overcome difficulties with inspecting certain furnace types. Driven by water through the internal passageway of a pass or coil, ultrasound technology is used to internally scan fired heater tubes. Measurements and surface condition data is recorded directly to the pig and downloaded to a laptop for analysis following the inspection. Problems such as corrosion, creep (such as diametric growth or abnormalities), pitting and other irregularities on the inner walls of the pipe, are detected and diagnosed before leading to process failure and even environmental disasters. Thanks to its narrow passageway capability, it can be used to inspect furnaces and heaters with tricky plug headers, featuring a central crossover passage with a 3-inch diameter, as well as 3-inch schedule 160 tubes with an internal diameter of 2.5 inches (63.5mm).


ENGINEERING PDATE

April 2020

In order to optimise data interpretation and analysis, The MERLIN system uses powerful, bespoke 3D meshing software to map every wall thickness, internal and outside radius measurement to a model of the heater pass. A copy of the viewing software, InsightVision, together with individual interactive viewing files is supplied to the client by Cokebusters as a supplement to every final inspection report.

It is intended to complement the data management and analysis software by offering clients an immersive view of individual fired heater process piping via full colour coded 3D models of process coils/tubes. InsightVision is fully interactive, featuring colour scaling, aspect ratio adjustment, zoom functions, grid referencing and rotation/panning in three dimensions, enabling the user to quickly identify any problematic areas. If any faults are found, teams not only know what the problem is, but know exactly where to go to replace the affected tubing, resulting in increased efficiency and productivity, improved safety and cost savings on maintenance.

NEED MORE INFORMATION? Cokebusters unique combination of new technology, quality, safety and experience results in safe, environmentally friendly and effective mechanical decoking system and inline inspection services to industrial facilities worldwide.

Find out more at www.cokebusters.com

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April 2020

ENGINEERING UPDATE

BLFT Stainless Steel Turbine Flow Meters BLFT Liquid Flow Turbine Meters are a lower cost alternative to existing products available in the market and can be specified in a wide variety of sizes and connection options. This range has been independently tested to UKAS national standards to guarantee performance. A choice of signal outputs and display options makes this range extremely versatile. This highly accurate Flow Turbine style meter is constructed from either 304 or 316 grade stainless steel and is ideal for the measurement of various low to medium viscosity liquids in a range of different applications. This model is supplied with a square wave pulse output or low voltage coil pulsed signal as standard, with a wide choice of digital flow displays and batch controller’s available. The standard low cost digital display is

powered by a lithium battery with a long battery life of 4 years, providing a choice of 4-20mA signal, pulsed output and programmable alarms. Internal parts of BLFT turbine meters are simple to replace for easy maintenance. This flow meter comes with threaded or flanged connections as standard, alternatively with hygienic tri-clamp fittings depending on the chosen model. Each meter is supplied with a multi-point calibration certificate to ensure traceable accuracy and repeatability. BLFT turbine flow meters are ideally suited for measuring low to medium viscosity liquids and can even

handle aggressive fluids or liquids that require hazardous area ATEX approval. Typical applications include measuring bulk fuels, solvents and light oils as well as chemicals, additives and water. Sanitary flow turbines are widely used in hygienic food and beverage industries to measure wine, spirits and beer as well as fruit juices, milk and other Sizes available range from DN4 to DN200 and models can be specified with a choice of maximum temperature, pressure and even face to face dimensions. BLFT bearings and shaft material is Tungsten carbide, while rotor material is CD4Mcu. Accuracy can be specified at +/- 0.5% or 1% of measured value with repeatability stated at +/-0.2%. This range can be supplied with a wide selection of basic or advanced flow computers offering temperature compensation and flow curve linearization. Turbine meters measure flow using the mechanical energy of the fluid to rotate a turbine rotor within the flow stream inside the meter. The rotations are measured and calculated to provide a proportional measurement relative to flow rate. The Principle is well proven and the application suitability list is very large. Bell Flow Systems mail@bellflowsystems.co.uk or call 01280 817304 for more information on the BLFT flow turbine meter range.

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ENGINEERING PDATE

April 2020

DS-OCT12-BLACKFAST_Layout 1 20/09/2012 16:28 Page 1

Tel: 0208 339 7370

Fax: 0208 339 7371 Unit 5 Russell House, Molesey Road Email: sales@blackfast.com Walton-on-Thames, Surrey KT12 3PE www.blackfast.com

Competence in power transmission whatever your industry or application

ARCUSAFLEX COUPLING

RCT COUPLING SERIES

ARCUSAFLEX VSK

Test Bench Applications

FLEXDUR FD-HS COUPLING

Power Generation Applications

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ARCUDENT GEAR COUPLING

Pump & Compressor Applications

MULTIMONT SELLA

Industrial Applications

Marine Engineering

Unit 4 Bankside Business Park Coronation Street Stockport SK5 7PG T: Office + 00 44 161 714 4191 | info@reich-uk.com PLEASE VISIT WWW.REICH-UK.COM FOR MORE DETAILS

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April 2020

ENGINEERING UPDATE

Automation - New Decade. New Expectations. As the wholesale and ecommerce industry has grown, so have customer expectations. Today customers are placing orders more frequently, in fewer quantities, later in the day and expecting delivery faster than ever before. Customers now consider 2-day delivery slow with next-day and even same day delivery becoming the standard. capabilities, and with a much heavier reliance on automation and robotics. In fact, we think it will begin to grow even faster than demand for storage and retrieval equipment has. The idea of a “dark building,” where robotics and automation run autonomously 24/7, is definitely making headway.” As companies transition to automated warehouse systems, the intralogistics industry will also change and grow. It’s important to research and evaluate the best solution and find a reliable intralogistics partner.”

I

nternally, companies are suffering from obstacles including warehouse space, accuracy, labour problems and theft. Externally, consumer loyalty may be impacted as a result of delivering incorrect orders, letting down shipping expectations and not having the capabilities to manage personalisation or global shipping.

supplies…car dealers without prime shopping week inventory: multiple layers of supplier disappointment and revenue impact can occur. On the B2C side, what’s worse than ordering a birthday gift online to have it arrive late and in the wrong colour? It is guaranteed that person will be telling all of their friends about the poor experience - and the retailer’s name!

When B2B warehouses can’t deliver as promised, chaos is the result. Suppliers are left looking foolish and without the goods they need. Construction crews without materials…hospitals without

According to Mark Dunaway, Kardex Remstar’s North American President Finance and Administration, “Over the next 5-10 years, the industry is going to see more automation with advanced

Chocolate World, is a Belgium based chocolate mould manufacturer with customers in more than 110 countries who had a need to optimise their warehouse logistics. With the installation of two LR 35 Vertical Buffer Modules and Power Pick Global, they have changed their process and are now delivering: same-day dispatch for orders placed by 3 pm, they can manage up to 500 orders and store 2,736 customised boxes per day. Another benefit is that their employees now have the tools to guarantee precise inventory overview and storage locations as well as the ability to train personnel without the need for an intense employee training. If you’re seeking modular, flexible and scalable warehouse automation which increases productivity, optimises warehouse space and saves you a whole lot of headaches, then look to automation for the future of your warehouse logistics.

To learn more about the automation and faster picking click here or contact Kardex Remstar at i n f o . r e m s t a r. u k @ ka r d e x . c o m or visit our website at www.kardex-remstar.co.uk

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April 2020

ENGINEERING UPDATE

Desuperheater with Segmented Disc Valve Controls Nozzle by Nozzle Steam is not only a supplier of energy, but is also an important source of energy for a wide variety of processes for all operators of thermal systems such as producers of sugar or paper. Using desuperheaters, it is easy to control the pressure and temperature of the steam and condition overheated steam for the particular consumer in the process. Producing slightly overheated steam that is 3-20 K above the saturated steam temperature to subsequently provide consumers with steam with an optimal heat transfer coefficient is a specialized art. Schubert & Salzer has developed a completely new kind of desuperheater by integrating a segmented disc valve with four injection nozzles. The main flow control element for the injected water - the segment discs which slide over each other and mutually seal each other are positioned perpendicular to the direction of flow in the valve body of the segmented disc valve. On a non-rotating segment disc with four segment openings, a movable disc with same number of segments rotates so that the four segment openings open precisely and continuously in sequence. Each segment opening is connected to an injection nozzle by a lance so that the four injection nozzles - depending on the control requirements – increase their flow rate. The 4 serial nozzles in the system offer a wide control range and ensure that the water pressure in the nozzles remains almost constant. This enables a

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much finer atomization of the water, and therefore optimal control of the steam. At the same time, the risk of accumulations of water in the steam system is minimized. With this special design, segmented disc valves are one of the few industrial valves that combine precise control under extreme operating conditions with high seal tightness, lower noise emissions, and low wear. Another advantage of the Schubert & Salzer desuperheater is that the control unit consisting of segmented disc valves with proven 8049 digital positioners is located outside of the flow of steam. This means the

amount of water injected is controlled outside of the hot steam pipe. Thermal distortion due to the temperature difference is thus eliminated, and leaks are minimized. Summary: With the Type 5090 desuperheater, Schubert & Salzer has made it possible to utilize the inherent advantages of segmented disc valves when conditioning steam. Operators of thermal systems benefit from the especially high tightness of the seals, minimized wear and optimal steam control.


JOC_1098 KRUK Automation Half H-A.pdf 1 24/09/2015 18:09:43 April 2020 ENGINEERING PDATE

Setting the benchmark... Faster, compact, energy saving and affordable...

Kawasaki’s latest robots increase one of the largest robot ranges available today. They are more compact, provide smooth control and give increased all round performance. For assembly the new collaborative duAro; for palletising the CP Series; the general purpose CX Series and the high-speed spot welding BX Series. Check out the new robots and see just how affordable they can be....

info@kawasakirobotuk.com kawasakirobot.co.uk +44 (0)1925 713000

Kawasaki Robotics (UK) Ltd

> Corrosion resistant for up to 1000 hours in salt spray > Manufactured from a premium alloy with less than 0.1% copper content for corrosion resistance > IP tessng performed aaer impact tessng to verify the seal is maintained when the enclosure is treated roughly > Impact resistant up to 7 Joules > Reusable seals (Up to 200 compressions)

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April 2020

ENGINEERING UPDATE

Customized Configuration Matching 400G Measurement Conditions

Anritsu Demonstrating Portable MT1040A Tester for 400G Networks at OFC Virtual Exhibition

Anritsu Corporation is pleased to announce the approaching commercial release of its Network Master Pro MT1040A for evaluating 400G networks. Prior to this release, Anritsu will be demonstrating its MT1040A at the OFC Virtual Exhibition 400G Ethernet has been used mainly in data centers, but the recent rapid growth in data traffic driven by rollout of 5G commercial services and expected future appearance of self-driving vehicles is seeing deployment of 400G Ethernet at non-datacenter locations. Since the MT1040A is a compact battery-driven 400G measuring instrument with directly inserted QSFP-DD or OSFP measurement modules, one unit supports not only 400G tests but also 10M~100G Ethernet, OTN, eCPRI/CPRI, SDH/ SONET, and Fibre Channel onsite measurements. Additionally, it can be combined with an optional OTDR module for fiber line maintenance as well as with a GPS module for remote measurements using GPS. The integrated auto-test functions help operators perform identical tests to obtain quantitative test results, helping improve onsite work efficiency.

