Engineering Update - December 2021

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PDATE December 2021

How MetLase expertise and fast-make tooling and fixturing methodologies are deployed cross-sector to solve your manufacturing and engineering challenges Also featured this issue:


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Power Security & Back-Up

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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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Instruments Ltd

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Taylor Owens 01843 267 690

December 2021

At the forefront of digital marketing, Engineering Update strives to bring its readers the latest in industrial engineering, in a format that provides the best usability and ease of use for it’s readers.

Editorial Assistant

Laura Sharpe 01843 448 443

Sales Director

Tim Johnston 01843 448 443

Publication Director

Kane Weller 01843 580 460

Publishing House

Jet Digital Media Ltd, Suite 1 & 2 Spratling Court Offices, Spratling Street, Manston, Kent CT12 5AN

December 2021 ENGINEERING

And that’s nearly a wrap – DK Holdings reflects on a successful 2021 2021 has been another successful year for DK Holdings Limited, a global market leader in Diamond Tooling solutions, manufacturing innovative tools and accessories for the Engineering industry from their modern ISO accredited production facilities in the heart of Kent since 1959. DK Holdings is now very much looking ahead to 2022, with their first trade show of the year being JEC WORLD in Paris from the 8th – 10th March. If you are heading to France, visit the dedicated team of sales engineers at stand F70 in hall 5! A Diamond Tooling solution for your organisation could be closer than you think! Contact details: DK Holdings Limited Station Approach Staplehurst TN12 0QN Telephone: 01580 891662 Email: Web: Twitter: @DK_Holdings



John Emptage, Sales & Marketing Manager “It was great to exhibit at trade shows again in 2021 including the Advanced Engineering show, held in November at the NEC, which was hugely successful for us". “We had a large number of leads across the two days and it was good to see so many people face-to-face and connect with our customers old and new again”. “We continuously strive to support our customers in reducing the environmental impact of their manufacturing processes. So it was a great opportunity for us to tell visitors about our Strip and Replate service, something we have offered for decades. By using this service, our customers are able to reuse and recycle their tooling which not only reduces the overall cost but also minimises waste.” “Another highlight for us was the relaunch of the DK website. The marketing team developed our new look online presence ( for the past year and we went live just prior to Advanced Engineering in November and have had very positive feedback so far. Not only can customers find details of our products and services but also the latest news. Online versions of our handy product guides are available. In addition, we have aligned our branding across our social media channels. Make sure you have a peruse and let us know what you think”

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Lamonde Automation Limited Quality Products: Expert Advice

December 2021 ENGINEERING


VITAL POWER PROVIDES BESPOKE POWER UPGRADE FOR ROAD SURFACING PLANT IN GLOUCESTERSHIRE Vital Power are critical power specialists, providing expert solutions for industrial diesel generators and UPS systems nationwide. On this power upgrade project, Vital Power supplied, installed, and commissioned a brand-new Atlas Copco QIS 335 industrial diesel generator at BituChem, road surfacing specialists in Gloucestershire. reliable power can be supplied for the foreseeable future. The QIS 335 comes complete with a robust Volvo TAD1341GE engine, Mecc Alte alternator & DSE 7320 control panel. This machine was also specified with a long run fuel tank to allow more time between fuel fills. BituChem is now on a tailored 5-year service & maintenance plan with Vital Power, complete with 24/7/365 call out facility to further protect site moving forward. A spokesperson from BituChem explained how “everyone at Vital Power is very professional. We couldn’t be happier with the result, and I couldn’t fault the work at all, we’re really pleased”. BituChem are reliant on power supplied from a generator to run a certain plant on site. The site’s existing generator was a 25-year-old, 300kVA diesel generator, which whilst still running, had started to show serious signs of old age. BituChem decided to look into replacing the generator for more reliable power on site, whilst future proofing their operations at the same time. Long-term trusted supply partner of BituChem, HFT Forklifts were asked to source an industrial diesel generator for the plant in Gloucestershire, in which Vital Power was approached to provide expert advice and assistance with the application. The main project goals were to find a solution that offered increased fuel efficiency, more power delivery and provided a long-term solution to powering the plant on site. Issues such as motor starts & low loading were key factors that BituChem wanted to consider, so choosing the correct power node was a critical element in this upgrade.


Following a period of load monitoring on site and considering the various motor starts involved during plant start up, Vital Power determined that a QIS 335 (300kVA prime/ 330kVA standby) was the appropriate generator for the task. As official UK dealers of the Atlas Copco QIS industrial diesel generator range, Vital Power then supplied, electrically installed, and commissioned an Atlas Copco QIS 335 on site to ensure

With UK nationwide coverage, 24/7/365 support, and highly trained in-house engineers, Vital Power is the UKs leading power solutions partner. Contact Vital Power to find out more: Tel: +44 (0)3339 960 886 Email: Web: Your Power Solutions Partner

Leaders in temperature measurement

Hand Held Instrumentation Heading 3

A selection of hand held instruments for many applications including a large range of digital thermometers, light level meter and a range of great value handheld sensors.

IR Industrial IR Medical Infrared Thermometers Thermometers

Pressure Manometers

Digital Light Meters


Temperature & Wood Moisture Meter Humidity Meter

Grain Moisture Meter Bognor Regis tel: +44 (0)1243 871280 Sheffield tel: +44 (0)1909 569446

December 2021 ENGINEERING


4Sight – take a different view on print, packaging & product inspection Vision solutions for industrial code printing have always been particularly difficult, especially with continuous inkjet. Similarly, automatically inspecting for packaging accuracy or for product quality is challenging in real world situations. Historically, therefore, these types of inspections have been carried out manually utilising valuable Operator and QC resource and time. AutoCoding Systems launched 4Sight initially to inspect printed codes to ensure all products leaving the factory were printed with legible codes in the correct location. However, the application has recently been extended to include additional types of inspection to tackle the challenges of packaging and product inspection. The 4Sight solution has already received global interest, particularly from customers looking for an alternative to expensive OCR/ OCV products. 4Sight uses a different, focussed approach to inline print quality inspection which does not follow the usual OCR/OCV route of teaching fonts. By using our detailed understanding of coding equipment and the characteristics of what they print, AutoCoding Systems has been able to develop a product which is adaptable to differing requirements, putting the user at the core of what they deem to be acceptable print quality – considering factors such as printing technology, speed of line and processing time. For code inspection, the unique feature of 4Sight is Inspection Depth which gives users the choice to define the level of quality required for their inspection. The objective is to determine, with a high level of confidence, that the print is of adequate quality for the specific application. The user can decide


on the print quality tolerance thresholds to define what is considered a good read, bad read and poor read on a per product basis. The deeper the inspection depth, the greater the processing time, but even at the highest inspection depth with the lowest tolerances, delivering exceptional results both in terms of quality and accuracy, the speed of inspection is faster and more reliable than conventional OCR. The latest version of 4Sight delivers even more flexibility and functionality than its predecessor. Additional inspection types include Barcode Inspection, Packaging Verification, 3D Dimensioning and Classify. 4Sight is capable of reading both 1D and 2D codes; barcode inspections can be combined with print inspection and packaging verification. With packaging verification, artwork comparisons can be carried out against a reference image to verify that the product packaging is correct. This type of inspection can also be configured with permitted rotation simplifying the process of inspecting circular products such as pots, bottles and tins. 3D Dimensioning uses the SICK Trispector P 3D camera to inspect product size, checking against reference dimensions and, therefore, volume. The quality and consistency of the top surface of the packaging can also be checked for issues such as damaged seals or open flaps. Classify allows users to compare image histograms against reference images and selects the best match. This type of inspection can be used for checking the quality of actual products, for example, toppings on biscuits or evenness of bake on crumpets, bread, biscuits etc. For increased versatility, multiple inspections

can take place simultaneously combining up to 8 different inspections across a range of up to 4 cameras. This allows users to set up multiple inspections in one configuration, looking at different objects in a specific field of view, each with their own region of interest. With three different set-up options; standalone, printer-led or integrated into a code deployment solution; even greater flexibility is offered. The newly enhanced HMI offers users easy-to-navigate, clear drop-down menus, with explanatory descriptions where relevant. The step-bystep Wizards ensure that new users, with the relevant permissions, can create new inspection configurations or load existing inspection configurations with ease. Managing Director, Mike Hughes, stated, “The 4Sight product is a game-changer when it comes to automatic print inspection. Many companies veer away from automatic print inspection because historically it’s been expensive, unreliable and complicated to set-up. 4Sight alleviates these fears by offering a viable alternative to OCR/OCV methodology.”


The AZM150 solenoid interlock can be combined with three different actuators for different installation situations: a straight actuator for sliding doors, an angled actuator for large revolving doors and a movable actuator for smaller revolving doors. One of the plus points of the interlock is the rotating actuator head which can be locked simply by putting the lid on rather than a screw fitting. The rotating actuator head has two feeder slots to enable a range of installation positions and approach options. This makes the interlock really flexible to use. The AZM150 is an electromechanical design which can be combined with high safety standards. The interlock comes with a low coding level as standard but is also available with an optional high coding level. The benefit for users: In accordance with ISO 14119, a higher coding requires fewer measures to prevent the bypassing of locking mechanisms, such as fitting out of range or in a concealed position. Schmersal is the only manufacturer which can offer electromechanical safety switches and solenoid interlocks with high coding levels. Scan the QR code to see the AZM150 in action or visit our website for more information.

SCHMERSAL | Enigma Business Park Malvern, Worcestershire, WR14 1GL

December 2021 ENGINEERING


How the Smart Factory becomes reality According to the latest Global Smart Factory Market Report and Forecast, 2021 – 2027 the worldwide Smart Factory market is expected to reach $138 billion by 2027, rising 10% each year.

SCIO’s cutting-edge solutions for autonomous material handling in intra-logistics and production.