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Product Outline The Network Master Pro MT1040A is a portable measuring instrument for evaluating the transmission quality of various networks operating at communications speeds from 10 Mbps to 400 Gbps. With an evaluation interface supporting SFP/SFP+/SFP28, QSFP+/QSFP28/QSFP-DD, and OSFP optical modules, the MT1040A can be customized easily for any application. Moreover, combination with the MU100020A/21A/22A/23A OTDR modules for the MT1000A for fiber tests as well as with the High Performance GPS Disciplined MU100090A enables precision latency measurements between remote fiber segments. Additionally, high operation efficiency is assured by a full suite of tools for easy editing of each test scenario as well as automation tools for one-button operation of complex tests. www.anritsu.com



April 2020

ENGINEERING UPDATE

Fabrication Design Considerations For Low Field Shielding Applications Typically, hydrogen atmospherically controlled heat treatment process called perfection annealing or final annealing is required after stamping, machining, bending, rolling, severe forming or welding, and is crucial in relieving material stress and developing the alloy’s maximum shielding performance. Handle annealed magnetic shields carefully to avoid severe deformation which causes reduced attenuation. The perfection annealed fabricated shields and parts are then tested at our in-house quality control lab to certify that the demanding specifications are met. Perfection Annealing Heat Furnace Chamber

One of the most important design questions is whether the source field is internal or external, and which field is most economical and practical to shield. Internal interference is created by designed-in components located within a circuit, system, enclosure, piece of equipment or room. External interference or the H-field source is created by unwanted nearby fields radiating from power lines, circuits, electrical enclosures, transformers, electro-magnetic machinery and the earth’s magnetism. Secondly, should the source of interference or the sensitive device be shielded? The answer to this question depends on several factors. Shielding the source may involve stronger fields, and therefore thicker materials. All interference sources must be shielded, or the sensitive device will still be affected. The usual approach is to shield the sensitive device. This prevents interference from both present and future sources. A hands-on approach to solving a shielding problem can be accomplished with the use of a lab kit, testing, and prototyping. Material selection will depend on the strength of the unwanted field (Ho) and the amount of field attenuation required. MuMETAL® is the preferred solution because of its reliable performance for reducing low-frequency electromagnetic interference (EMI) between the range of 30 Hz to 300 Hz. Available as stress annealed (partially annealed for ease of machinability) sheet stock, it is used for fabricated shields such as enclosures, cylinders, cans, channels or 3-D boxes. Complex cylindrical shaped shields are the most efficient for redirecting and reducing magnetic fields. Magnetic shielding alloys have sensitivity to mechanical shock - bending, forming, even severe flexing may give some reduction in the alloy's magnetic permeability. But modern, vacuum-refined alloys have a lower sensitivity to shock, and normally withstand regular handling without significant loss of properties. Another consideration is cutting the alloy without affecting the alloy properties and degrading the performance. Cutting by shearing, EDM, waterjet, photochemical etching, or blanking dies typically only affects that portion of the alloy immediately adjacent to the edge, and the shield will exhibit normal shielding performance. If the alloy had already received its final magnetic anneal, re-annealing should not be necessary.

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Magnetic shielding applications may occur at a high vacuum. Co-NETIC® AA alloy is specifically formulated for maximum magnetic shielding properties and has some physical properties similar to stainless steel. Out-gassing is minimal and cleaning for high vacuum applications can follow the same procedures used for stainless steel. Co-NETIC® and NETIC® magnetic shielding alloys have a positive coefficient of permeability with respect to temperature. This is a quick way of saying that the permeability increases as temperature increases. The Curie temperatures are between 850°F (454°C) and 840°F (449°C) for Co-NETIC®, NETIC® and MuMETAL®. At operating temperatures above the Curie temperature, the shield will not provide any attenuation of the magnetic field. Roll-off of permeability begins as operating temperature nears (within 25°F) the Curie temperature listed, so a safety factor for allowable operating temperature should be used. Temporary temperature excursions above curie temperature do not degrade the alloys. Shielding function is restored when the temperature again falls below Curie point. High permeability MuMETAL® and Co-NETIC® alloys have an optimal temperature range in which the permeability peaks. Permeability starts to drop below -40°C, making it unsuitable in low temperature applications. Cryo-NETIC® sheet, our proprietary cryogenic nickel-iron soft magnetic alloy is ideal for shielding magnetic fields at extremely low temperatures down to 4 Kelvin (liquid helium). Located in the USA Chicago metro area, Magnetic Shield Corporation has been a leader in the custom shielding fabrication market, manufacturer, and supplier for over 75 years; providing expertise and engineering consulting on thousands of projects, applications and shielding designs. For more information regarding our proprietary shielding alloys and forms available, wiring and cable shielding, Zero Gauss Chambers, and modular MuROOM® view our websites here www.magnetic-shield.com, or www.mu-metal.com.



April 2020

ENGINEERING UPDATE

Oxford Advanced Surfaces and 2-DTech sign collaboration agreement on graphene enabled surface treatments Oxford Advanced Surfaces (OAS), a pioneer and market leader in the surface treatment of polymeric, plastic and composite materials by the application of highly reactive carbene chemistry, has entered into a collaboration agreement with 2-DTech Limited, a subsidiary of Versarien plc. The aim is to develop a new range of products that incorporate nanomaterials, such as graphene, into OAS’ proprietary Onto™ chemistry platform to deliver enhanced mechanical performance and improved electrical and thermal conductivity. OAS’s patented Onto™ chemistry platform delivers a range of versatile and reliable chemical surface treatments that are used to improve the adhesion of paints, coatings and adhesives to composite materials and engineering plastics. Current Onto™ products are used in demanding applications ranging from

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transportation and aerospace to wind energy. By combining 2-DTech’s graphene products into OAS’s unique OntoTM chemistry, the collaboration is intended to produce a range of new products that will potentially allow both companies to address a wide range of applications and address new materials challenges encountered in both our current and potentially new markets. Dr Jon-Paul Griffiths, Chief Technology Officer, Oxford Advanced Surfaces said: “Challenging applications for new and

existing materials require innovative surface treatments; through our collaboration with 2D-Tech, we have the opportunity to develop new products by incorporating nanomaterials, such as graphene, to meet these challenges.” Steve Hodge, Versarien Chief Technology Officer, commented: “We are delighted and very excited to work collaboratively with OAS; our aqueous GraphinksTM and OAS' aqueous based adhesion promoters (OntoTM) are a natural fit and can bring about unique opportunities and markets that we haven't yet explored.”


ENGINEERING PDATE

April 2020

100 95 75

25 5 0

|43 NG UK Advert 190x130mm_122019_prepress 11 December 2019 10:57:53


April 2020

ENGINEERING UPDATE

Nidec Leroy-Somer announces the launch of TAL 0473, its latest next-generation alternator based on the ".3" technological platform. The TAL 0473 is the latest addition to the range based on the .3 platform. It replaces the TAL 047 and benefits from improved performance. The TAL 0473 delivers a nominal power between 400 and 660 kVA at 50 Hz (from 495 to 825 kVA at 60 Hz). The alternator features a SHUNT excitation system and an R150 regulator as standard. An AREP+ auxiliary winding excitation system with R180 regulator version is also available to further improve transient performances and provide high overload capacities. It is interchangeable with the TAL 047 (shaft height and feet configuration), and can therefore be coupled with all diesel engines on the market for this power range. The TAL 0473 will be available for orders in April 2020.

The TAL 0473 offers the following power nodes: - 400, 410, 455, 500, 550, 600 and 660 kVA at 50 Hz - 495, 510, 570, 625, 690, 750 and 825 kVA at 60 Hz Like the entire TAL product range, the TAL 0473 is suitable for all electric power generation applications, excepted marine. It delivers high performance, thus offering new possibilities to manufacturers of generator sets. The TAL 0473 offers an efficiency of up to 94.9% at cos φ 0.8, which ranks it among the best in the category. Thanks to the new AREP+ excitation system, the TAL 0473 also offers improved transient performance, especially with start-up kVA improvements of up to + 15%. The ".3" technological platform was first introduced in 2010, allowing significant performance improvements, in particular thanks to a revolutionary patented cooling system which optimizes the air flow in the machine, limiting hot spots that can damage windings insulation. The achieved level of performance and efficiency makes it possible to offer compact alternators. To match the evolution of customer needs, the rotor system of the TAL 0473 has also been revised to further improve its inertia characteristics. "This alternator ends a cycle, since it is one of the last in our range which had not yet switched to the .3 platform" said Wenbin Ding, low voltage range product manager "We are delighted to finally be able to offer the same level of optimized performance on all of our low voltage products.” The LSA 47.3, based on the same technologies, will also soon be marketed to replace the current LSA 47.2.

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April 2020

ENGINEERING UPDATE

RPI celebrates 80 years of leading the world in rotary measurement at Control 2020 with launch of TruMotion and QuadProfile horizontal axis RPI Ltd is celebrating 80 years of leading the world in rotary measurement at Control 2020. To mark its anniversary, RPI - the world’s leading specialist developer and manufacturer of precision positioning devices for high accuracy rotary and angular inspection systems - will be launching TruMotion, a manual spin rotary table designed to inspect circular components such as gauges, bearings, aero engine components and optical assemblies in a shop floor environment whilst maintaining world class accuracies more commonly seen in the standards laboratory. The QuadProfile horizontal axis will also be debuting at this year’s show. Designed as an additional rotary axis for high precision co-ordinate measurement machines (CMMs) it delivers high speed measurement of smaller parts such as inner engine blades and gears. Jim Palmer, RPI’s sales manager, said: “We’re delighted to be celebrating our eightieth birthday at Control. As a German-owned company, we couldn’t have picked a more perfect venue for the party. We grew out of a number of acquisitions including Eimeldingen, which was based in Baden-WüRttemberg . “The world has changed a lot since the 1940s but our passion to design and manufacture exceedingly dependable, low maintenance products, with a service life measured in decades, not just years, remains as true today as it was eighty years ago. We’re very excited to launch our latest products, TruMotion and QuadProfile horizontal axis, at this year’s show and we hope they’ll create a real buzz!” RPI will also use the show to demonstrate GeoInspec - a manual spin air bearing rotary table for optimal circular geometry inspection. Automated data collection hardware used with both TruMotion and GeoInspec will also be on display. Other products on show include: QuadSlimLine rotary table for use with CMMs for inspecting component parts such as gas turbine discs and fan blades. Specifically designed as a fourth axis, they are accurate to 2 arcs second. RPI has been supplying the CMM market since 1977 and can boast more than 750 successful installations worldwide. Meanwhile, visitors to RPI’s stand can also see LabStandard and LabStandardAIR High rotary tables.

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Typically used for calibration of inclination sensors and navigation systems such as gyroscopes enabling both horizontal and vertical application, they offer sub arc second angular accuracy and precision geometry for inspection and calibration labs, with the versatility of both single and dual axis making them accurate to +/- 0.5 arcs seconds. This is equivalent to hitting a golf ball at a hole more than 22km away and scoring a hole in one every time! The LabStandardAIR has been designed as a contact free system and eliminates features which may detract from achieving the optimum rotational performance. The rotating elements are supported on super high precision, air lubricated, hydrostatic bearings and are not subject to disturbances associated with gear drives. RPI grew out of acquisitions from Optical Measuring Tools, Airmatic, Horstmann and Eimeldingen. It is now one of the world’s largest designers and manufacturers of solution driven, highly accurate inspection systems and services that measure circular geometry and angular positioning. Using its 80 years of rotary expertise, RPI supplies progressive engineering industries, including the aerospace, gas turbine and dimensional metrology sectors, with exceedingly dependable, low maintenance products with a service life measured in decades, not just years. For more information, visit www.rpiuk.com or to see TruMotion and QuadProfile horizontal axis in action, drop by stand 7108, hall 7 Control Show 2020 in Stuttgart, 5th to 8th May 2020.



Events

April 2020

ENGINEERING UPDATE

E-learning to mitigate Coronavirus disruption Countries are ramping up efforts to prevent the spread of COVID-19 coronavirus, described this week by the World Health Organisation as a pandemic. It is clear that globally, growing numbers will be self-isolating, with educational establishments closing and companies –­including many in the lifting sector – asking employees to work from home as part of dealing with this severe health crisis. The impact of Coronavirus will be serious but it will eventually dissipate. It is important that, in the meantime, we do all we can to ensure disruption is minimised and we are able to hit the ground running when conditions return to normal. Fortunately our interconnected world makes this less of a challenge, and many colleges and businesses are already looking to e-learning for continuity of education, training and productivity. LEEA will be carrying on as normal during this health crisis, taking all necessary precautions in delivering face-to-face training, But e-learning is an option many are likely to consider at this time. E-learning is an established and important delivery method for

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LEEA’s specialist training services, CPD and Accredited Training for the global lifting sector. Most of the association’s broad range of training courses are available online, offering a number of benefits such as allowing individuals to study at their own pace and at times that suit them. The courses are not restricted to defined term times and can be commenced whenever it suits an individual. All an e-learner needs is Internet access on a PC, laptop or tablet. Course materials are available

to download and an assessment venue and date can be chosen to suit. Traditionally LEEA’s lowest cost, most flexible and convenient training option, e-learning can now step up to become an essential tool to help the global lifting industry mitigate coronavirus disruption to the continuing journey to raise standards. www.leeaint.com


ENGINEERING PDATE

Events

April 2020

OLYMPIA GRAND, LONDON, UK

Infrarail to be postponed to CONNECTING THE INDUSTRY May 2021 12 - 14 MAY 2020

13TH INTERNATIONAL RAILWAY INFRASTRUCTURE EXHIBITION

13th International Railway Infrastructure Exhibition to be co-located with Railtex 2021 at NEC in Birmingham

Mack Brooks Exhibitions has today announced the event. While it is disappointing to postpone, it is imperative that postponement of Infrarail, the UK’s leading showcase of we prioritise the health and safety of everyone involved. Our railway infrastructure technology and expertise. The 13 th goal remains to provide the best customer value for everyone edition of the event, which was planned to take place at attending Infrarail by delivering a high-quality exhibition in London Olympia from 12 to 14 May 2020, is postponed 2021. We believe the decision to co-locate Infrarail with next following the escalation of COVID-19 in Europe. The exhibition year’s Railtex exhibition with the help and support of our will now be co-located and take place alongside Railtex 2021, partners will allow us to maximize the potential of both events, the UK’s premier exhibition of railway equipment, systems uniting the whole rail industry”, concluded Nicola Hamann. ONL The full scope of infrastructure sectors on display, including: IN and services, taking place at the NEC in Birmingham from 11 REG E VISI Track construction and maintenance ISTR T Mack Brooks Exhibitions as the organiser of Infrarail, trusts – 13 May 2021. N Signalling OW ATION that the decision to postpone the show to next year will enable Communication and passenger information Speaking about the announcement, Nicola Hamann, Infrarail to continue to serve the rail industry as the leadingOPEN Measuring, monitoring and testing systems Managing Director of Mack Brooks Exhibitions, said: “The showcase for every aspect of railway infrastructure technology Station equipment health and safety of our exhibitors, visitors and staff is our and expertise in the secure and safe conditions needed. The number one priority. After many weeks closely monitoring the Infrarail Team will communicate closely with customers and to a Register Tel:notices +44 (0)1727 400over the coming weeks and thanks their exhibitors, evolving situation around COVID-19 and the issued 814 partners mackbrooks.co.uk by the World Health Organisation as wellinfrarail as Public@Health partners, suppliers and visitors for their support during this England, the UK Government, the local authorities in London challenging time. *On-site Reg and in close coordination with all partners involved, we have For updates and further information, please visit the event decided to postpone the exhibition.” 9657_IF_2020_A4_Advert_Visitors.indd 1 website: “This is not a decision we have taken lightly; our customers, partners and the Infrarail Team worked incredibly hard on this https://www.infrarail.com/

OLYMPIA LONDON

CONNECTING THE INDUSTRY

FRE E

www.infrarai

12 - 14 MAY 2020

|49 The full scope of infrastructure sectors on display, including:


Events

ENGINEERING UPDATE

April 2020

Distilling your chemical engineering knowledge and skills with Henry Kister The Institution of Chemical Engineers (IChemE) is committed to supporting the professional development of chemical, process and biochemical engineers worldwide

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ach year we train nearly 2,000 people from 60 countries with our comprehensive programme of open and incompany professional development courses. We cover both technical and nontechnical topics and IChemE is proud to be a market leader in process safety training and best practice. One of our most popular technical courses is Practical Distillation Technology, which has been running for well over 20 years. This course gives comprehensive coverage of distillation technology with a particular emphasis on the problems that can occur and how to solve them. It also provides an excellent opportunity to develop key techniques that can promote trouble-free operation and reduce distillation cost.

background in all phases of distillation, including operation, troubleshooting, design, start-up, and research. At Fluor Henry designs, revamps and advises on distillation processes, equipment and controls for the chemical, petrochemical and oil industries. He is also extensively involved in field consulting, start-up and troubleshooting assignments and in developing Fluor’s in-house distillation technology.

The course is delivered by worldrenowned distillation expert Henry Kister.

Henry is the author of three distillation textbooks, over 100 technical articles and has presented this course 450 times in public and for major corporations in 22 countries on all six continents.

Known as ‘the tower doctor’ Henry is a Flour Corporation Fellow and Director of Fractionation Technology, with a vast

The main topics that the course covers are how to avoid fractionation pitfalls, troubleshooting distillation

World-renowned trainer

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simulations, tray hydraulics and limits, troubleshooting tray towers, troubleshooting packed towers, debottlenecking, distillation control and how to avoid tower malfunctions. These topics are delivered through a series of lectures and interactive discussions, with case studies scattered throughout to illustrate the key principles and to distinguish good from bad practice. Held once a year in the UK, Practical Distillation Technology consistently gets excellent feedback from delegates, with companies often sending employees year after year and delegates travelling from across the world to attend. This year’s course takes place on 19-21 October at the Heathrow Holiday Inn, London. For further details and to book visit www.icheme.org/distillation.


S A V E THE DATE 29-30 SEPTEMBER 2020 HALL 1, NEC BIRMINGHAM

For more information on exhibiting, contact Louise Pudney on 01622 699 104 or at lpudney@datateam.co.uk. www.sensorsandinstrumentationlive.co.uk


Events

April 2020

ENGINEERING UPDATE

New date for Belfast PROFINET, PROFIBUS and IO-Link seminar New date for your diary - 20 October. Due to the Covid-19 pandemic, we have decided to postpone our planned Belfast seminar to October in the sincere hope that it will be OK by then.

PROFINET to Profibus DP, PA, IOLink and OPC UA Industrial network commissioning and testing •

Taking place at the Templeton Hotel, Belfast, this event will address the key practical issues arising from the use of digital communications technologies in automated manufacturing and process industry applications, with particular attention to Industry 4.0 and the Industrial Internet of Things (IIoT). Covering key application areas such as control systems and energy management, pulp & paper, chemical, utilities, pharmaceutical, mechanical handling and logistics, robotics, automotive engineering, electrical and electronics assembly, packaging and printing, it focuses on the practical aspects of using PROFINET, PROFIBUS and IO-Link, from system design and safety & security considerations through to fault-finding and maintenance.

Learn how to simplify the process of testing, how to prevent network failures and resolve cable and network issues faster.

EMC for Networks •

The ever-increasing use of highfrequency switching devices in industrial automation can result in intermittent communications problems. This presentation will discuss the issues and explain the relevance of the recently released PI guidelines “Functional Bonding and Shielding for PROFIBUS and PROFINET”.

Industrial networks safety & security •

Topics will include (subject to change):

The basics of legislation and responsibilities for cybersecurity, safety and functional safety for Industrial Automation.

Introduction to PI Group – including highlights of new supported technologies

Update on Industry 4.0, IIoT, TSN and APL

An overview of the Group’s structure and global representation, taking a look at the protocol basics and their benefits to UK industry.

Explanation of IIoT, IND4.0 and Big Data, and how PROFINET is placed as the ideal network to fulfil the above.

PROFINET network design

Live Demonstrations

Supported by an exhibition with demonstrations of actual tools used in configuration and maintenance, the seminar will be of great value to Designers, Production/System Engineers, Instrument Technicians/Engineers and C&I Engineers involved in the design, operation and maintenance of modern automated factories and process plant.

The fundamental principles of good network design and the main factors that must be considered at the design stage of an automation system.

Network gateway technology •

Presentation and demonstration of network gateway technology,

With nearly 80 million nodes installed worldwide, PROFINET, PROFIBUS and IO-Link are truly market leaders, providing state of the art digital communications addressing all the needs of manufacturing and process industries, significantly lowering capital expenditure on installation, commissioning and maintenance. They offer

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unprecedented integration of automation, control, monitoring and safety systems using standardised and widely supported communications and networking solutions. This seminar is ably presented by specialists from PI UK member companies. Attendance is free of charge to pre-registered delegates from the User community, i.e. companies that own, operate, design, build or maintain automated process plant and manufacturing facilities. The event will provide delegates with an excellent networking opportunity and the ability to speak to experts. Important Notice re: COVID-19 Please note that if any of these events have to be postponed due to COVID-19, we will let all registered attendees know as soon as we know. So please do not let that deter you from registering! If you would like the option to receive the presentations that were due to be given and be kept informed of any new event dates, please register using the appropriate link below and be sure to tick the "please add me to your mailing list" box on the registration form. Also, if you'd like to get into direct contact with any of the presenters, please tick the box: "The presenters and exhibitors at this event would also like to provide you with relevant information. If you would like us to pass your contact details to them for this purpose, please tick to confirm." More information and online Registration Birmingham, April 28 http://bit.ly/PUK28April Glasgow, May 27 http://bit.ly/PIUKScotland Belfast, October 20 http://bit.ly/PIUKBelfast In case of difficulty contact Ann on tel: 00 44 207 193 8018 or email admin@profibus.org.uk Places are limited so don't delay - book today


The Sensor Show Congress

Munich, Germany

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115 Speakers

7500 Meetings

950 Exhibitors*

48,000+ Visitors*

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April 2020

ENGINEERING UPDATE

Optimised Camera Sensor Lenses Resolve Optics is a leading designer and OEM supplier of special optimised lenses that exactly match your camera sensor. Industrial camera sensors come in a wide range of sizes from 1/4-inch to 1-inch and beyond. The lens(es) you choose to integrate into your product will play a pivotal role in determining your camera performance. A lower resolution lens will reduce the achievable image quality from a high megapixel camera sensor. Likewise selecting non-optimised lenses may compromise your products performance due to limiting the field of view (FOV), increase image distortion or vignette light impacting your camera sensor. Having a lens custom designed to match your camera sensor will unlock the full potential of your product and also will give you an edge over competitive cameras using non-optimised optics. For larger format camera sensors

(>1.5-inch) few off-the-shelf lenses exist. As well as providing very high resolution over a large image format – Resolve Optics has designed several sensor matched large format lenses. These specialist lenses for close-up imaging were designed to deliver a large depth of field, low distortion edge to edge, applicationspecific F-number and exceptional contrast.

photographic lenses. For further information on specialist lenses matched to get the best from your camera sensor please contact Resolve Optics Ltd. on +44-1494777100 or sales@resolveoptics.com.