In fact, it is rapidly becoming clear that successful adoption of smart factory practices and strategies may be the determining factor between the winners and losers in tomorrow’s world of manufacturing industries. Smart, integrated, highly-automated plants will be a requirement to stay competitive, because without secure, efficient and flexible intra-logistics and production, you might end up pricing yourself out of the market due to higher production costs than your competitors. In the end, companies which are fastest to implement these processes will have significant advantages. Barriers, and how to get over them Managers often see obstacles to the Smart Factory, perhaps based on previous disappointing experiences when they tried isolated single solutions instead of aiming to integrate all production and intra-logistics in an overall system. As an example, a hundred robots may run perfectly on their own, but if you want to gain the cost benefits you are seeking they all need to be seamlessly integrated and coordinated as a


complete continuous process. Only then, can they work smoothly together as part of a real Smart Factory. Putting it all together A true Smart Factory is a completely integrated, highly-automated, manufacturing area that connects all intra-logistics and production steps using hardware and software that accesses a real time data base. This is only possible if you connect and integrate everything in one overall system covering parts & raw materials, logistics, machines and sub-processes. In this way, logistics and production are one unit, allowing you to see at one glance and in real-time where every single part and every single step in your production is. Real-time data and advanced automation make the factory an integrated unit of connected, digital, flexible and safe processes. This is vastly different from the traditional series of discrete, disconnected steps that most manufacturing plants are operating upon today. Making sense of the complexity Our company SCIO Automation has long experience as a strong and reliable

partner supporting Smart Factory implementations all over the world. Based on our deep experience we look at the client’s process landscape and make specific, targeted suggestions for automation solutions – both from our portfolio as well as third-party products. And if there isn’t a solution on the market, we are most likely able to innovate and develop customized products like our AGV-conversion kit for any commercially available tugger train on the market. The key is for managers to switch from a ‘hardware-only’ mindset to imagining overall integration of digitally-enabled process environments using software which connects everything in one system, based on real-time data. Employing this approach, which we’ve refined and proven widely, we are making the Smart Factory of the future a reality today. For more information visit


Series 35X


IS THE OPTION Pressure Ranges 0…0,3 to 0…1000 bar Accuracy ±0,05 %FS

Total Error Band ±0,1 %FS @ -10…80 °C Interfaces RS485, 4…20 mA, 0…10 V Operational Temperature Range -40…120 °C

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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: |


December 2021 ENGINEERING

We have had another interesting, varied and busy year with a wide variety of projects successfully delivered to customers across a wide range of manufacturing industries. We have many years of working with suppliers to the automotive industry as well as with the permanent marking of components and parts for traceability and tracking purposes. One such project this year was to design and build a machine to laser mark tamperproof labels for part identification of components for a client in the automotive racing industry. In support of critical industries, we engineered a machine for a new client to automate the production of straps for face masks. We are now working on new projects with this client focusing on process automation, increasing productivity, improving standardisation and ensuring consistency. A second project requirement due to the COVID pandemic was the build of a repeat machine of one produced some 15 years ago for Intersurgical’s plant in Lithuania. Intersurgical is a global designer, manufacturer and supplier of a wide range of highquality medical devices for respiratory support. TF Automation revisited the original design and have basically produced the same machine to support the existing one, using the latest technology to laser mark the manufacturer’s logo and product reference on their Hydroguard Mini medical oxygen filters. We were delighted this year to launch our newly updated website, focusing on the engineering and manufacturing of bespoke special purpose machinery. The revamped site focusses on the company’s capabilities and expertise in a wide range of disciplines from process automation, robotics, laser marking and assembly and testing. An important new area on the site, highlighting TF’s vast experience, is Industries, which identifies the main sectors the company has supplied to for many years, including Automotive, Aerospace, Medical and Industrial. To find out more or to discuss your next automation project with our design team, contact us on 01274 308005 or or visit our website





ULTRASONIC THICKNESS GAUGE WITH HIGH TEMPERATURE PROBE The Cygnus 4+ General Purpose thickness gauge is a light, tough multi-mode thickness gauge. It features a sunlight readable display with Live A-scan, intuitive menu and sequential data logging for easy reporting and analysis. Used with Cygnus High Temperature Probe, the Cygnus 4+ can measure remaining wall thickness of high-temperature, in-service assets without shutdown or isolation.






...plant maintenance, marine structures, ship inspections, oil and gas facilities, offshore platforms, wind farms, metals protected by thick/special coatings (e.g. 3 LPE and 3 LPP). Safe operation in Explosive Atmospheres: Class I, Division 2, Group D Locations only, as defined in NFPA 70, Article 500.


December 2021 ENGINEERING


How Horizontal Innovation enhances your business agility What can seem like a daunting problem in your business can sometimes be simply resolved by transferring technology from another sector - but accessing and transferring can be difficult. MetLase is experienced in this horizontal innovation transfer.


ENGINEERING PDATE December 2021 In one of the most disruptive years in manufacturing, some businesses have embraced and accelerated their digital journeys while others were required to put digital transformation on hold and are now playing catch-up. In both of these cases, businesses can benefit from MatLase’s approach. MetLase, a joint venture between Unipart and Rolls-Royce, explains how horizontal innovation could be

the key to unlocking potential growth opportunities to bring emerging businesses out of the COVID-19 pandemic stronger and more agile to create competitive advantage to the manufacturing industry. With foundations based on horizontal innovation, MetLase draws on the heritage of both parent companies in aerospace and automotive. The vision, to take expertise in fast-make tooling and fixturing methodologies cross-sector to rapidly solve some of industries greatest challenges. Breaking down your current restrictions The UK is recognised for its creativity, research, and innovation, but often technologies or processes can get locked into one sector or industry. MetLase offers digital manufacturing solutions which can be embedded in your manufacturing processes to standardise for consistent and accelerated quality and delivery. By sharing best practice crosssector, MetLase wants to break down barriers to enable innovations to be used where they are needed, and not just in the sector in which they are created. The key to success “The power of a true cross-sector solutions provider like MetLase is the visibility of the engineering challenges and how we have solved them across the sectors we serve. Combined with a highly skilled and knowledgeable team, this mix accelerates horizontal innovation, allowing us to solve the complex manufacturing challenges that our clients pose” explains Dr Stewart Lowth, Product Development and Innovation Manager at MetLase

Stewart continued, “This horizontal innovation is especially evident in our digital platform, where inspiration from highly connected and robust consumer electronics has been applied to industrial measurement. In one example, “smart-phone” style sensors were used to replace a manual measurement process. We looked beyond traditional industrial sensing and found a synergistic technology that matched the accuracy and cost requirements of our client, predicting a time saving of up to 45%. MetLase has continued to adopt, diversify, and develop Industry 4.0 technologies to drastically improve the performance of their fast-make tooling and fixturing. Founded on a premise of horizontal Innovation, MetLase parent companies joined forces with a mission to adapt our advanced aerospace-grade fixtureing technologies to the production challenges of other industries. Beneficially, this mandate also allowed MetLase to level the learning from these other industries back into the aerospace sector, addressing the challenges they faced around lowering costs and increasing productivity. Lowth concluded: “We believe we have an engineering team experience, as well as expertise across multiple sectors – knowledge and capability needed to deliver a solution for every problem imaginable. “So, we invite industry to challenge us with your manufacturing problems and let us deliver the solution.”


December 2021 ENGINEERING


ALL IN THE DETAIL Here, Mark Cattle, Director at Prima Tooling, provides an update on what the company delivers as part of the production process for all of the tooling it manufactures. 'Precision has always been, and continues to be, one of the factors that drive our manufacturing process'.


utting tool manufacturing demands ever increasing quality, and more than ever Prima Tooling continues to deliver the detail as Mark Cattle explains: “We have invested heavily over the past nine years in FeatureCAM software so that the precision of our tooling starts right from the beginning. “FeatureCAM is renowned in the milling world. However, we ensure that by having the latest version for more 5-axis functionality, as well as added control and simulation capabilities, means our tool designs enable us to produce consistently accurate tool bodies, that are balanced by design.” Measuring with precision and using state-of-theart measuring equipment from both Walter and Zoller, Prima Tooling's process for accurate production continues. Operated in a climate-controlled environment the data retrieved from its measuring machines feeds back directly into the grinding and erosion processes. “Pre-grinding, we have the best 'teammate' a Zoller Venturion presetting and measuring machine. And, by using both 'through light' and 'light' measuring the Walter Helicheck scans both newly manufactured and reserviced tools; capturing them in all of their geometry allowing us to quality control every tool through its entire


length and all of its angles. By measuring complex tools with the highest precision, down to the μm, our optimally set tools, achieve a longer tool life. One of the key performance factors on the tool design according to Prima is, in addition to the tool and the tool holding, is the balancing. Understanding its tooling application in 'the real world' the company appreciates the improvements required to enhance the customers manufacturing capability. With this in mind, and in line with its 'Defining the detail' ethos Heat Shrink Fit tooling is offered, fitting either new tools or for serviced contracts where the tool can removed before and refitted after servicing. Paul Wiggins, Director, explains: “We have a lot of customers reach out to us, as they are experiencing manufacturing problems and are looking for a different solution to their current tooling. One of the common issues we come across is tooling that isn't balanced correctly.” Ensuring that every tool is correctly balanced on the company’s Haimer machine means that all tooling, be it new or tooling that has come in for servicing, is returned to the customers in the 'most productive state possible'. “We invested in Haimer as the company understands the spindle speed of modern machine tools, which have increased on a continuous

basis in the last few years in order to achieve higher cutting volumes and machine in a profitable manner,” Paul Wiggins continues. “The increases have also raised the demands for the tools and holders used, because the higher spindle speeds make the effects of imbalance increasingly more noticeable. The consequences are vibrations, bad surface finish and shorter tool life. “Only the high-precision balancing of tools and tool holders can provide access to the complete capability of modern machine tools with regards to speed, cutting volume and the surface finish achieved. Balancing results in reduced vibrations, it reduces wear of the spindle and tool, as well as downtime. Resulting in a more robust process.” Mark Cattle concludes: “We have been manufacturing cutting tools for over 40 years, it would be easy to be stagnant in our manufacturing. However, we understand the need to develop our tooling to match the everchanging demands of the industries we work with, such as aerospace, automation, and general precision engineering. As well as the challenges of new materials such as composites and non ferrous metals.”


> 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)

Dixon Loading Arm & Accessories Quality components, efficient design

Overcome some of the typical issues and complications faced in the transfer of liquids with Dixon’s new loading arm. • • •

+44 (0)1772 323 529 • •

Configured and built to a customer’s specification Innovative counterbalance mechanism Easily maintained and adjusted

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December 2021 ENGINEERING

Multiple Brands, One Universal Attachment Chain No matter what brand of chain you use, Donghua’s Universal Attachment Chain will replace 99% of other manufacturer’s chain.