Drawing upon approaching 30 years experience – Resolve Optics Ltd. has built a strong reputation for specialist lens design and manufacture of production quantities of custom large format lenses on time to strict quality and target price guidelines. The company has the proven and rare capability to produce OEM quantities of custom lenses with the look, feel and quality equivalent to the best professional

Visual Inspection in Nuclear Environments Resolve Optics reports on how its non-browning lenses are helping a specialist camera manufacturer to supply a turnkey solution for monitoring remote operations in high radiation environments. For the high radiation environments experienced in Nuclear Power stations, Nuclear fuel recycling plant and high energy physics facilities, conventional TV cameras and lenses have a very short life due to radiation damage. Cameras and lenses specifically designed for such environments can operate for 10,000 times longer. Tony Moon of Custom Cameras Ltd (Wells, UK) said "Our radiation resistant cameras are used in a growing number applications within the Nuclear power industry and large scale physics facilities. In designing cameras for these applicactions, we have to consider the tolerance to radiation of all components as well as the overall design. A key component of this radiation resistant camera system is the lens. We choose to use fixed focus and zoom non-browning lenses from Resolve Optics because of their in-depth knowledge of the requirements of optics used in a nuclear environment, willingness and ability to adapt designs to suit

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customer requirements, excellent technical support and competitive pricing”. Drawing upon nearly 30 years experience – Resolve Optics has built a strong reputation for specialist lens design and manufacture of smaller production quantities of radiation resistant lenses and optical products on time to strict quality and target price guidelines. All optical elements within Resolve Optics non-browning lens designs are made using cerium oxide doped glass or synthetic silica enabling them to withstand radiation doses of up to 100,000,000 rads and temperatures up to 55°C without discolouration or degradation of performance. All Resolve Optics radiation resistant lenses provide high image resolution and minimum geometric distortion from 400 to 750nm.

For further information on nonbrowning lenses being used in environments subject to radiation please visit www.resolveoptics.com/ radiation-resistant-lenses-3/ or contact Resolve Optics Ltd. on +44-1494-777100 or sales@resolveoptics.com For further information on specialist camera systems for operating in hostile environments please visit www.customcameras.co.uk or contact Custom Cameras Ltd on +44-1749-870066.


29 SEPT - 1 OCT 2020 NEC, BIRMINGHAM

FREE TO ATTEND REGISTER NOW THE COMPLETE PRODUCTION LINE EVENT See the latest processing and packaging machinery, robotics and machine vision in action Network with industry peers and gain valuable insight at our must attend seminars

ppmashow.co.uk OWNED AND ORGANISED BY


E-Grippers

Deliver Benefits For Automated Assembly Applications Recognised as experts in automation and handling technology, Zimmer Group now offer a series of highly functional and easy to control electrically driven grippers. Designed primarily for assembly tasks and for handling small parts, these latest generation products deliver a number of distinct advantages for automated assembly operations. Electrically operated grippers from Zimmer’s GEP2000 series offer a number of advantages for small parts handling including: adjustable gripping forces of between 80 N and 400 N and jaw strokes of between 10mm and 16mm. Another important feature of this range of grippers is their mechanical self-locking mechanism, which prevents the loss of the workpiece in the event of a power failure. All grippers within the range feature an integrated control system and are available in three control versions: With IO-Link, digital I/O and digital I/O plus an analogue output to set or interrogate the jaw positions. With the IO-Link version, the gripper offers all the system-specific advantages of that interface, which includes not only simple handling and operation, but also easy integration. By connecting a single cable, the gripper can receive data from and transmit data to the master controller. Parameters such as gripping force and gripping speed are set centrally. The gripper uses IODD (IO Device Description) to send signals to the higherlevel control system. The resultant benefits include considerable time savings during initial setup or when replacing the gripper. IO-Link also sets new horizons for advanced diagnostic functions and predictive maintenance, which in turn enhance machine availability. No additional hardware, in the form of other controllers is required thanks to this highly sophisticated control system. The IO-Link master is all that is needed to act as a link between the gripper and the fieldbus, and no additional software needs to be installed on any PLC being used. Zimmer Group also provides its own Human Machine Interface (HMI) for easy operation. This tool, which has a special gripperadjustment user interface, is able to store parameters for up to 32 different workpieces. In the I/O version, the grippers operate as simply as a conventional pneumatic valve. The gripper opens when it receives a control signal, and the jaws are closed when it receives another one. In this cost-effective version, a four-pole cable that supplies the gripper with both electrical energy and control data is all that is required. A commercially available central distributor can be used to control several grippers at the same time. Should gripper position information be required, this can be achieved using magnetic field sensors, which can be accommodated in the two grooves incorporated within the gripper.

The gripper is able to use these sensors to send a signal as soon as a set query position is reached in just the same way as a traditional pneumatic gripper. Zimmer Group has developed a simple solution for adjusting the maximum gripping force, which can be set directly on the gripper using a potentiometer with four separate positions. This is not only quick and easy, but also offers the advantage of the setting being easily visible, even if the power has failed or if the gripper has been removed. For applications where more precise information relating to the position of the gripper jaws is required, Zimmer Group offers a digital I/O version together with analogue sensing. An analogue sensor, which outputs a voltage of between 0 and 10 volts, depending on the jaw position, is integrated into the gripper as standard. This voltage can be evaluated using an analogue card in a higher-level control system, making it possible to determine the position of the gripper jaws with an accuracy of less than 0.05 mm.

Robust Mechanical Design Delivers Longevity In Service Zimmer Group’s GEP2000 series electrically powered grippers feature an industry leading mechanical configuration. The hard anodised aluminium housing is at the heart of the grippers’ robust construction and reliability, and the field proven flat guide design will allow the gripper to perform 10 million part handling or assembly cycles without requiring maintenance. All versions in the range offer a mechanical emergency release, which is an important safety feature. Should there be a need for the gripper to be opened manually, in exceptional circumstances, the screw on the self-locking gearbox can be turned using a separate screw which is easily accessible externally. As a result, the gripper can still be opened, even in the event of a power failure when for example, a workpiece needs to be removed. All grippers are sealed to IP40 standard, and their high accuracy allows for rapid replacement minimising any interruption of production. The grippers in the GEP2000 series are powered by 24 VDC, and the gripper jaws are able to operate with a current draw of less than 500 mA. The current draw only increases to 2 A, a current that all conventional IO-Link masters can supply, for a few milliseconds at the moment of start-up, when the mechanical selflocking mechanism is released, and the motor is being brought up to speed.

www.zimmer-group.de/en


Güdel’s Gantry Robots Bring A Gentle Touch to Bakery Automation

Fast food restaurants are popular the world over, no more so than in the USA, where there are some 200,000 sites, serving approximately 50 million customers each day. With around 60,000 of these restaurants dedicated to hamburgers, supporting these businesses are the bakeries that have the challenge of producing vast quantities of fresh buns each day. Production volumes such as this require the implementation of automation, and since 2003, Pennsylvania based Workhorse Automation has been leading the commercial bakery automation sector with a wide range of pan handling and storage equipment, including 4 axis palletizing robots, used for pan stacking applications. However, if greater levels of flexibility and improved capacity are to be achieved, then alternative solutions would be required.

Following extensive research and development, Workhorse Automation settled on a solution based upon a 2-axis Güdel ZP-4 gantry robot module, with Allen-Bradley motion and programmable logic controls. This new solution allows Workhorse Automation’s clients to increase stacking system speeds whilst continuing to deliver the safe, gentle, and accurate stacking systems that customers have come to expect. To create a user and maintenance friendly turnkey automated system, Workhorse Automation’s engineers integrated the conveying systems, end-of-arm tooling and an Allen-Bradley control system to the gantry. The company’s first Güdel gantry-based system, installed several years ago, continues to operate successfully at Northeast Foods – Automatic Rolls of North Carolina. This facility produces 1,400 buns per minute, or 2 million over a 24-hour period, primarily for McDonald’s restaurants, using the Güdel gantry-based pan-stacking systems together with

the Workhorse Automation automated storage and retrieval systems (AS/RSs). Each Workhorse Automation system includes as many Güdel ZP-4 gantry vertical axes as necessary to meet the throughput requirements of the system. Therefore, in some systems, two vertical axes are located over the same bun-pan conveying system to meet processing requirements, with each vertical axis individually capable of stacking and destacking pans. The Z and Y strokes of the gantry will be determined by the individual customers application requirements on the size and number of pans to be handled. The pan stacking / de-stacking system provides a critical function in the process, as pans are specific to the type of bun being produced. The Northeast Foods facility makes four different styles of buns every day, each requiring a different style of pan. The changeover process of the pans is automatically handled by the automation, with the system moving from one pan type to the next without significant loss of throughput. The only time humans interact with the system is to visually check and confirm that the last pan has cleared the system at the end of a production run. “The Güdel gantry system allowed us to significantly improve the pan-stacking process,” says Ken Mentch, Workhorse Automation Sales Manager. “With Güdel’s gantry robots, we can increase the pan size and weight handled, as well as handle multiple pans simultaneously, reducing the motion speed requirements. The gantry gives us the exact work envelope needed for the application, increasing system safety and reducing the floor space required.” In addition, replacing the conventional magnetic machine used previously for pan stacking — known in the industry as the “pan crusher” — reduces the damage to the pans and the noise generated from the pan-handling process. “The gantry allows us to create a gentler, quieter and smoother automation system,” Mentch says. During the past few years, the bakery industry has taken note of the gantry system’s improved operation and reliability, moving the industry away from traditional technologies and toward robotic automation. Not only are current customers installing additional systems but new customers are coming to Workhorse for these proven solutions as well. Güdel has supported Workhorse Automation through this growth phase.

www.uk.gudel.com


April 2020

ENGINEERING UPDATE

Torsion Springs offer axial energy and control - from Lee Spring Where axial rotation requires control, a torsion spring from the Lee Spring catalogue range is often the right solution. These compactly wound ex-stock springs look like a common compression spring mounted on a rod or into a cylinder, but are activated by radial leverage on their end legs.

Common applications involve the need for a pre-loading to act as a counter-weight, e.g. a rear tailgate or garage door. Other typical applications include clothes pins, clipboards, window shades, counterbalance mechanisms, ratchets and various types of machine components. Torsion springs are used for hinges, counterbalances and lever return applications and as couplings between concentric shafts, such as in a motor and pump assembly. Many electronic devices utilise small torsion springs to provide smooth operation of pop-up covers on various players, cameras, instrumentation etc. Lee Spring now offer a total of 7 angle sections for their torsion springs in all standard ex-stock sizes,

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both left and right hand wound, which also facilitates usage in pairs to provide a balanced force at each point, so ensuring that the returned piece seats properly. They are available in plated music wire and passivated stainless steel. Torsion spring ends can be bent, twisted, hooked or looped to suit project needs, and are offered in a choice of 90°, 120°, 180°, 210°, 270°, 300° and 360° free leg position. Specialist design engineers are also ready to help with custom leg end style choices including straight torsion, straight offset, hinged, and hook ends. Specialist miniature torsion springs are available with an outside diameter from 2.62mm, through to full sized units of over 50mm. These are

covered by huge depth of stock at Lee Spring which ensures rapid one-off order delivery and timely production scheduling, in music wire or 302 stainless steel. In coming to a custom specification, we believe designers will benefit from the guidance provided on the Lee Spring “Spring-i-pedia” site springipedia.com where relevant formulae and other information can be found in establishing design parameters for torsion springs. Further information on Lee Spring products can be found on their website - www.leespring.co.uk or by following them on Twitter twitter.com/leespringuk.


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April 2020

ENGINEERING UPDATE

Mobile app helps identify replacement chain A FREE mobile App, which is the first of its kind in the UK, helps engineers identify replacement chain when they’re on-site. Developed by Donghua Limited, the Chain ID App captures key information so that the right replacement chain can be identified quickly and easily. The Chain ID App was first launched in the UK in 2017, in response to the number of calls Donghua received from engineers needing help identifying the right replacement chain for a piece of equipment. A Chain ID tool was initially launched on their website in 2016 and from this, the company developed an App which was launched the following year and included additional functionality to upload an image. Since then more forms have been added to the App covering a wide range of chain types including Agricultural Chain, Conveyor Chain, Leaf Chain and Roller Chain. Most recently, a new Drive Chain Calculation form was added for Roller and Conveyor Chain. By inserting data relating to input power type, power source, loading classification, sprocket information and input speed, Donghua can advise customers of the drive calculation and the most suitable set of drive chains. Bob Wellsbury, managing director of Donghua Limited and the creator of the App, explains: “The free App is a simple way to provide us with key information so the right replacement chain can be identified within one hour*. Feedback from users has been positive and confirms that it is a useful tool to help engineers know what chain they need to order when they’re on site.”

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Above: Screenshot of Donghua’s Chain ID App Left: Screenshot of image upload functionality

Donghua Limited celebrated its 10th anniversary in the UK last year and is part of the Hangzhou Donghua Chain Group, which is one of the world’s largest manufacturers of chain. Their UK head office and warehouse is located in Wolverhampton, West Midlands and includes a 25,000 square foot warehouse, a workshop for assembling Attachment Chain & Bespoke Chain plus a technical laboratory offering conformance, concentricity, bore size & parallelism testing of high precision parts. The Chain ID App is available to download for free on the App Store and Google Play. * Response times quoted apply to enquiries received between 8:30am-4pm Monday-Friday. Enquiries received outside these hours will be answered next working day.


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April 2020

ENGINEERING UPDATE

VentilatorChallengeUK Consortium A consortium of significant UK industrial, technology and engineering businesses from across the aerospace, automotive and medical sectors, has come together to produce medical ventilators for the UK. The VentilatorChallengeUK Consortium (“the consortium”) is led by Dick Elsy, CEO of High Value Manufacturing Catapult, a group of manufacturing research centres in the UK. Over the past week the consortium has been working hard to investigate production of a range of ventilator design options to meet a high-level specification for a Rapidly Manufactured Ventilator System (“RMVS”) developed by clinicians and the Medicines and Healthcare products Regulatory Agency (“MHRA”). The consortium has evaluated all requirements to design, manufacture, assemble and test components, as well as finished medical ventilators. Companies in the consortium have now received formal orders from the Government in excess of 10,000 units. The consortium will now accelerate production of an agreed new design, based on existing technologies, which can be assembled from materials and parts in current production. The device combines existing proven clinical equipment and is the clinicians’ first choice for the RMVS. The regulator has been involved throughout and we anticipate a straightforward and very prompt regulatory sign off after the final audit. The consortium is now working at full speed to take the necessary steps in order to increase production of this design. Production will begin this week. The consortium also includes another producer of medical ventilators and it will provide them with additional manufacturing support and assembly facilities in order to scale up production of a second existing ventilator design which has full regulatory approval. In response to the NHS’ requirements to treat coronavirus patients, there are a range of other projects aiming to increase ventilator production. The VentilatorChallengeUK consortium is committed to playing its role in delivering both medical ventilator designs to the required specifications and, in conjunction with these other companies, organisations and groups, aid the delivery of additional ventilators to the NHS. The

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companies involved have taken many of their people from key company projects to do this and serve the national need. Dick Elsy, the High Value Manufacturing Catapult’s chief executive, said: “This consortium brings together some of the most innovative companies in the world. Every day, their highly-skilled staff collaborate to create solutions that help millions of people, and this project is no different. They are working together with incredible determination and energy to scale up production of much-needed ventilators and combat a virus that is affecting people in many countries. I am confident this consortium has the skills and tools to make a difference and save lives.” For more information visit our website: www.ventilatorchallengeuk.com If you want to help: We recognise that many companies and individuals with relevant expertise will be keen to help in the effort to produce more ventilators for the UK and will want to be a part of this project. We would ask that all offers of support are registered through the Government’s web page rather than by approaching the consortium directly, and we would appreciate the media reinforcing this to enable the consortium to focus on this critical mission. This will mean that if we need help we will be able to source it through that mechanism and, in the meantime, will be able to focus all of our energies on the urgent task of production.



ENGINEERING UPDATE

April 2020

Providing quick, simple and accurate thickness measurements with minimal preparation Cygnus thrive on developing a product range that is applicationdriven and user-focused. While the Cygnus 6+ has been specifically designed to be easy to operate, it also has an excellent array of other features, including: •

• • •

This UK based ultrasonic manufacturer are the pioneers of the multiple-echo measuring technique, which has long been an industry standard for through-coating measurement of material thickness. Storage tanks can be susceptible to a high level of corrosion both from their contents and from the outside environment; and the Cygnus 6+ PRO has been designed specifically for Engineers who need to take quick and accurate thickness measurements. The Cygnus 6+ is perfect for testing levels of corrosion on storage tanks such as fuel depot tanks, commercial and domestic LPG tanks, propane gas cylinders, air cylinders for divers, water storage tanks, effluent tanks and pressure vessels. This gauge has been rigorously tested to military specification: drops from height onto concrete, extreme vibrations and extreme temperatures – and is completely environmentally sealed to IPX7 and IP6X. The Cygnus 6+ has also been tested to MIL-STD-810G Method 511.5 Procedure I (explosive environment compliant).

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Versatile measuring modes: Multiple-Echo giving the ultimate accuracy through coatings up to 20mm thick and; SingleEcho and Echo-Echo measuring modes for extreme corrosion. A-scan display that helps to verify true back wall readings in difficult measuring applications. Live B-scan display with auto start / stop which shows a cross sectional view of a material. Comprehensive data logging offers the ability to input templates making it perfect for recording measurements on symmetrical storage tanks which helps to ensure thickness readings are taken in a methodical manner, with the data easily transferred to a computer or spreadsheet for reporting. MSI™ (Measurement Stability

Indicator) which verifies stable and reliable readings. Bluetooth™ for data transfer

The gauge has a large front colour LCD display that can be viewed in all lighting conditions plus an end-mounted rotatable LCD with grayscale setting for bright sunlight, an easy to use keypad and an intuitive menu. The gauge body has been designed to be comfortable to hold and protects against bumps whilst offering maximum strength with its hard-internal shell. For more information about these and other Cygnus products, visit www.cygnus-instruments.com. Alternatively, call us on +44 (0) 1305 265533 or email sales@cygnus-instruments.com. Quote EU0420 for a 10% discount on a gauge.


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April 2020

ENGINEERING UPDATE

EVAPORATIVE COOLING HAS CLEANED UP ITS ACT, BUT IS IT UNDER-PERFORMING? Mark DONOGHUE, DIRECTOR AT DHD COOLING, EXPLAINS WHY CHECKING MECHANICAL SYSTEMS IS JUST AS IMPORTANT AS COMPLYING WITH WATER SAFETY IN COOLING TOWERS As cases of Legionnaires’ disease continue to be reported throughout the world we must acknowledge the due diligence that UK owners, operators, water treatment companies and the HSE have applied in ensuring that evaporative cooling systems meet some of the most stringent industry standards in order to avoid these outbreaks. This is a single minded and worthwhile pursuit, but key industry figures are questioning if this is what’s best for overall plant performance and the environment. Achieving regulatory compliance of operating cooling towers means that organisations have appointed the right people to correctly treat their systems to prevent the buildup of harmful bacteria. By utilising the skills of a water treatment company, your business is fulfilling its responsibilities to implement processes in order to prevent putting employees or the public at risk. However, cooling towers have a primary function which also depends on the mechanical condition of the equipment, and the many nuances of the individual components selected to produce the cold water that your processes demand to make them work. One fan is not necessarily the same as another, one type of heat exchange media is not the same as another, and one distribution system is not the same as another. The bottom line is: one model does not fit all. Cooling towers are not too complicated; they promote the efficient transfer of heat mostly through evaporation into a stream of air in order to remove that heat from a process to keep it operating within acceptable temperature limits. While these temperature limits vary from one process to another, a lot of processes can benefit from being cooler, which can lead to increased output and increased profit.

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Whilst it is essential that the internal components are the right ones for your cooling systems, industry experts are urging plant owners to consider options that can increase airflow, improve water distribution, increase safety and contribute to increased heat transfer performance. Plant Owners are reporting that they are benefiting from improved efficiency and performance by applying different operating philosophies and exploring alternative methods of control in addition to looking at performance enhancements through equipment upgrades. Maximising performance is all about getting the most out of each and every component in a system. Cooling systems play a pivotal role in overall system performance, so simply valeting a system on an ad hoc basis isn’t sufficient to improve or even maintain its performance. Just like a car, the bonnet needs to be opened to see what’s going on inside, and to consider each and every part as critical in achieving the best overall results. In addition to improved performance, businesses may be surprised to see how much revenue can be saved with a small investment in their cooling towers. Their cooling towers could be preventing them from realising the full potential of their plant. DHD Cooling is supported by Vantage PR


ENGINEERING PDATE

April 2020

The demand for stainless steel clamps is especially high for the bottling, packaging and processing technology as well as for outdoor appliances and equipment bearing thermal loads. We work constantly and with great dedication on innovative products and solutions for our customers. The range of linear, lifting column, profile and connecting technology products include catalogue as well as tailor-made products, system solutions such as platforms, work stations and special projects. We are happy to advise you in choosing a product or to develop a tailor-made system solution with you from our extensive modular product range. RK Rose+Krieger 26 Faraday Road Aylesbury

API pump applications?