Bob Wellsbury, managing director of Donghua Limited, explains “Because our Universal Attachment Chain has the same critical dimensions as other manufacturers’ chain, it means distributors and end-users are no longer tied into using the same brand for their replacement Chain. It provides the UK market with a unique ‘one chain fits all’ solution’.” which helps ensure the attachment links engage with the sprockets together to eliminate undue stress which can cause fatigue failure of the attachments. By ensuring Attachment Chain is measured, pre-loaded and matched, Donghua’s Attachment Chain is ready to fit from the box, saving engineer’s valuable time. Add a 72 hour turnaround to quote and deliver readyto-fit, you can see why Donghua’s Attachment Chain has become a popular choice in the UK.

Chain manufacturers typically design and build attachments that are unique to their own brand of chain which makes it difficult to replace with a different make. However, Donghua, one of the world’s largest chain manufacturers, has designed a range of Attachment Chain that does just that.

Chain with little or no pre-load will have increased initial elongation before it levels off. To reduce the initial elongation which can often be found in ‘in-house’ built chain, Donghua’s Pre-loading machine pre-stretches their Attachment Chain to provide the best possible service and fatigue life.

With a 25,000 sq ft warehouse which stocks common builds of Attachment Chain and loose attachments, plus a network of UK Product Partners and Stockists who carry their own stock of chain, there’s plenty of Attachment Chain available ex-stock to supply the UK market.

Their Universal Attachment Chain has been designed specifically for the UK distribution market who supply end-users with chain from a range of manufacturers.

When two or more chains are used in parallel, such as in the food processing industry, precise positioning of chain is required. Donghua’s Matching Machine matches chain to within a close tolerance for correct tensioning

For more information about Donghua’s Attachment Chain visit their website at: attachment-chain or call the team on 01902 866200.

Donghua’s Universal Attachment Chain is built in the UK in a purpose-built, technical workshop at Donghua’s UK headquarters and distribution centre in the West Midlands. The facilities have been specifically developed to allow for quick turnaround of standard Attachment Chain and the design and build of bespoke Attachment Chain. The workshop boasts some impressive machinery including a Chain Length Measuring Machine which measures chain to within 10 microns per metre (that’s thinner than a human hair which is approximately 70 microns) and is capable of measuring up to five metres of chain at a time.










+44 (0) 1844 204420 Email us at

Ecopac (UK) Power Ltd, Unit 4, Ridgeway, Crendon Industrial Area, Long Crendon, Bucks, HP18 9BF

December 2021 ENGINEERING

Meltio is a disruptive Technology. It is changing the way we make metal parts. Using WP LMD a Directed Energy Deposition (DED) process that precisely stacks layers of weld beads when introduced into a laser generated melt pool. The Meltio ecosystem produces near net shape parts of extremely high density with minimal machining required reducing time, cost and waste. At the heart of the system is the Meltio print head. This patented design can operate within a standalone machine as the M450 or can be integrated with an industrial robot or CNC system to reach large part sizes or offer a complete hybrid manufacturing system. You can turn any machine tool into a hybrid manufacturing system with no inherent size constraints, bringing new capabilities to a wide range of industries and applications. As an open material system Meltio is capable of producing parts in a wide range of materials including steel, titanium and Inconel from off the shelf stockists makes the system lost cost and safe to run. Low Acquisition Cost. Low Running Cost. High ROI. Safe. Reliable. Simple. An example of how Meltio's cutting edge technology allows 3D printing parts with unparalleled geometry freedom! Engine manifolds, used to guide gases from engine to exhaust, need to be optimised continuously to achieve the highest performance possible. Meltio’s LMD ( Laser Metal Deposition) process enables smooth walls on large components while avoiding internal support structures by using 5axis. It also allows avoiding multiple welds and complex manual setups, perfect for the low volumes of motorsport production quantities. 3DGBIRE aims to provide a 360-degree service and offer personalised consultations, application design consultations, advanced AM training, lifetime technical support and a print bureau service to support in peak times, to enable you and your business to get the most from these groundbreaking technologies.



T +49 2961 7405-0

Made in Germany

Your Specialist for



© REMBE® | All rights reserved

Consulting. Engineering. Products. Service.

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

December 2021 ENGINEERING


Automated Parcel Consolidation Saves 80% Storage Space The automation of the process from good to person picking and buffer storage consolidation is making it easier to meet customer demand. Kardex customer Hella is a logistics service provider with long-standing experience in the automotive industry. They ship more than 2,000 orders to global customers every day and found that storing these orders until it was time to ship the stock out took up a lot of space. Traditionally they used a manual processes of loading cartons onto pallets and storing them until needed, but optimisation for leaner processes was required so they investigated ways to increase ergonomics, reduce sort and search times, and minimise walking distances. They made the decision to purchase a six-meter high Kardex Vertical Buffer Module LR 35 as it was the most efficient and economical solution to meet all their requirements now, whilst enabling future growth. The LR35 is utilised as a consolidation buffer for customer orders awaiting shipment and uses conveyor technology, so they are now able to transport various sized cartons automatically. Once a truck has arrived, a complete retrieval list for the relevant cartons starts. The cartons are pre-sorted by size and weight and ordered and are delivered via two access openings. Employees scan the cartons and move them onto a pallet. “With the LR 35, we were able to save 80% of storage space and no longer face any capacity restrictions,“ says Raphael Heimann, Project Manager Intralogistics, Hella Distribution GmbH.


To learn more about how the LR35 can manage your order picking and consolidation requirements click here. Or contact Kardex on 01992 557237, email:

Protecting Your Plant Before

Rotech Motion Sensor’s can be used whenever information or monitoring of shaft rotation, position, direction, speed, slip etc is required! Rotech Motion Sensor’s can be used for indication, control, interlocking, protection, sequencing, alarm initiations and many more functions! Rotech Motion Sensor’s can be used wherever materials are transported or processed By conveyors, elevators, screws, mixers, etc!






RELIABILITY Tel : +44 (0)151 356 2322 Website: Fax: +44 (0)151 356 2437 Email:

Monitoring the world



ess space, more output is not surprisingly high on the ‘wish list’ for any forward thinking manufacturer and the ArcWorld standard systems available from YASKAWA are ideal for replacing, or supplementing manual welding required in metal manufacturing applications. These fully integrated systems offer the distinct advantage of being selfcontained, so it’s a bit like buying any machine tool, you choose the size of machine you need and a location to install it and away you go. The YASKAWA ArcWorld HS Micro and RS Mini systems are easy to install, operate and relocate in a small footprint of either 2.3 sq. metres for the Mini, or as little as 1.4 sq. metres for the Micro. Both systems offer the possibility for operators to double their output with up to half the preparation time, compared to manual welding. The Micro system is supplied complete with robot and controller and its hinged door opening provides lots of options even though it’s a very small, compact system. The Mini system has a revolving door and table, which again means maximum flexibility within a compact system. The systems are designed to allow quick changes of jigs, which is crucial in helping to reduce the all-important setup time and improving production output compared to conventional manual welding practices. Furthermore, improved operational consistency by never missing a weld and ensuring the same quality of weld at the end of the shift as at the start, also means reduced ‘spatter’ which improves the capacity for fettling. Both systems incorporate a MOTOMANAR900 robot with YRC1000 controller, a start / stop button panel and fume extraction hood. They also feature a platform and casing with dark green polycarbonate glare shield protection and CE-marking. The Yaskawa Motoman ArcWorld Micro and Mini robotic welding systems are pre-engineered, pre-assembled and shipped ready to weld and represent the latest generation of cost-effective automated solutions for welding applications. They can be configured with your choice of welding power source and are ready to mount your component tooling.

For more information click here.


ULTRA COMPACT, SELF CONTAINED ROBOT WELDING SYSTEMS Exploring the benefits of using robotic systems across a wider range of manufacturing applications has accelerated recently where investment in the most up-to-date systems is making a significant contribution to maximising efficiency. Welding applications are a good example and the availability of new, highly flexible, space-saving systems is helping manufacturers to integrate robotics into their welding and fabrication processes.


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December 2021 ENGINEERING


he Nichicon brand is known worldwide as a manufacturer of high-quality capacitors. However, their product range is expanding. This also applies to products available for purchase at TME. Today we are pleased to present the latest addition to our range. These are SLB series, miniature lithium-ion batteries from Nichicon.


Miniature lithium-ion batteries from Nichicon

Li-ion technology from watches to cars Lithium-ion (Li-ion) batteries are manufactured in a wide range of sizes, capacities, and shapes. They have gained popularity primarily due to their relatively low weight, high density (volume to capacity ratio) of stored energy and longevity. They are used not only in consumer devices (laptops, cameras, etc.) but also in the automotive industry. Lithium-ion batteries have their limitations, e.g. with regard to temperature, storage conditions as well as limited cycle life, but along with lithium polymer cells they are the most popular solution in the field of rechargeable energy sources. The most common li-ion battery format is 18650. In other words, a cylinder 18 mm in diameter and 65 mm high. These battery packs are used in, e.g., power tools and electric bicycles. Since the design of the electrodes is based on tightly wound strips of material coated with i.e. carbon and lithium salts, other battery shapes/ sizes are possible. They can be much smaller; offer increased safety with also increased cycle life in order to adapt to the requirements of modern equipment, e.g., energy-saving Bluetooth devices, remote sensors, IoT devices etc.


The Japanese giant launches an offer of compact energy sources. Nichicon batteries SLB03070LR351BS SLB08115L1401PM SLB12400L1511CV The shape of the SLB series resemble capacitors (including terminals adapted for THT mounting). They also have a compact size. The table below lists the specifications of these products, detailing their currently available sizes. The charge/discharge rate of the cells draws special attention. This rate is 20C (20 x C rate), which means a charge or discharge rate of up to 20 times the battery capacity divided by one hour - and therefore the SLB series can be charged literally in a few minutes. Due to the lower specific energy, these batteries are characterised by a nominal voltage of 2.4 V DC Symbol: Capacity: Diameter: Height: Max. Current: Service life:

SLB08115L1401PM 14mAH 8mm 11,5mm 280mA 10 000 cycles

In addition to the mentioned parameters, the SLB series has a temperature range from -30°C to 60°C - which allows them to be charged at very low temperature. The manufacturer emphasises that its new offering is primarily aimed at the growing segment of miniaturised IoT devices - although the batteries can also be used for RTC and memory backup. In the era of the development of energysaving systems, which today also include microcontrollers, the presented Nichicon solutions are a real alternative to larger power sources, also in wirelessly charged systems. Furthermore: the manufacturer points out that its products are designed to minimise the risk of spontaneous combustion or explosion. This applies to all rechargeable cells. Nichicon manufactures its systems in such a way as to minimise the likelihood of similar incidents - even if the cells are intentionally damaged. For detailed product information, check out the technical documentation available in the TME catalogue. We kindly encourage you to read on.