Buckinghamshire KTR manufacture a range of couplings to meet the special requirements of HP19 8RY applications in the oil & gas industry, in particular API 610, 671 and 685. pump Furthermore, KTR offers ATEX approved products - including jaw couplings, gear 01296 611660 couplings, steel laminae couplings and oil/air coolers - for hazardous operating conditions. For more info visit us at SPE Offshore Europe 2019 - stand 3G80 www.rose-krieger.co.uk www.phoenix-mecano.co.uk

3-6 SEPT 2019

www.ktr.com

www.ktr.com

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April 2020

ENGINEERING UPDATE

Electrostatic when handling bulk materials Electrostatic charges with regard to explosion safety

E

lectrostatic charges can occur when two surfaces are rapidly separated, whereby at least one surface must be an insulator. Critical processes, for example, are pneumatic conveyors, Big Bag filling stations, or even silos with the danger of a conical pile discharge. In order to avoid electrostatic discharges at such FIBC filling stations, it is necessary to assess the bulk material and to select the proper FIBC Type.

How do electrostatic charges develop, and how does the grounding work?

Fig. 1: Electrostatic discharges and their ignition potential. Source: www.bgrci.de

grounding can be carried out by means of a cable and clamp. Another option is the grounding by means of a grounding monitoring system such as FARADO FIBC. An approval function enables the Big Bag Type C to only be filled if the grounding is correctly established.

Electrostatic charges and the associated discharges are considered as one of the 13 possible ignition source types to be considered in a plant-related risk assessment. A distinction is made between the most varied types of discharge which, depending on the type, can be responsible for igniting gases or dusts Fig. 1).

Selection of the suitable Big Bag Big Bags, also referred to as FIBC´s, are divided into types the A, B, C, D, which can be categorized according to their protective characteristics as follows: • Avoid brush discharges: Type C and D • Avoid propagating brush discharges: Type B, C and D • Avoid spark discharges: Type B, C and D Type C Big Bag has conductive filaments, which makes it necessary to ground type C Big Bag. Such

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Fig. 2: Electrostatic charges by means of grounding monitoring device FARADO FIBC

Type D FIBC transfers the resulting charges to the environment via dissipation. However, this requires grounding of all conductive equipment and objects located within reach of the type D Big Bag. Likewise, persons must wear conductive footwear, otherwise these persons will be charged up as well and act as an ignition source themselves. The Big Bag must be selected strictly in accordance with the requirements of IEC TS 60079-32-1 “Explosive Atmospheres – Electrostatic hazards, Guidance”, and depends on the

minimum ignition energy (MIE) and the zone classification. However, the division also depends on the zone defined on the outside. If a gas zone is present at the same time, special measures must be considered.

Electrostatic charges during the filling of silos with a pneumatic filling Another source of electrostatic charges is in places where a pneumatic transport or pneumatic filling of silos by trucks is carried out. If an explosive atmosphere develops outside the truck, and the truck charges up electrostatically due to the conveyance, there will be an acute risk of explosion. For this purpose, always ensure that the truck is properly grounded. Here, there are also systems on the market that are able to monitor the proper grounding of the truck and, via relays, provide an approval system that can be used to control valves or other equipment (Figure 4). In addition to grounding the truck, care must also be taken to ensure that the conveying line is properly executed. Adequate means that this must be electrically conductive/conductive dissipating and grounded. Insulating intermediate pieces such as sight glasses or similar should be avoided, as these may lead to propagating brush discharging.


ENGINEERING PDATE

April 2020

Use of the different types of FIBC Bulk Product in FIBC MIE of dusta MIE > 1000 mJ 3 mJ < MIE ≤ 1000 mJ MIE ≤ 3 mJ

Surroundings Non flammable atmosphere

Dust zones 21-22b

Gas zones 1-2b (Explosion Groups IIA/IIB)c

A, B, C, D

B, C, D

C, Dd

B, C, D

B, C, D

C, Dd

C, D

C, D

C, Dd

Measured in accordance with IEC 61241-2-3, ASTM E2019 and EN 13821 with a capacitive discharge circuit (no added inductance) See D.2 for the definition of zones. c See D.3 for an explanation of Explosion Groups. d Use of Type D should be limited to Explosion Groups IIA/IIB with MIE ≥ 0.14 mJ. NOTE 1: Additional precautions are usually necessary when a flammable gas or vapour atmosphere is present inside the FIBC, e.g. in the case of solvent wet powders. NOTE 2: Non-flammable atmosphere includes dusts having a MIE > 1000 mJ. NOTE 3: The MIE limit of 3 mJ is based on the incendivity of cone discharges. Cone discharges might have a much higher energy in a Type B FIBC than in a Type C or D FIBC because the wall of a Type C oder D FIBC will be at close to zero potential. Based on this fact the internal field distribution will be such that in Type C oder D FIBC cone discharges will at most only jump across half the diameter of the FIBC. A calculation with the formula given in A.3.7 for the largest FIBC commonly used (diameter of 1,5 m) yields 3 mJ for powder with a median size of only 0.055 mm in a Type B FIBC, whereas in a Type C or D FIBC the 3 mJ limit is only reached with a coarse powder having a median size of 0.27 mm or higher. However, such coarse powders usually have a MIE higher than 3 mJ. a

b

Fig. 3: Selection of suitable FIBC types depending on bulk material and operating conditions. Source: IEC TS 60079-32-1

Conical pile discharge in silos An often not considered circumstance is the possibility of so-called conical pile discharges in silos. Bulk solids are generally not to be regarded as conductive, and are dangerously charged during the pneumatic conveying. If the silo is correspondingly large and the median of the bulk material is also larger in median, there is a risk that the cloud of dust above the bulk material will ignite due to a conical pile discharge. If the conical pile discharge cannot be excluded as an effective ignition source, a protection through protective systems must be established in case of doubt. Flameless explosion venting by means of a Q-Box or explosion suppression by means of the Q-Bic

offer numerous options for the indoor installation. The protection of adjoining plant components must also be taken into account during the protection design. Thus the supply line must be isolated against the pressure and flame of a possible explosion. This prevents the explosion from striking back, e.g. into the conveying truck or into the Big Bag loading station. In addition, the silo discharge must be equipped with an appropriately certified rotary valve, e.g. Ex II (1) 2 D, to prevent the explosion propagation in this direction.

Fig. 5: Explosion protection by means of Q-Box and quench valve on a silo with the risk of conical pile discharge

Authors Marius Bloching - Corporate Senior Engineer Explosion Safety Alexander Kemmling - Sales Executive Explosion Prevention

www.rembe.com

Fig. 4: Grounding monitoring of a truck by means of FARADO

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April 2020

ENGINEERING UPDATE

Practical planning tool for designers The Schmersal group presents the new PSC1 configurator: Machine manufacturers and machine operators can now easily and quickly configure a safe control system for their systems according to their individual requirements with the PSC1 configurator from Schmersal, a 7 x 24-hour online tool. The PSC1 Configurator is selfexplanatory, easy to use, and provides a meaningful planning base for designers in just minutes. It is now available as a web version at: www.psc1.de. The configurator is also convenient to use on iPads/touchpads using an iOS/Android app. Starting from a selection of safety sensors and safety outputs, this planning tool automatically chooses the optimum PSC1 safety control (by price) and also shows how much space the assembly needs on the DIN rail configured for each case. At the same time a parts list with article description, material number and details of the devices is generated. This parts list is linked with Schmersal’s online catalogue so additional information on the devices can be accessed as required. The parts list can be stored in Excel or PDF format and sent directly to Schmersal by email to obtain a quote customised to the user. Various fieldbus protocols available The safety controller PROTECT PSC1 allows the adaptation of the

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safety functions to a wide variety of applications. Core components of this control system are freely programmable compact controllers (PSC1-C-10/100), for which IO expansion modules are available for the safe signal processing of mechanical and electronic safety switchgear. The compact controllers can be equipped with a universal communication interface. This enables the selection and implementation of different fieldbus protocols easily using software. The PSC1 therefore only requires one hardware element to create a connection to most common forms of fieldbus systems. The following field bus protocols can be selected in the PSC1 configurator: PROFINET, PROFINET PROFIsafe, EtherCAT, EtherCAT FSOE, Profibus, Profibus ProfiSafe and Ethernet IP.

In addition, the user has an optional SD memory card available with which programs once created can be backed up. With this, for example, reprogramming is no longer necessary if the hardware is replaced. Also, planning a safety system for a further machine or a local automation concept is possible in the PSC1 configurator. The “topology” function shows in the configurator how the control systems of the two machines are linked together. The PSC1 configurator is available in the following languages: German, English, French, Spanish, Italian, Portuguese, Japanese, Chinese


PROTECT PSC1: Programmable modular safety controller

FUNCTION INDICATOR LED STATUS DISPLAY

PSC1 status display

7 Segment display

MICRO SDHC Storage medium for safety related programs RS485 - USB PC + PSC1 program port

SDHC+SMMC INTERFACE Communication interface for decentral slave and master modules LED I/0 STATUS 14 safe digital inputs, 2/4 safe digital outputs PN/PP 2 relay safe outputs, 2 signal outputs 2 pulse outputs

FIELDBUS INTERFACE Standard and secure fieldbus

Schmersal is not only a manufacturer of safety components but also a system supplier. The safety control system PSC1 consists of freely programmable compact safety controllers with I/O extension modules for signal processing of emergency stop switches, guard door switches, light grids and additional mechanical and electronic safety switchgear. Additionally there is the possibility via numerous functions to monitor axis. Using the universal communications interface a connection can be established to all the standard field bus systems. W ith its combination of properties, the new safety controller from Schmersal is unparalleled, as the PROTECT PSC1 has unique features that clearly set this control system apart from other solutions on the market.

www.schmersal.co.uk / uksupport@schmersal.com / 01684 571980

Scan the QR code for more info


April 2020

ENGINEERING UPDATE

system data via AS-i, EtherCAT, Modbus TCP, Profinet, EtherNet /IP, TCP/IP, UDP/IP and stored on the SD card or in the internal flash memory. If necessary, the integrated real-time clock provides a time stamp for each recorded data block. This simplifies the documentation and diagnostics of processes. SmartPLC for process visualisation: SmartPLC features a freely programmable web visualisation based on HTML5 to provide maximum transparency. An internet browser with HTML5 capability is sufficient on the final unit (PC, tablet, smartphone). No further software is required. Even the SmartPLC full graphic display is freely programmable for visualisation tasks.