The original source of text:

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December 2021 ENGINEERING


Power loss protection can you afford not to have it?

Why power protection is a must for industrial SSDs When power is terminated before a shutdown notification is completed, an “unsafe shutdown occurs,” preventing data in the temporary buffers from being safely flushed onto the nonvolatile NAND. This causes data to be corrupted or lost, and may render the storage device unusable. Examples of unsafe shutdowns include unexpected power outages, accidental removal of the SSD from the computer, unplugging the storage device while power is still on, or battery power loss. Such occurrences can potentially damage a storage device and corrupt data unless there is an effective power loss protection (PLP) mechanism. SSDs are particularly vulnerable to


power-loss events. Unlike HDDs, SSDs do not have mechanical parts, so every component is electronic. The internal data management of an SSD involves many operations that occur in the background, and every power failure can mean undue interruption of those operations, which could affect drive performance. That’s not forgetting system downtime, engineering resource and associated costs for loss of revenue which all could be considerable. So what solutions are on offer in the market? ATP Introduces MCU-based PLP in Latest NVMe/SATA SSDs Taiwanese manufacturer ATP electronics has introduced the N600 Series M.2 2280 NVMe and A600 Series Serial ATA (SATA) SSDs, which feature a completely new design of the power loss protection (PLP) array.

The PLP utilizes a new power management IC (PMIC) and new firmware-programmable MCU (microcontroller unit). The new MCU design is integrated into ATP’s latest PLP technology, which allows the PLP array to perform intelligently in various temperatures, power glitches and charge states. In addition to the MCU-based PLP array, the M.2 2280 NVMe N600 Series modules combine the speed and performance of PCIe NVMe with the reliability and endurance features of 3D NAND flash, the high capacity of triple level flash (TLC), high-performance 8-channel controllers, and end-to-end data protection. So how does the MCU enhance the Power loss protection mechanism? The MCU intelligently monitors de-glitch power failure conditions


The following table illustrates the advantages of SSDs with MCU-based control compared with SSDs that do not: SSDs without MCU

SSDs with MCU

PLP capacitors need to discharge/reset before power-on

Immediate power-on initiated regardless of residual voltage on PLP capacitors

If power-off state is extremely short: • PLP might discharge incompletely • Controller reset might fail • SSD might not be recognized and will not be able to reboot

If the power-off state is extremely short: • No need for the PLP to discharge completely • MCU resets the controller • SSD can be recognized and will reboot correctly

SSD power on-off with/without MCU

and checks the health status of capacitors through the I2C interface, with the Polymer tantalum capacitors providing sufficient sustaining power for data cache flushing, if a surprise powerloss condition occurs.

In addition the microcontroller unit can keep detecting power failure conditions; for example, for a 2.5” SSD, if input voltage drops down to less than 4.0V for several consecutive milliseconds (de-glitch), the MCU will notify the controller to start cache flushing and at the same time, the capacitors will be activated to provide the sustaining power for cache flushing.

Getting under the cover of the SSDs we can see how this works in the diagram below;

Precise Control of Reset Signal Generation and Power Up/Down Sequences

Suppression of power-up inrush current according to customer request.

Input over-voltage protection to prevent damage to the SSD circuitry.

Fast Power On/Off Control

Prevents potential issues in the power up/down of the SSD.

Customization Options •

The new MCU-based design allows PLP capabilities to be tailor-fitted according to unique customer requirements, application-specific needs, or use cases.

ECC Engine / RAID Support •

Features and Benefits Enhanced Device Protection

Cuts the time required from power-off to re-power on the SSD.

Error detection and correction with redundant backup algorithm to eliminate the possibility of uncorrectable errors.

Better Data Integrity •

Input power noise de-glitch to prevent incorrect cache flushing caused by false triggers such as noisy or unstable host input voltage.

Under-charge/over-charge protection for hold-up power capacitors.

End-to-End Data Path Protection •

Prevents unauthorized access to data while it is being transferred from one storage device to another.

To sum up The new MCU-based design combines hardware and firmware solutions that safeguard data as well as the storage device for higher levels of integrity and reliability. ATP SSDs with MCU -based PLP include mSATA, 2.5” SSDs, M.2 2242/2280 and NVMe modules with both I-Temp and C-Temp support. ATP’s industrial memory and storage solutions undergo stringent testing and validation to meet the highreliability, high-performance and high-endurance requirements of mission-critical applications to deliver the best total cost of ownership (TCO) value. For more information on ATP’s MCU-based industrial flash storage products, contact Simms International.


December 2021 ENGINEERING


Optimum Flow Meter Accuracy Critical to Biofuel Production As the UK hosts the UN Conference on Climate Change, Titan Enterprises determines it a fitting time to report on the success of its long-term OEM customer, Green Fuels Limited. With decarbonisation, circular economy and sustainability hitting the top of the agenda around the world, Green Fuels advances biofuel technologies and joint ventures to achieve its contribution to the global net zero target. For over 13 years, Titan’s Oval Gear (OG) flow meters have been an intrinsic component within Green Fuels’ biodiesel plants converting bio waste into sustainable biofuels. Green Fuels’ award-winning research and pioneering process plants have powered buildings with sustainable fuel from used cooking oil, and most recently developed a process to convert fish oil and sewage sludge to biofuel. Jason Askey-Wood, Green Fuels’ UK Managing Director, commented: "Accuracy of measurement in our chemical processes is critical and Titan’s range of oval gear flowmeters provide just that. Simple, accurate and chemically resistant, Titan’s OG flow meters, with the addition of the Namur switch, were the ideal solution for precise batch dosing within a potentially hazardous environment.” Titan’s OG Series flow meters are designed to give reliable, high performance across a wide range of applications. Almost immune from the effects of varying liquid viscosity, density and temperature, the measurement performance of oval gear flowmeters improves as liquid viscosity increases. Titan offers intrinsically safe options for its Oval Gear measurement devices to ensure safe operation in potentially explosive atmospheres, such as those encountered in the chemical, biofuel and petrochemical industry. As well as being constructed from durable materials including Stainless Steel, Hastelloy and PEEK, a fully certified NAMUR Proximity Switch can be installed into the Oval


Gear flow meters. The NAMUR Proximity Switch is an intrinsically safe sensor specially designed for use in hazardous locations, enabling the OG series flow meters to deliver highly accurate flow measurement in explosive atmospheres. Jeremy Thorne, Titan Enterprises’ Operations Manager said: “Titan is privileged to play a cameo role in the technological advancements that Green Fuels is achieving within the sustainable fuels market. The OG flow measurement devices are ideal for use with aggressive chemicals, combining durable materials, robust design and proven technology to ensure they will have a long product life with reliable, accurate operation throughout.” Jason adds: “It’s an exciting time for Green Fuels with carbon reduction and

climate change at the top of the worlds’ agenda. We have seen a shift in our business in developing joint ventures with both advanced economies such as Oman and developing countries, working together to find sustainable fuel solutions for the Transport and Energy sectors as they look to decarbonise and reduce harmful emissions.” For further information on Titan’s oval gear flowmeters please visit To discuss an optimised flow measurement device for your OEM application please contact Titan Enterprises on +44 (0)1935 812790 or email For information about Green Fuels visit

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With intelligent and robust sensors, ifm offers solutions for the most demanding production environments found in the food industry. The intelligent MVQ valve sensor continuously monitors valve position and has diagnostic outputs for valve seat and stroke time errors. This prevents unpredictable, costly production downtime whilst maintaining product quality. The O6 Wet Line optical sensor and full-metal inductive sensors performance is uncompromised in high humidity environments. They are also resistant to high pressure water and chemical washdown. In combination with matching ecolink connectors, a guaranteed watertight connection, up to IP69K, makes sudden sensor failures due to moisture ingress a thing of the past! All of these sensors transmit their process and diagnostic data, digitally and without any conversion losses via IO-Link: avoiding any unwanted surprises. ifm – close to you!

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December 2021 ENGINEERING


Growth in Gasket and Sealing Sector Despite a Challenging Year Simon Winfield, Chairman of the UK Gasket & Sealing Association (UKGSA) and director of MacLellan Rubber, shares his reflections on 2021 and looks ahead to 2022. Despite the challenges of the last two years, UKGSA Members have continued to invest in and improve their businesses with many seeing growth in 2021 and forecasting further growth in 2022. Our Members service a diverse range of industries from Electronics to Utilities, Offshore Engineering to Construction and many more besides, and whilst many have seen declines in some sectors both at home and abroad, they have responded with new innovative products or by pursuing new markets. Social distancing measures impacted events earlier in the year, but our Annual Golf Day and Charity Dinner in September was well attended, attracting new guests to the event. Members welcomed catching up face to face and a number of companies have since joined the Association to benefit from networking with Members, technical support and collaborative opportunities. Sentiment during the year has varied between Members and, as you might expect for world-class manufacturing businesses, their approach to dealing with Brexit; new International Trade Deals, and more recently Supply Chain challenges that have seen raw material prices spiral by 20 – 50% or more and lead times expand beyond any normal expectations, has been robust and assertive. Many are positive about the opportunities that a UK uncoupled from the legislative bonds of Europe offer, others more concerned about competition from unregulated parts of the world undermining the quality of products or unfair, low cost sources devaluing core markets.


The industry as a whole is facing significant challenges, even beyond those of the financial crash, and these on their own threaten to undermine much of the advancement that our Members have achieved. In our most recent Members survey, their main concerns were: • • • • •

Shortages of Raw Material Monthly raw material price increases Sky rocketing shipping costs into and out of the UK Additional administration costs for exporting and importing Shipping delays

All of these issues weaken UK PLC as a supplier to world and, whilst everyone is in the same position and legislators will undoubtedly point to market forces, the risk for our Members is higher than for lower cost markets. It is of course not all bad news. UK PLC has a great reputation around the world and our Members are some

of the best innovative, high quality, customer focused manufacturers in the UK. They have continued to grow their businesses by focusing on and promoting those strengths worldwide, often working in partnership with other Members to provide a comprehensive package to their customers. 2022 doesn’t look to be offering much respite from these challenging times, but our Members see opportunities in any situation and we expect to be reporting on their further successes throughout the coming year. To find out more about the UKGSA visit our website:


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Mecmesin pioneers the world’s ultimate digital force gauge Mecmesin, a leading global designer and manufacturer of force, materials, and torque testing equipment, announced today the launch of its ground-breaking VFG digital force gauge. The VFG combines a highly responsive, capacitive 5” colour touchscreen with sophisticated force and torque measurement features driven by the power of Mecmesin’s Vector OS. Vector OS is the technology platform at the heart of the VFG enabling operators to customise the touchscreen interface, configure the tester to their requirements and analyse test results quickly in the field.

Established for over 40 years as a British manufacturer of force & torque test equipment, feedback from Mecmesin’s global customers across all industries has been instrumental in shaping the latest generation of digital force gauges. The VFG is packed full of innovative features and the intuitive touchscreen interface makes it easy to navigate. Just swipe or press and hold to access menus, toolbars, and settings. Available in 10 models with capacities ranging from 2.5 to 2500 N (0.5 to 550 lbf), the VFG caters for a diverse range of applications. Each gauge is highly accurate to ±0.1% of full-scale with readings displayed in all common measurement units; N, kN, mN, gf, kgf, lbf and ozf.


The VFG offers enhanced test features and data analysis capabilities: • •

Max and 1st Peak mode - registers the key values from the test Graphing mode - generates a live curve on the display to help identify critical events during the test Fast data-acquisition rate of 2,000 times per second - ensures sudden break-force readings are captured accurately 5 MHz internal sampling rate – detect events with greater precision Enhanced alarm configurations, including a ‘pre-alert’ warning, notifies operators if the test specimen is inside/outside tolerance Onboard statistics - stores displayed readings to a built-in memory for statistical analysis within the gauge Output data directly to a PC or

additional sensors to perform tests of all capacities for tension, compression and torsion – all with one gauge. It is powered by a fast-charge lithiumIon battery and is supplied in a robust carry case with a standard accessory kit plus a USB-C charging/data cable and USB-C to -A adapter. A removable rubber bumper is pre-fitted to protect against accidental damage if the gauge is dropped. A calibration certificate traceable to national standards is included at no extra charge - ensuring full compliance during external audits.

printer for further analysis Expandable external memory - saves all the raw data-points on a 32GB micro-SDHC card so you can test rapidly now and download results later

The VFG is constructed in a rugged aluminium housing, shaped to fit the hand and small enough to be comfortably used as a hand-held device. It is easily attachable to a motorised stand, thereby making it an affordable first step to more controlled tension and compression testing where optimum repeatability is required. Alternatively, this powerful digital force gauge can also be integrated as a key component into custom test rigs. The VFG also acts as a universal display for a selection of external ‘smart’ force and torque transducers, just ‘plug-and-play’. This means users can expand a VFG by connecting

Designed for the most demanding tension and compression measurement applications across a wide range of industries, the VFG is the ultimate force gauge for assessing product and material quality. “Mecmesin has been manufacturing digital force and torque gauges for over 30 years and the new VFG represents the perfect blend of performance and functionality combined with the very latest touch screen technology.”, said John Page, PPT Group Managing Director,” The VFG has clearly reset the bar in the industry and represent the best-in-class force and torque instrumentation on the market today.”


December 2021 ENGINEERING


New - UKAS Humidity & Temperature Calibration YOUNG CALIBRATION CONTINUES TO EXPAND ITS’ ISO/IEC 17025:2017 UKAS ACCREDITED CALIBRATION SERVICES, EMPHASISING THE MEDICAL, PHARMACEUTICAL, AND ENVIRONMENTAL INSTRUMENTATION SECTORS. RECENT UPGRADES INCLUDE THE ADDITION OF RELATIVE HUMIDITY, DEW POINT AND TEMPERATURE CALIBRATION SERVICES. UKAS Accredited Humidity and Dew Point Calibration were recently obtained to further support the pharmaceutical and environmental monitoring sectors. Young Calibration was approved for its extension to accredited scope for dew point temperature calibration from -20 to 70°C and relative humidity from 5 to 95% across a temperature range of 0 to 60°C. Customers can now benefit from complete system calibrations for indoor air quality meters (IQA), ventilator analysers, thermohygrometers and weather stations. UKAS Accredited Temperature Calibration is also a new addition to the accredited services available, specifically for the Calibration of resistive temperature probes, thermocouples, liquid baths and dry block calibrators. The laboratory covers a range from -40 to 200°C. System measurements are derived from multiple secondary reference probes and stirred liquid baths, with a CMC available from ± 0.05°C across the 0 to 200°C temperature range. Additional air probe calibrations can be undertaken in a controlled environment air chamber from 0 to 60°C, with a CMC from 0.19°C. UKAS Accredited Air Velocity Calibration services continue to be supplied by the UK’s leading accredited laboratory, with open-jet and enclosed Eiffel-design wind tunnels utilising Laser Doppler Anemometry. Young Calibration can conduct cross-correlation comparisons and blockage corrections for a range of air velocity devices. With complete system parameter calibrations for temperature, barometric pressure, differential pressure and humidity, Young Calibration is a solution for all anemometer types, including ultrasonic, hotwire thermoanemometers, rotating vane, rotating cup and pitot tube probes. The extensive laboratory offers an accredited velocity range of 0.05 to 80 m/s, with a measurement uncertainty as low as ±0.15%. UKAS Onsite Calibration covering mainland, offshore and remote outposts worldwide, calibrations are available for absolute and gauge pressure, relative humidity, temperature, frequency, resistance, voltage, current and temperature simulation. Young Calibration also offers traceable services with calibration engineers experienced in a range of instruments installed within production lines, manufacturing plants, medical service centres and test houses.


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December 2021 ENGINEERING


The Future of Tank Storage Here, Rikki Bhachu, StocExpo’s Head of Marketing, puts a spotlight on some of the mantras shared by the event’s Forty Under 40 and identifies some common themes and opinions shared by the rising young stars of the industry.

A Changing Industry Like all industries, the tank storage sector has been impacted by COVID-19 and Brexit. It has also had to adapt to megatrends such as globalisation, changing demographics, disruptive technologies, sustainability drives and geopolitical developments. It’s safe to say that the tank storage industry is going through an interesting time and it’s crucial that all those involved are equipped to take note and respond in order to be set up for success. Where better to seek advice for the future than with the current crop of tank storage rising stars? Let’s hear what they have to say.

Riza Altunergil, V.P. Business Development, Aager GmbH

“Innovation is the ability to see change as an opportunity not a threat.”

“Love what you do, yourself and others."

Josefien Groot, Co-founder and CEO, Qlayers B.V.

Praneel Lal, Marketing Manager, FUELCHIEF “The path to personal achievement is different for everyone, no path is straight and no path is without its cracks.” Luke Robbins, Commercial Director, North West Europe, CLH Group “Say yes to and get involved in as many different opportunities as you can.” Kartik Gala, CEO, Woodfield Systems International

Hear From the Forty “Dream big, think fast and act on it.” Syed Daniyal Hasan, Assistant Operational Planner, HTL-vtti "Every problem has a solution. One just needs to be creative enough to find it."


Caitlin Geisinger, Business Development Manager, Burns & McDonnell Engineering

“Nothing is impossible, the word itself says I'm possible.” A Final Word It is the next generation of tank storage professionals that will drive the industry forward to bigger and better things. We can’t rely on old ways of thinking. The industry is at its best when teams work hard together to change things for the better. StocExpo’s Forty under 40 will be celebrated at the event running from 8 – 10 March and they’re invited, as guests of honour, to a special Next Gen debate taking place during the show. For more information about the event and to register to attend, visit

8 - 10 March 2022 Ahoy, Rotterdam

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December 2021 ENGINEERING


ADVANCED SERVO MOTORS TRANSFORMING 3D METAL PRINTING The combination of the latest Servo Motor designs, extremely flexible robots and an eclectic mix of other advanced technologies are the key factors driving the rapid growth of new fabrication processes in manufacturing. Specifically, servo motors and robots are transforming additive applications and revolutionising the way prototypes, parts and products are made. Additive and subtractive manufacturing techniques are two prime examples which have provided fabricators with the efficiency and cost-savings helping them to remain competitive. Referred to as 3D printing, additive manufacturing (AM) is a non-traditional method that utilises digital design data to create solid three-dimensional objects by fusing materials, layer by layer, from the bottom up. Often making near-net-shape (NNS) parts with no waste, the use of AM for both basic and complex product designs continues to accelerate in industrial applications, such as automotive, aerospace, energy, medical, transportation and consumer products. On the contrary, the subtractive process entails removing sections from a block of material using highprecision cutting or machining to create a 3D product. Despite key differences, additive and subtractive processes are not always mutually exclusive because they can both be used to complement various stages of product development. For example, an early concept model or prototype is often created by the additive process and once that product is finalised larger batches may be required which opens the door to subtractive manufacturing. In time sensitive applications hybrid additive / subtractive techniques are being applied to repairing damaged or worn parts, or even creating quality parts with less lead time. The benefits of advanced Servo Motors is an important factor in the transformation of 3D printing applications, where dimensional precision and finish quality is key and it’s why end-users are turning to 3D printers with servo systems (as opposed to stepper motors) to ensure optimal motion control. Motion control specialist YASKAWA has developed its range of servo motors which includes the SIGMA-7 series which are proving to be transformative in helping fabricators overcome the common issues via printer boosting capabilities. For example, these robust motors incorporate vibration suppression filters as well as anti-resonance and notch filters which together ensure extremely smooth motion that can eliminate visually unpleasant stepped lines caused by stepper motor torque ripple. Also, the latest speed enhancements mean print speeds of 350mm/sec are possible, more than doubling the average speed of a 3D printer using a stepper motor. Similarly, a travel speed of up to 1500 mm/sec can be achieved using rotary or up to 5


metres/sec using linear servo technology. This extremely fast acceleration capability enables 3D print heads to be moved into their correct positions more rapidly removing the need to slow down the entire system to reach the desired finish quality. This means users can fabricate more parts per hour, without sacrificing quality. Automatic tuning on servo systems means users can independently perform their own custom-tuning so they can adapt to changes in the mechanics of a printer or variances in the process. Stepper motors don’t utilise position feedback, so it’s impossible to compensate for process changes or discrepancies in mechanics. Additional benefits of servo systems include absolute encoder feedback so users only need to perform a homing routine once resulting in increased uptime and cost savings. Systems with stepper motors lack this feature as they need to be ‘homed’ every time they are powered-up. Servo systems also incorporate feedback sensing whereas stepper motor systems do not. The extruder of a 3D printer can cause bottlenecks and jams in the printing process which if undetected, can ruin an entire batch. With over 22 million servo systems in the field Yaskawa has the experience and technical know-how in motion and control. The result: excellent performance and outstanding reliability. +44 (0) 1295 272755

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December 2021 ENGINEERING

Mecmesin VTG Tornado creates a storm Mecmesin announced today the launch of its ground-breaking VTG digital torque tester, combining a highly responsive, capacitive 5” colour touchscreen with sophisticated torque measurement features driven by the power of Mecmesin’s Vector OS. The VTG Tornado is packed full of innovative features, accessible via an intuitive touchscreen interface that sets it apart from other torque testers. It is easy to navigate, just swipe or pressand-hold to access menus, toolbars, and settings. Vector OS is the technology platform at the heart of the VTG Tornado enabling operators to customise the touchscreen interface, configure the tester to their requirements and analyse test results quickly in the field.