All-in-one

Smart PLC from ifm electronic does it all. There are PLC’s and there are safety PLC’s. Then there is ifm’s SmartPLC. The SmartPLC is an elegant combination in one housing of both a safety PLC and a standard PLC. SmartPLC possesses the flexibility for a multitude of tasks, even where the safety rating reaches SIL 3 / PL e. SmartPLC is not just a standard PLC with a standard PLC, it is also an AS-I gateway to either Profinet or Ethernet/ IP and it also acts as a datlogger. It’s a visualisation system, a protocol converter and an intelligent evaluation unit in conjunction with the new ifm system solution apps. SmartPLC is all you need in one housing. All-in-one. The two integrated safety and standard PLC’s operate in tandem, using powerful processors, large memory and a multitude of supported protocols for the control of sophisticated systems - and all this at an unbeatable price! The safety PLC is certified up to SIL3, PL e and handles eight safe local inputs and four safe local outputs. It also includes user-friendly diagnostic functions, such

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as status indication for safe I/Os and error memory with time stamp for up to 2,000 messages. The safety PLC is programmed using CODESYS V3. The standard PLC can also be freely programmed using CODESYS V3. Its software and hardware operates independently of the safety PLC, but it can of course communicate with it and exchange data. SmartPLC as a gateway: without running a programme, the SmartPLC can simply be used as a direct gateway for AS-i on one side, and Profinet or EtherNet/ IP on the other. The integrated display and the easy web interface display all the available status information for the user and support diagnostics in case of a fault. SmartPLC as a data logger: the data logger function records operational

As easy as using a smart phone: the SmartPLC as a platform for ifm system solutions. The new ifm system solution apps make it a simple task to handle various sensor types. Modern sensors offer more and more intelligent functions that can also be made available to the PLC via interfaces like IO-Link or TCP/ IP, but to make full use of them the PLC programmer has to individually implement the functionalities in the PLC. This can be very time-consuming and costly, especially when it comes to implementing the required user interfaces. The tailored apps from ifm can be loaded onto the SmartPLC without programming software. The apps are loaded and configured via the integrated web interface, so all necessary settings can be carried out easily using a device with an internet browser. It’s as easy as using a smart phone and is a simple step on the road to Industry 4.0. SmartPLC as a protocol converter: With sensors and Ethernet based devices connected to your fieldbus, the SmartPLC can be used as protocol converter between Profinet, EtherNet / IP on the one hand and AS-i, EtherCAT, Modbus TCP, TCP/IP, UDP/IP and IOLink on the other. ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products.


All in one! The fail-safe SmartPLC from ifm Two separate plc’s in one compact housing: one for safety-related applications, the other as a standard plc or platform for other operations. Both plc’s communicate with each other so that complete machine control, including safety functions and visualisations can be carried out with just one Smartplc, AS-i offers unbeatably simple and flexible wiring of standard and safety-related signals.

www.ifm.com/uk/smartplc ifm telephone: (020) 8213 2222


April 2020

ENGINEERING UPDATE

Installing 5G devices beyond manufacturing Essentra Components guidance The Essentra Components Knowledge Centre contains a wealth of information for engineers including this guidance document concerning installation of 5G equipment in the mobility, healthcare, agriculture and telecoms industries. Design, production and installation engineers are expected to face new challenges with 5G-based equipment and this analysis of trends in hardware components will be of interest at all levels. The guidance from Essentra Components can be viewed on their website at www.essentracomponents.com/en-gb/news/news-articles/beyondmanufacturing-how-will-5g-affect-other-industries, along with other relevant material addressing “What does 5G mean for design engineers?” among other subjects. Further information on Essentra Components products can be found on the Essentra Components website – www.essentracomponents.com or contact sales@essentracomponents.com. Follow them on social media: facebook.com/essentracomponents/, www.linkedin.com/company/essentra www.youtube.com/channel/UCD-2g7tiLiKxsDptdC79BNQ

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April 2020

ENGINEERING UPDATE

Calculating robot ROI How to determine the true cost of robotics Google Trends data demonstrates that web searches for the phrase, “how much does a robot cost?” have doubled since 2009. Determining the total cost and return on investment (ROI) of a robot isn’t straightforward, as Nigel Smith, managing director of industrial robot supplier TM Robotics, explains. When you factor in the robot’s engineering and maintenance costs, budgeting isn’t always as easy as requesting a quote. As well as installation costs, factories may need to build segregated work areas or additional backup power units before a robot can be deployed. That’s not to mention peripheral technology, such as sensors, variable robot grippers and any necessary mounting apparatus. A report by the Boston Consulting Group suggested that, in order to arrive at a solid cost estimate for robots, customers should multiply the machine’s price tag by a minimum of three. Let’s say a six-axis robot costs £65,000, customers should therefore budget £195,000 for the investment. That said, should the robot require a more extensive equipment overhaul, a multiplication of four or five times the cost of the robot may be required. Then, of course, there are variable costs to contemplate. These include the labour, energy, materials, ongoing maintenance and production supplies required to deploy a robot successfully. Due to the varying nature of manufacturing facilities, these costs can fluctuate dramatically depending on the industry sector and size of the operation. Manufacturers can only calculate the ROI of an investment after establishing the robot’s total purchasing cost. Even then, manufacturers must consider several other elements, starting with robot use. Consider the following example. A food manufacturer plans to use two

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SCARA robots to automate pick-andplace processes. The robots will run for three shifts a day, six days a week, 48 weeks of the year. The equivalent labour usually requires two operators per shift, equating to six operators to complete the same throughput over a working week. Using the average salary of a UK production operative as an example, at £25,000 per annum, removing these roles would reduce labour costs by £150,000 a year. However, human labour is not eliminated. A good rule-of-thumb for labour estimations alongside a robotic system is 25 per cent of current costs, reducing the total labour budget to an impressive £37,500 per year. Minus this figure from the total robot purchasing cost we determined earlier, and manufacturers have an estimated ROI for the first year. That said, there are some flaws in this method of ROI calculation. Many of these figures are estimates. For a true reflection of ROI, manufacturers should conduct a thorough cost analysis based on the operations of their facility, as well as a risk assessment.

But what about the complementary benefits of robots that aren’t considered in this calculation? Robots offer peace-of-mind for delivering productivity gains to improve a factory’s bottom line. For instance, eliminating the likelihood of human error in manufacturing processes can reduce scrap material, minimise reworks and improve the consistency of products. According to the Annual Manufacturing Report 2019, over three quarters of manufacturers are ready to invest in new technologies to boost productivity. No doubt, robots will be among these investments. However, as manufacturers consider investing in robotic technology for productivity, it’s vital they have a clarity of ROI validating purchasing decisions. For further guidance on calculating robot ROI, or help deciding on the correct robot for your application, speak to the experts at TM Robotics, supplier of Toshiba Machine robots. Call +44 (0) 1785 225416 or e-mail info@tmrobotics.com.


ENGINEERING PDATE

April 2020

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April 2020

ENGINEERING UPDATE

ProSolv® high performance vapour degreasing solvent, simple “drop-in” replacement for n-Propyl bromide and trichloroethylene Vapour degreasing is one of the most widely used cleaning systems in the engineering industry. The most commonly used solvents are based on Trichloroethylene, n-Propyl bromide and other chlorinated solvents which under EU REACH regulations may require authorisation for use as metal cleaners after July 2020. If you are using vapour degreasing solvents based on any of these solvents EnviroTech Europe can offer excellent drop-in replacement products developed from 40 years of experience supplying market leading cleaning solvents to the engineering industries. ProSolv® is an alternative chemistry developed by EnviroTech Europe to replace chlorinated solvents. It can be used in most existing vapour degreasing equipment and can be used safely for immersion cleaning using ultrasonics, for which it has

been optimised. with a high specific gravity and very low surface tension. Unlike some other chlorinated and halogenated blends such as trichloroethylene, ProSolv® is an excellent choice to replace flammable solvents such as MEK, Acetone, Isopropyl alcohol (IPA) or hydrocarbons where manual wiping or brush cleaning is the preferred method. It is a non-flammable azeotropic blend which can be used for manual cleaning in suitably ventilated areas and recycled by distillation for reuse through many cycles. It is a very stable mixture with no need for monitoring or the need for additives or stabilisers. In other applications ProSolv® offers a cost-effective alternative for halogenated solvents in

formulations for dip, spray or aerosol applications and as a fast-drying carrier solvent for oil, silicones and other lubricants. Simple to install in any standard machine for vapour and vapour liquid degreasing. ProSolv® is non-flammable (No Flash Point) with high solvency (KB Value 91) with a very low surface tension and low boiling point making it highly productive and economical in use. A very stable azeotrope in use no additives or testing required. Leaves minimal Non-volatile residue. Importantly the ProSolv® formulation is kind to the environment as it contains no hazardous air pollutants and is safe for users. It has zero ozone depletion (ODP) with very low global warming potential (GWP). ProSolv® is compatible with all metals. Manufactured in UK with excellent customer service, technical support and training from qualified distributors throughout Europe. For more information please visit: www.vapour-degreasing.com/ prosolv

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Leaders in Surface Engineering for Critical Components www.cwst.co.uk

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Curtiss-Wright Surface Technologies | www.cwst.co.uk eurosales@cwst.com | +44 (0)1635 279621


April 2020

ENGINEERING UPDATE

Compact, robust and versatile: the Han® 1A from HARTING HARTING has over 70 years’ experience of producing robust industrial connectors. From the very beginning, the focus was always on developing a product which would be easy to handle, durable and adaptable for a range of uses. Another important consideration was an ethos of continuous innovation, which gives users reliable solutions even as markets and industries evolve. In the case of the Han® 1A, HARTING has recognised and responded to the demand for smaller interfaces to power engineering equipment. It requires up to 30% less space than the Han® 3A and provides all the benefits of a modern network. Constructed from lightweight, durable polyamide plastic, the Han® 1A employs a system of modular inserts, making it extremely versatile. For power, it can transmit a maximum of 16 amps and 400 volts. Modules for Cat. 5 or Cat. 6A are available for data transmission and up to 12 D-Sub contacts can be used for signal interfaces. A shielded version is also available for areas which are susceptible to interference. Only two components are required to quickly assemble an IP20 solution, while additional housing elements or

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single wire seals can easily extend the degree of protection to IP65, making it suitable for use outdoors. Accessories such as fasteners for wall mounting and colour coding pins to help identify different lines and reduce cabling errors are also available. What’s more, as the entire Han® 1A connector system is based on just a few components, material supply is greatly simplified as a plug-in connection consists of a maximum of twelve different contacts. This gives you the flexibility to easily create simple and efficient interfaces for applications in mechanical engineering, automation, robotics, transportation, traffic engineering and the energy sector. In mechanical engineering, it provides an efficient solution for connecting tools and smaller machine modules such as heating and cooling units, fans, control terminals, lighting systems, drives and vibration conveyors.

As it complies with the following railway standards, EN 45545-2, R22-24, HL1-3, IEC 61373-Cat.2, the Han® 1A is also ideal for use on door systems and ramps, door openers, push buttons, lighting systems and screens. To learn more about this miniaturised, lightweight innovation, please visit www.harting.com/UK/engb/solutions/han-1a or email salesUK@HARTING.com .


Size doesn‘t matter to be a hero. Han® 1A - Compact, robust and versatile.

Space-saving connectors for mahcinery and railway vehicles ■ Compact and lightweight: Our smallest industrial connector with the necessary shielding with plastic (polyamide) housings. ■ Flexible applications (IP20 / IP65): Options for data, signals and power with a density of 12 D-Sub contacts. ■ Cost & time savings: Bulkhead surface mount and cable-to-cable with snap-in latch or lever lock mating.