Benefits of dual zone display Representing a major step forward in portable torque testing, the VTG Tornado boasts an array of advanced capabilities. It includes a dual zone display with the upper zone clearly showing the peak readings in, and other common units of measurement. The lower zone provides a live graphical plot of the torque applied so that critical events can be easily identified. For example, when testing plastic closures the key parameters, such as the release torque, bridge-breaking of a TE band and strip torque, are all clearly shown. Alternatively, the lower zone can be allocated to a statistical overview, which calculates the Max, Min, Average and Standard Deviation from the peak readings captured and stored in the VTG’s memory. A configurable first-peak function, coupled with the standard maximum reading, ensures that both the initial slip torque and the secondary break torque are captured. This is particularly valuable when measuring the performance of plastic and metal tamper-evident closures (e.g., ROPP), where a maximum reading alone is insufficient to determine both characteristics. Individual results can be transmitted immediately via RS232 to a PC or printer for analysis. Additionally, an internal memory of over 500 peak results is also available for mass storage when batch testing. An external SD memory card captures all the individual data-points for each test in .csv format so that they can be exported to Excel and other software packages.

Built-in safeguards The VTG Tornado also features a configurable alarm setting to alert an operator with red & green lights during testing when the torque reading falls within or outside the tolerance limit.




Ideal for use in a range of industries

To avoid the risk of operators inadvertently changing units of measurement or the operating mode, there is a password-protected lock function. This is particularly useful when the instrument is being used over several shifts by operators of differing skill levels.

Designed to meet the demands of testing from applications as diverse as the low-level torques associated with small rotary knobs and controls through to actuation torques of medical devices and release torques of packaging caps and closures, the VTG Tornado is the ultimate digital torque tester.

Equally at home in the laboratory or at the point of production, the compact and portable VTG Tornado features a tough, water-resistant casing (rated to IP54), fabricated in non-painted polypropylene, making it suitable for use in pharmaceutical environments. Four models are available with capacities ranging from 1.5N.m for delicate assessments, to the 3N.m, 6N.m and 10N.m versions for increasingly robust applications. A calibration certificate traceable to national standards is included at no extra charge - ensuring full compliance during external audits.

“Mecmesin has been manufacturing digital torque testers for over 30 years and the new VTG Tornado represents the perfect blend of performance and functionality combined with the very latest touch screen technology.”, said John Page, PPT Group Managing Director,” The VTG Tornado has clearly reset the bar in the industry and represents the best-in-class torque instrumentation on the market today.”


December 2021 ENGINEERING


10 MILLION MATING CYCLES With GAME-CHANGING QUICK-CHANGE HEAD Save time and money! In areas with a high degree of automation and short cycle times, speed is of the essence.

This extends the potential service life of the connector and the quick-change head – from a minimum of 100,000 mating cycles to a maximum With maximum failure protection and numerous of 10 million mating cycles. transmission variants, the ODU-MAC® Silver-Line is specifially designed for automatic docking. Thanks to the ODU SPRINGTAC® contact technology, the Silver-Line also offers excellent Now, with the addition of a quick-change head, this vibration resistance and the modular connectors connector range also becomes a potential game- are characterized by a compact and sturdy universal changer. design. With the ODU-MAC® quick-change head, you can save valuable time and simultaneously extend your connector’s service life. With just two screws, the interchangeable part of the connector can be easily replaced, making it ready for use again in a matter of seconds.

Depending on your requirements, you can choose from seven different docking frames and adjust the length as needed. Then, simply assemble these with the desired modules – our configurator makes this easy – for more information click here

ODU UK Ltd. The cable assembly on the base part remains Phone: 0330 002 0640 unchanged as the exchanged part is removed from e-mail: the front. 44|

Weidmiiller More productivity in your workplace with our THM MultiMark printer Let’s Connect

MultiMark: the smart all-in-one solution In Weidmüller, you have a trusted and reliable partner with years of experience in cable preparation, processing and systemised marking. Our THM thermal transfer printer integrates cutting and perforation tasks into the printing process; it can divide endless materials into arbitrary lengths. The result is a noticeably simpler production of custom cuts with a respective inscription assignment. Using the Mulitmark printer, you reduce the potential sources of error with complete data consistency. You will streamline timeconsuming work processes and increase your productivity.

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December 2021 ENGINEERING

ABB’s Robot Podcast returns for Season Two, exploring the world of robotics and automation Weekly panel of experts from industry, media and academia look at the cutting edge of robotics, analysing how advances in automation are benefitting society and businesses, and what the future holds Following a well-received first season, The Robot Podcast from ABB returns for Season Two with a wide-ranging exploration of the world of robotics and their benefits to society and industry. The new season kicks off with Episode One on November 17th and looks at how everyday technologies have evolved over the last ten years; how robotics and automation will revolutionize the decade to come; and how AI and robotics can be an accelerator for industries worldwide. Across six entertaining episodes, a wide variety of societally relevant topics will



The ABB Robot Podcast Release Schedule



Release Date


2021 – The Dawning of a Transformative Decade



Sustainable Construction



Robotics in Education



Digital Twinning



The Retail Revolution



Megamix (Season Highlights)


be discussed by the panel of assembled experts and commentators. Robotics in construction and education; the game-changer that is digital twinning; and the current retail revolution lead by automation – The Robot Podcast shines a light on all these hot topics. Fran Scott, a regular contributor to the BBC and Channel 4 in the UK, returns as host. Fran said: “It’s great to be back presenting another season of The Robot Podcast. Over the next six weeks, myself and a team of experts will investigate the cutting edge of robotics and automation, as well as what it means for us and the way we live our lives. From major changes in the way we shop, to our search for sustainable solutions;

a shifting workforce to the increase in digital simulations – we’ll explore it all in a way that makes sense to our growing gang of listeners.” Subscribe now to The Robot Podcast wherever you get your podcasts, or via and podcasts/the-robot-podcast, so you never miss an episode. If you missed Season One, you can catch up on all previous episodes at the same link. The Robot Podcast is part of the ABB Decoded series of podcasts.

Reduce unscheduled shut downs, reduce maintenance costs and improve plant safety with our Valvescan Diagnostic Monitoring System. Our revolutionary system is an end-to-end solution that captures data from every valve operation, analyses it and provides targeted alerts on the valve health without any requirement for involvement from plant personnel or any potential impact on the asset real-time control integrity. It is a true IIoT solution for automated valves. This system is not only a pioneering development in valve monitoring, it is also; ● Cost effective and easy to install ● Works with all existing valve systems ● Enables data retrieval and transmission to the cloud ● Provides a ‘real time health’ check on the valve and alerts when performance drop off is detected

Contact us to find out more:

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December 2021 ENGINEERING


Telsonic Launch Telso®Terminal TT7 Digital Innovation For Ultrasonic Metal Welding Telsonic AG, recognised as a world leader in the development and manufacture of Ultrasonic Technology for welding, cutting, cleaning and screening, once again demonstrate their commitment to product development and innovation with the launch of the new Telso®Terminal TT7. This new system is set to revolutionise ultrasonic metal welding applications in a variety of areas, especially within the fast growing Electromobility Sector where there is an increasing demand for the highest levels of quality and process control in cable assembly, terminal assembly and battery production applications. The Telso®Terminal TT7 incorporates the latest version of Telsonic’s proven PowerWheel® welding technology which ensures maximum reliability and optimum process control for welding metal cable cross sections up to 200mm2. Additional benefits include the ability to change tools in under 5 minutes, thanks to the TT7’s new quick-change system. The Telso®Terminal TT7 also features standardised interfaces for digital networking and ease of integration into production systems. The Telso®Terminal TT7 will make its exhibition debut at Productronica, the World’s leading trade fair for Electronics Development and Production, being held between the 16th and 19th November 2021 in Munich. Telsonic AG can be found on stand B4.319 where representatives will be happy to explain the benefits of the new technology and also discuss specific applications


(The new Telso®Terminal TT7 features a modern, innovative system design and multiple features which guarantee the highest levels of quality and performance for metal welding applications)

Tel: 01296 611660 Email: 26 Faraday Road, Aylesbury Buckinghamshire HP19 8RU

December 2021 ENGINEERING


Bringing flexibility to additive manufacturing

To provide engineers with more flexibility when using additive manufacturing systems, global engineering technologies company Renishaw has launched a new range of 3D printing machinery, which can be seen at Formnext on 16th to 19th November 2021. The RenAM 500S Flex, a single laser additive manufacturing (AM) machine and the RenAM 500Q Flex, a four laser AM machine, are variants of the RenAM 500 range. Both systems feature a simplified powder handling system, which is suited to manufacturers who must regularly swap build materials during production, such as research and development (R&D), pre-production or bureau environments. The range features the same industry leading optical, chamber and gas-flow designs as the RenAM 500 series and produces the same high-quality parts, but also provides additional flexibility when changing powders. The simplified, non-recirculating powder system enables manufacturers in R&D, pre-production or bureau environments to easily change between materials,


without compromising on part quality or build capacity. To avoid cross contamination, engineers can easily clean the system between powders by changing out hard to clean parts, rather than manufacturers having to invest in a new machine for each material test. Parts can also be swapped in again if the operator wants to retest the same material again, further reducing costs. “Manufacturers can quickly change powders in the RenAM 500S Flex and RenAM 500Q Flex in-house, giving them the flexibility they need to meet customer demand,” explained Lily Dixon, AM Project Manager at Renishaw. “Once the pre-production stage is complete, the common build environment allows any parameters to be directly transferred to a

RenAM 500Q with powder recirculation, without the need to retest the gas flow, chamber and optics. Manufacturers can also build full size parts on a small scale before mass production.” Dixon continued, “If the manufacturer no longer requires a flexible AM system, the Flex can even be converted into a recirculating machine — a feature that is unique to this system. Converting the system provides manufacturers with the highest productivity AM option for serial production.” To find out more about the benefits of RenAM 500S Flex and RenAM 500Q Flex, as well as other additive manufacturing equipment from Renishaw, visit the Renishaw website


Articulated Torsion Pipework In Hoses Rotating Cylinders

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pressure 1/4” to 40” and beyond. Vacuum to over 20,000psi. Stock and bespoke production. Unique bearing/seal design for longer life. ISO 9001 CE marked where applicable.


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Petrochemical Products

Fluid transfer products for upstream, downstream and refining • Hoses and hose assemblies • Hose & pipe fittings • No-spill couplings • Safety breakaway fittings • Blow-Out prevention couplings • Global inventory and locations • Sales and technical support • In-house engineering & design • Pressure Equipment Directive • ISO 9001 accredited

• Hydraulic Fracturing: Low Pressure Systems • Loading arms • Liquid level sensing • Zero emission valves

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December 2021 ENGINEERING


HARTING unveil multifunctional connector solution HARTING has responded to the trend towards miniaturisation across industries and sectors with the Han® 1A, which has been designed to take up less installation space. Thanks to the easy ‘click and mate’ design, the connector can be assembled in seconds without the need for any tools. Only two components are required to quickly assemble an IP20 solution, while additional housing elements or single wire seals can easily extend the degree of protection to IP65. The adaptable connection technology offers a secure solution whether you require rapid onsite installations using screw contacts or the pre-assembly of separate units with crimp contacts. Thanks to this flexible approach, it’s easy to create simple and efficient interfaces for use in 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. Constructed from lightweight yet durable polyamide plastic, the Han® 1A is extremely adaptable because it employs a modular system of inserts. This means it can integrate contacts for the delivery of data, signal and power. Modules for Cat. 5 or Cat. 6A are available for data transmission and up to 12 D-Sub contacts can be constructed for signal interfaces. For power applications, it can transmit a maximum of 16 amps and 400 volts. A shielded version is also available for areas which are particularly susceptible to interference. 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. To learn more about the Han® 1A, please visit or email


Often the little things provide the greatest benefits.

Han® 1A - Compact, robust and versatile.

The new standard for small, universal industrial connectors ■ Uses up to 30% less space: Compact connector for power that can be installed in the field ■ Flexible in use: Transmits data, signals and power with up to twelve contacts ■ Highly versatile: Modular system of inserts and accessories for indoor and outdoor applications (IP20 / IP65)

One Range. No Limits:

December 2021 ENGINEERING


FORTRESS RAISES FOOD SAFETY BAR WITH NEW RAPTOR X-RAY Food inspection specialist Fortress Technology Europe is paving the way for greater food safety and peace of mind for UK and European manufacturers, unveiling its new ‘best value to performance’ Raptor X-Ray.

Meeting retailer demands to increase detection of physical and harmful contaminants and mitigate costly brand recalls, the contaminant detection and checkweighing expert has engineered one of the most reliable, energy efficient, cost saving x-ray’s on the market. A single lane x-ray, available in two belt widths – 300mm and 400mm, the Raptor X-Ray reliably inspects and rejects packaged meat, cheese, chilled and confectionery products that present with metal, glass, wood, rubber, high density plastic, stone and calcified bones – a requirement imposed by most major food retailers today – at 100ppm.


Its full 1.7 metre enclosure maximises contaminant detection sensitivity and reliability by dissipating any heat created by the HMI and generator. All accomplished without using an energy-intensive air conditioning unit. Instead, the Raptor X-Ray pulls in fresh air and uses a more energy efficient fan generator to circulate air through the cabinet to regulate the filament temperature to support higher inspection reliability and x-ray tube stability. In 10 years, this air-flow technology has resulted in a zero tube failure rate. With filaments in an x-ray tube running hotter when more current is demanded, the Raptor typically runs at half voltage -

80kV. This helps to prevent overheating, Even after 24-hours of continuously inspecting food packs, operatives can place an un-gloved hand directly on the X-Ray generator and it is still cool to the touch. Designed to inspect all pack formats measuring 300mm by 400mm and 150mm deep, the Raptor X-Ray performs quality control tasks that the human eye would easily miss. Including monitoring fill levels, identifying ingredient clumps, broken or missing product and spotting damaged packaging.


All supermarket COPs ready to go Collating live OEE data and reporting results directly to QA and technical personnel , the advanced software enables fast, reliable and easy product set up. Increasing throughput and maximising detection of contaminants, while significantly reducing the number of false rejects. Uniquely, the Raptor X-Ray software also automatically incorporates every UK retailer COP that exists, integrating

of other food x-ray machines on the market-, the Raptor X-Ray’s solid framework reduces vibration, which affects the reliability and performance of x-ray tubes. High-density leadimpregnated acrylic sliding doors fully contain the radiography beams, protecting operatives and recording just 0.5 microsieverts (mSv) at 10cm from the surface of the unit. By far exceeding the set maximum dosage of 1 mSv. Sloping angles, magnetic x-ray curtains, a tool-less unclippable conveyor and IP69k sensors makes the Raptor X-Ray one of the easiest machines to sanitise.

into a testing software preprogrammed into the machine menu. Production operatives simply select the retailer and product being inspected on the 15-inch HMI home screen, run a calibration and QA test, pass the test packs through the x-ray, confirm rejection and remove from the reject bin. After pressing pass and signing the digital report, a report is instantly dispatched from the HMI over the company network directly to the technical manager’s inbox. In less than a minute, a new product application is ready to run.

CO2 reductions

With all the drive motors located within the mechanical side of the cabinet, it offers the very best ingress protection, safeguarding cables from getting wet and damaged. Rather than applying unhygienic labels to the machine where dust and debris can accumulate, all instructions and industry-approved markings are laser etched directly onto the steel cabinet.

integrated with upstream flow wrapping or packaging machines and controlled via the single Raptor X-Ray HMI.

The energy saving all-electric actuator plays a critical role in efficiently pushing rejects from overhead into a BRCapproved reject bin located to the side of the conveyor. The entire system only requires a maximum 10 amps to operate, compared to an air conditioned x-ray which typically needs 16 amps. Equating to approximately £4,000 power saving per machine, per year. Made from 6mm thick stainless steel sheeting - virtually double the thickness

Modular by design, the Raptor X-Ray can be integrated with the new Fortress Raptor Checkweigher to create a high performance combination inspection system. The electronics can also be fully


December 2021 ENGINEERING


Glass reactor accessories minimise downtime for vessel changeover Asynt has introduced two new innovative kits for scale-up laboratories looking to minimise downtime when changing between different glass reactor vessels. Offering the flexibility to work with glass reactors from different manufacturers, the new ReactoMate Quick-release Couplings allow you to securely attach or detach flexible hosing to your DN or KF glassware in just seconds – with or without tools. Manufactured from chemically resistant PEEK and stainlesssteel components, the high quality, chemically resistant and reliable kit is easy to use and puts minimal stress on your vessels glass joints. Built to operate from -20 to +120 °C, Asynt's robust new kit is proven to provide fast, reliable,

trouble-free connection / disconnection time after time.

materials, vessel set-up, automation and much more.

The ReactoMate Drain Manifold kit is designed to allow chemists to drain recirculating thermal fluid quickly and easily from their reactor vessel jackets, further minimising downtime between vessel swapping. Precision engineered with a high build quality, the ReactoMate Drain Manifold kit prevents fluid loss and contamination during the transition between vessels.

For further information on these new ReactoMate accessories please visit reactomate-quick-release-couplings/ or contact Asynt on +44-1638-781709 /

Proven in laboratories worldwide, Asynt offer a ReactoMate glass laboratory reactor system to suit almost every synthesis need from 100 ml - 30,000 ml plus. Designed by chemists for chemists, ReactoMate systems are optimised to your precise needs with a vast array of options available to alter vessel dimensions, vessel and lid


Asynt is a leading supplier of affordable products, consumables, and services for chemists in industry and academia. With a sales team of trained chemists, Asynt can draw upon their in-depth application knowledge to provide a high level of customer support for its DrySyn Heating Blocks, CondenSyn waterless condensers, Turn-Key solutions for Controlled Lab Reactors, Synthesis Tools, Evaporators, Temperature Control Systems, Vacuum Pumps and Lab Safety Equipment


Foremost increase industrial product range by increasing cooperation with IDEC A wide range of new products for machine builders, industrial control and safety Foremost Electronics, the engineeringled Essex based importer and specialist distributor of electromechanical components is continuing to grow its product offering into the industrial and automation markets with increased cooperation with IDEC, leaders in machine automation and safety. IDEC are putting greater focus on machine building, industrial control and safety which are markets already served by Foremost with a wide range complementary products such as enclosures and cable glands. Foremost’s position in the marketplace makes them an ideal partner to meet IDEC’s new goals. IDEC have recently introduced a number of key products and solutions, dedicated to industrial specialists allowing them to benefit from: time saving, safer working environments and simplified operations. The KW2D RFID READER smartly manages access, traceability and user authority for machines and devices or inspection history and can track entry/exit at work areas. The RFID technology solution is a perfect mix between compact technology and smart design to manage the mode of safe operation as specified in ISO 16090. By connecting with devices such as touch panels and PLCs, the RFID reader can be used for a wide variety of applications. The HT3P SAFETY COMMANDER™ can convert a tablet computer into an industrial HMI with safety functions such as a hardwired three-position enabling switch and E-stop. It is a lightweight, compact, and secure solution for teaching, programming and maintenance of robots and systems. It combines flexibility and safety while saving the costs of bespoke teaching pendants or permanent touch panels in each workplace. IDEC 3rd GENERATION EMERGENCY-STOP SWITCHES ensure the safety of personnel and machinery. Unlike traditional E-stop switches, IDEC X-series E-stops utilize exclusive “Safe Break Action” that turns the machine off if a failure occurs within the E-stop itself. CONTROL PANEL SWITCHES WITH PUSH-IN TERMINALS save assembly time and manufacturing costs. Wiring time can be reduced by up to 55% with IDEC PUSH-IN technology. Terminals equipped with this

technology are easy to wire, thanks to a tool-less yet safe and secure connection. This guarantees excellent contact safety, even in demanding applications, with vibration & shock resistance. Alan Vincent, Sales Director of Foremost, comments, “We are very pleased to increase our long-standing relationship with IDEC. Foremost already supply a wide range of products from Global brands to industrial and automation system builders placing us at the heart of the markets IDEC has targeted for growth and new products.” For more information on the expanded IDEC product range available from Foremost please visit call +44 (0)1371 811171 or email Foremost Electronics Ltd has provided over 30 years of service as a direct importer and specialist distributor of electro-mechanical components including switches, enclosures and accessories, connectors, control knobs, thermal fuses and optoelectronics. Foremost are also a supplier of joysticks and controllers for both OEM and stand-alone applications and have specialist online stores for IP Joysticks and Electric Vehicle Connectors and Accessories Foremost serve a wide number of diverse markets including industrial, instrumentation, audio/broadcast, rail, medical and education.