One Range. No Limits: tiny.cc/han_1a


April 2020

ENGINEERING UPDATE

Zecchetti Handling Technologies Using Cube67 fieldbus with Evolution Power Supplies – increasing run time and system availability. Conveyor and palletizing systems from Zecchetti Handling Technologies are capable of processing over 60,000 plastic bottles an hour. To increase the machines run-time and add essential diagnostics capabilities, they use Murrelektronik’s Cube67 fieldbus system with IO-Link sensors and the Cube67 Diagnostic Gateway module. In the cabinet, they opted for efficient Evolution Power Supplies ensuring extremely high reliability and continuous 2-phase operation. A perfect combination, enabling Zecchetti engineers to create solutions to meet their customer’s need. About Zecchetti What moves 1,000 plastic bottles a minute, is over 100 meters long and is made in Italy? A handling machine from Zecchetti! With over 19,000 square meters of production facility, Zecchetti can realize unparalleled handling solutions for their customers all over the world. Just outside of the city of Parma, in the Emilia-Romagna region of Northern Italy, lies packaging valley. Surrounded by centuries old castles and parmesan cheese manufacturers, this is where the handling technology company Zecchetti is headquartered with over 100 employees. Since 1960, they have been manufacturing turn-key automation systems for empty bottle conveying and palletizing to both glass and plastic bottle producers. They also provide automated warehousing installations for small workpieces, bins and pallets. But not all their machine lines handle such traditional bottles. The complexity increases when asked to develop systems to handle glass bottles shaped as a high heel, or even a fish. “These are some of the most memorable applications and always present their own fun challenges,” said Luca Facchini, technician at Zecchetti.

The Challenge Requirements like speed and high run-times are non-negotiable and help strengthen their end customers’ competitive advantage. To tackle these challenges and deliver the best solutions possible, the team of engineers at Zecchetti are continually innovating and working with new technologies. One of the answers for the team is to rely on the modular Cube67 fieldbus I/O system from Murrelektronik. This system was an easy choice for them because they can easily integrate the Diagnostic Gateway module and IO-Link Devices into their automation concepts. Cube is a modular fieldbus system designed for decentralized installation concepts. Its flexibility makes it easy to develop the right solution for any application. The Project As their systems are shipped all over the world, Zecchetti opted for the Evolution Power Supplies. Evolution has output voltages ranging from 12 – 48 VDC and UL approval, making it the ideal choice for international use. The price/performance ratio and power boost (50%) was attractive for Zecchetti as Evolution offers all the features required at a very competitive price. The 2-phase continuous operation helps prevent downtime on the power side – so if one side fails, the other side is prepared. Ideal for Zecchettis as their machines run 24/7. Due to the modular nature of Zecchetti’s machine concept, working with the Cube67 system enables them to simply combine different machine components. Installing Cube67 modules on the machine processing areas makes it easy to connect them during transportation and commissioning. When comparing this installation to single wire solutions, Cube67 saves time and reduces wiring mistakes. Features like plug-in connections and robust and compact design, the Cube67

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system offers a valuable cost-benefit ratio across the entire life cycle of a machine. Simplified engineering design, fast machine assembly, error-free commissioning and maximized system run time make for efficient packaging operations. Because the applications and processes are modular, working with Cube67 helped Zecchetti simplify installations. Integrating IO-Link devices in Cube67 open additional possibilities. Features like adding an additional 20 meters (65 feet) of cable to the IO-Link sensors and the possibility to connect up to 128 IO-Link devices to a single bus module are important to handling customers like Zecchetti because their machines and applications need to fulfill long length requirements. Relying on the intuitive Murrelektronik Cube67 webserver made it easy for them to integrate IO-Link devices as generic devices because they didn’t need any additional software or interfaces. “It’s intuitive to use and we don’t have to give our teams any additional software training,” said Guido Corradi, technician at Zecchetti. The Cube67 Ethernet/IP bus node’s webserver allows Zecchetti to configure and program the whole Cube67 system quickly and easily. And via the integrated backup function, they can store the configuration and simply upload this to the next machine. Sixty percent of Zecchetti’s customers use ProfiNet, while forty percent rely on EtherNet/IP. The Cube67 system makes it possible to switch out the bus module without changing the whole system. By simply switching out the bus module, Zecchetti can standardize the placement of the fieldbus modules and adapt the system to a new protcol. “By using Cube67, Zecchetti simplifies their installation while increasing output, which is a key value add for them,” said Daniele Bizzarri, District Manager at Murrelektronik.


Renold Gears OQSx Oil Quality Sensor

The Renold Gears OQSx Oil Quality Sensor is your ideal solution for accurate real time gearbox oil condition monitoring. Easily and quickly installed the OQSx detects all wear and contamination elements to an exceptionally high level and provides an accurate statement of oil condition second by second – in any oil type and in any application, giving you a true 360 degree view of how your oil is performing.

> Accurately reports precise condition of oil in real time > Patented technology > Independently certified for accuracy, sensitivity and reliability > Robust and reliable in the harshest conditions > Easy to install > Configurable for any oil type, in any application

e gears.sales@renold.com

w www.renold.com


April 2020

ENGINEERING UPDATE

Static Safety when Transferring Materials with Road Tanker Trucks As a product (liquid or powder) moves through the transfer system and interacts with pumps, valve, filters, meshes and pipe walls during processing, it will be building up the amount of electrostatic charge it carries. In electrical terms this is commonly described as static charge accumulation. When the product is transferred into the road tanker, this in turn becomes electrified and subjected to a rising voltage.

F

or example, a typical road tanker when it is being filled with a liquid at recommended flow rates, but is without static earthing* protection, could have its voltage raised to between 10,000 volts and 30,000 volts within 15 to 50 seconds.. This voltage range is very capable of discharging a high energy electrostatic spark towards objects at a lower voltage potential, especially anything at earth potential. Examples of objects at earth potential could be operators working in the vicinity of the road tanker or the filling pipe situated in the hatch on top of the road tanker. To counteract this risk, it is important to ensure that the road tanker does not have the capacity to accumulate static electricity. The most practical

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and comprehensive way of achieving this is to make sure that the road tanker is at earth potential, especially before the transfer process starts. The Earth-Rite® RTR (Road Tanker Recognition) system performs three critical functions which ensure the fire and explosion risk of an ignition caused by static electricity is eliminated. determine if the driver or operator has made a secure connection to the body of the road tanker verify it has a low resistance connection to True Earth via the

structure to which it is connected, e.g. the loading gantry establish and continuously monitor the connection resistance between the road tanker and the verified earth ground is 10 ohms or less Search “Newson Gale RTR” on YouTube to watch an animation showing the application process.


April 2020

AVT Reliability Inc Launches in the USA Market-leading plant reliability specialist AVT Reliability® has opened its first subsidiary in the USA. The move is part of a clear plan to expand its global reach, following the recent acquisition of Van Geffen in the Netherlands. AVT Reliability® Inc, which is owned by Rotherham based AES Engineering Ltd, has established a base in Rockford, Tennessee, alongside sister company AESSEAL® - the world’s largest homogeneous designer and manufacturer of mechanical seals. US customers will benefit from its Machine Sentry® suite of products, including: •

The MSF-1 Fixed Sensor, which has full Hazlock certification

ADA™ - the Automated Diagnostic Assistant, which can predict stage 2, 3 and 4 bearing

failure and detect a wide range of other common fault conditions •

EasyBrace™, the universal bracing system designed for the reduction of structural vibration in small bore pipes

Machine Sentry® was showcased for the first time in America at the MARCON 2020 maintenance and reliability conference this month (March), and was received very positively by leading experts attending the show. Frederic Thomas, Managing Director of AVT Reliability® said: “We are at

a turning point in our strategy and are very excited to be introducing our advanced solutions to the American market. “We work constantly to improve the reliability and lifespan of our customers’ assets, via innovative and sustainable solutions, and are proud that our European customers report increased uptime and reduced maintenance and operating costs. “We look forward to establishing the AVT Reliability® reputation for added value in the US.” www.avtreliability.com

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Directory

April 2020

ENGINEERING UPDATE

T&D Corporation Mr Minoru Ito, European Sales Office, Gronauer Straße 1, 61194 Niddatal, Germany 0049 (0)6034 930970 europe.office@tandd.de www.tandd.com

Unit 3A, Whitworth Court, Manor Park, Runcorn WA7 1WA. Tel.: (0044)-330 002 0640, sales@odu-uk.co.uk www.odu-uk.co.uk

ECi Software Solutions

TR Fastenings LTD

Si One, St Ives Business Park, Parsons Green, St Ives, PE27 4AA +44 (0) 333 123 0333 www.eci.eu eu-sales@ecisolutions.com

Trifast House, Bellbrook Park, Uckfield, East Sussex, TN22 1QW Free phone: 08454 811 800 E-mail: sales@trfastenings.com www.trfastenings.com

Phoenix Mecano Ltd

Blackfast Chemicals Ltd

26 Faraday Road, Aylesbury, Buckinghamshire, HP19 8RY +44 (0)1296 611660 www.phoenix-mecano.co.uk

Unit 5 Russell House , Molesey Road, Walton-onThames, Surrey, KT12 3PE 0207 339 7370, sales@blackfast.com www.blackfast.com

Monitran

Ecopac (UK) Power Ltd

Monitran Ltd, Monitor House, 33 Hazlemere Road, Penn, HP10 8AD, UK T: +44 (0)1494 816569 E: info@monitran.com www.monitran.com

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ODU-UK LTD.

Unit 4, Ridgeway, Crendon Industrial Area, Long Crendon, Bucks, HP18 9BF Tel: +44 1844204420 www.ecopacpower.co.uk


ENGINEERING PDATE

Directory

April 2020

Foremost Electronics Ltd

Seepex UK Ltd.

14 Bluegate Business Park Great Bardfield, Essex CM7 4PZ TEL: +44 (0) 1371 811171 FAX: +44 (0) 1371 810933 WEB: www.4most.co.uk

3 Armtech Row Houndstone Business Park Yeovil, Somerset, BA22 8RW

HRS Heat Exchangers 0-12 Caxton Way Watford Business Park, Watford, Hertfordshire, WD18 8JY Email: info@uk.hrs-he.com Tel: +44 (0)1923 232 335

T +44 1935 472376 sales.uk@seepex.com www.seepex.com

Ilapak Ltd 29 Riverside Way Uxbridge UB8 2YF

1 Brownfields Court Welwyn Garden City Hertfordshire AL7 1AJ

BÜLTE GmbH Kunststofferzeugnisse Carl-Sonnenschein-Straße 22 D-59348 Lüdinghausen – Germany Phone: (+49) 02591 / 91 94 – 0 info@bulte.de www.bulte.com

Wood Automated Systems UK (ATG – Systems) Tenter Road, Moulton Park Industrial Estate Northampton, NN3 6AX +44 (0)7827 327231 Tim.Bednall@woodplc.com www.the-atg.com

Lascar Electronics Ltd UK Module House Whiteparish, Wiltshire SP5 2SJ +44 (0)1794 884 567 sales@lascar.co.uk www.lascarelectronics.com

Rotech Machines Limited

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