December 2021 ENGINEERING


Tebis 4.1 Intelligent Manufacturing Offers Automation, User-Friendliness and Practical Implementation Tebis 4.1 is a complete CAD/CAM system that’s designed for intelligent manufacturing. It enables CAD/CAM users to perform tasks in design, manufacturing preparation and NC programming in a single system with a high degree of automation. Tebis presented the most important new developments in CAD and CAM at the EMO in Milan (4th – 9th of October). Tebis is consistently moving forward with greater automation, userfriendliness and practical implementation. It has clearly demonstrated the many advantages of rule-based procedures by drawing on its proven internal expertise with both CAD and CAM applications. Major innovations Faster preparation for manufacturing: Highly automated, flexible preparation of CAM programming with parametric CAD templates Every imported data set has to go through a design process to be prepared for CAM programming. This usually takes many individual work steps: Bores for clamping systems must be placed, tilt axis systems defined, fill surfaces designed, blanks created, connection points for setups generated, clamping devices positioned and retract planes defined. These many individual steps can be automated in Tebis using parametric CAD templates. These templates can be extended as needed and modified to meet customer-specific requirements. Users can remain flexible: changes like the selection of a different clamping system can now be controlled directly and conveniently with the user parameters in the object tree.

As always in Tebis, all system components are fully accounted for in collision checking and simulation. Programming is incredibly easy. Tebis automatically generates NC code for any machine and supports all control-specific program structures. Easily machine surfaces with 5-axis barrel cutters Tebis also introduced a function that simplifies programming of multi-axis toolpaths for pre-finishing and finishing with circle-segment cutters, also known as “barrel cutters.” It automatically determines the best setting for manufacturing the machining area totally free of collisions. The function simultaneously calculates the optimal contact point at the surface boundary to ensure material removal over the largest possible area. Machining is indexed or 5-axis simultaneous: the user can independently specify the preferred variant or can leave the decision up to the system.

Optimal cutting conditions for roughing rotationally symmetrical parts A real plus for combined turning/milling operations: In addition to cylindrical parts, now tapered parts like screw conveyors can also be machined with high efficiency. The tool first roughs the part to the maximum possible depth with a low stepover and large downfeed in a single pass, then it machines the residual stock from bottom to top with a smaller cutting depth – precisely to the stock allowance. This procedure reduces tool wear and ensures a high material removal rate on the machine. Improved support for multi-channel machine tools This innovation is beneficial for manufacturing companies that rely on combined turning/milling operations, especially if the components to be machined have a high milling fraction: Tebis can now be used to program toolpaths for sequential processing on machines with multiple tool and component holders. The individual steps – like milling with a milling head or turret, stabilizing with a centering tip or clamping with a sub spindle – can be combined in any way. All tool and component holders are stored in the virtual Tebis process libraries, which can be interchanged quickly and flexibly during programming.


Tebis (UK) Ltd Tel: 02476 158178 Email:


Multi-position A-coding facilitates flexible, fault-free use Two-piece M12 panel mount connectors from binder, equipped with square-flange housings and multi-position, lockable A-coding, simplify secure sensor/actuator connections in factory automation and robotics. binder, a leading supplier of industrial circular connectors, offers various A-coded M12 connectors as part of its 763 product series, which are equipped with a square-flange housing for assembly. As a special feature, the multi-position A-coding supports variable cable installation. Also advantageous for flexible use: flange housing and contact carrier can be processed separately.

A-coded M12 connectors consisting of square-flange housing and contact carrier: users can position the coding nose in 45° increments, which facilitates secure, mating-fault-free installation at various angles Photo: binder

Background: the A-coding Industrial-grade, standardized M12 circular connectors with A-coding according to DIN EN 61076-2-101 are a well-established component of sensor and actuator systems in typical factory automation and robotics applications. Their coding, which serves to avoid mismating, ensures precise assignment of the pin and socket contacts in the process: A-coding generally stands for applications in signal transmission with DC voltage over 3 to 12 pins. The principle of partial assignment of the contacts ensures the plug-in compatibility of product variants with different but lower pin counts. Multi-position coding is advantageous, for example, if the installation has to be carried out at different angles due to the mounting conditions. At the field level of automation, both inside and outside the control cabinet, A-coded M12 signal connectors support efficient, cost-effective sensor/actuator communication in particular. Two-piece design simplifies the application The square-flange variants of the 763 series generally consist of two parts: the metal flange housing and a contact carrier. The latter is equipped with a lockable coding nose that can be rotated in 45° increments. The two-part design supports userfriendly, safe assembly in practice. Change of size made easy The 763 series includes M12 A signal connectors equipped with 4, 5 and 8 pins as well as single wires or solder

contacts. The single-wire version has a square housing 20 mm or 26 mm wide. In the variant with solder contacts, it measures 20 mm. The 26-mm square housing of the M12 single-wire version has the same drilling scheme as that of the M16 form factor. This allows users to switch between the design sizes without having to adapt existing housings, for example of field devices such as sensor/actuator boxes. Technical product details The rectangular-flange M12 connectors with multi-position, lockable A-coding are specified for a maximum wire gauge of 0.25 mm2 (AWG 24). In all 4-pin and 5-pin versions, the rated currents reach 4 A (3 A UL), 2 A (1,5 A UL) with 8. The rated voltages are 250 V (4-pin), 60 V (5-pin) and 30 V (8-pin). The corresponding rated impulse voltages are specified as 2500 V, 1500 V and 800 V, respectively. The connectors meet the density requirements – combined with suitable sealing but without a defined tightening torque – in accordance with protection degree IP69. They are designed for operating temperatures from -40 °C to +85 °C. About binder binder is a family-owned business that is shaped by traditional values. Based in Neckarsulm, Germany, it is one of the leading specialists in the area of circular connectors. binder has been synonymous with the highest quality since 1960. We work with 45 distribution partners on five continents and employ 1,800 staff worldwide. The binder group is comprised of the binder headquarters, 16 affiliated companies, two systems providers and an Innovation and Technology Centre. For more information, please contact: Binder UK Ltd. Unit D, ATA House Boundary Way Hemel Hempstead Hertfordshire HP2 7SS Telefon: +44 1442 257339 Telefax: +44 1442 239545


December 2021 ENGINEERING


Sneak Peek - Contrinex M12 & M18 Metal-Bodied Photoelectrics Launch at SPS Exhibition In a sneak peek of being announced at the upcoming SPS Exhibition in Hannover, Contrinex will launch metal-bodied M18 sized photoelectric sensors which feature the same exclusive ASIC technology as their plastic-bodied counterparts. Contrinex’s plastic-bodied ‘M18PA’ sensors have proved to be very popular because they combine industry-leading performance with great pricing, and these new robust metal-bodied ‘M18M’ sensors are also likely to continue the success. Available in a choice of sensing technologies, with best-in-class sensing distances at highly competitive prices, they offer Diffuse sensing (up to 1.2m range); Reflex (up to 7m); Through-beam (up to 30m); and high-performance Backgroundsuppression sensing (Up to 250mm distance). The M18 sensors will also be joined by smaller M12 metal-bodied sensors, the ‘M12M’ family, which will utilise the same technology in Diffuse, Reflex and Through-beam sensing options. Sharing Ecolab* approval with the plastic-bodied M18PA photoelectric sensors will enable the use of these sensors across a wide range of applications in the food and beverage sector. (*Ecolab approval is pending on the new M12M and M18M photosensors).


The additional robustness to mechanical shock and excessive vibration provided by the rugged chrome-plated brass (M12M) and stainless-steel (M18M) sensor housings can be utilised where required and work seamlessly alongside the plastic-bodied versions installed in less-demanding environments, like secondarypackaging. Shatter-resistant PMMA optics not only enable their use in food and beverage and harsh environments but also focus the optical sensing beam and are key to the sensor’s high performance. In line with Contrinex’s position as the manufacturer of the largest selection of sensors with IO-Link functionality, IO-Link is also offered as a no-cost option on the M12M and M18M sensors. The feature-rich IO-Link functionality provides real-time access to process data as well as user-configurable outputs, sensitivity adjustment, event flags, dual-channel operation and sensor-temperature measurement. Designed with the needs of OEMs and System Integrators in mind,

these new M12M and M18M metalbodied photoelectric sensors offer cost-effective, yet highly capable solutions across multiple industry sectors, together with ease of use and high reliability. PRODUCT ADVANTAGES • Robust & reliable in harsh environments • Chrome-plated brass (M12M) or stainless steel (M18M) metal housings • Resistant to washdown & process fluids • Shatter-resistant PMMA optics, lighter & tougher than glass • Focused beam • Exceptionally reliable detection • Preventative Maintenance alarm trigger • Long sensing ranges • Unrivalled price/performance ratio • -25°C to +65°C • IO-Link Ideal for Industry 4 Read more at, Click to download Contrinex’s C23PA & M18PA Series Photoelectric Sensor flyer, or Click to download Contrinex’s Product Overview brochure to find out more.


A safe choice: draw-wire mechanisms for encoders ifm electronic is now offering a range of draw-wire mechanisms that provide a simple, reliable and accurate way of measuring position and distance over long straight spans. Featuring robust construction that ensures reliable operation in demanding environments, even when the draw wire is subjected to continuous strain, the new E614xx mechanisms are suitable for use with almost any encoder that has a 58 mm synchro flange and a 6 mm shaft. Typical applications include monitoring the height of fork-lift truck forks, the extension of crane booms and the vertical position of trolleys in high-bay warehouses. Essentially, the wire-draw mechanisms comprise a housing containing a spool of wire cable, the end of which is attached to the target object. As the target moves, the spool rotates and this rotation is captured by the encoder that has been attached to the mechanism, allowing position of the target to be evaluated. Ifm draw wire encoders have high shock and vibration resistance thanks to their magnetic sensing principle and can be used in harsh environments where alternative technologies might struggle. ifm is currently offering the draw-wire mechanisms in four versions: E61439 which is suitable for cable spans up to 1.9 m with linearity of ±0.02%, E61440 for spans up to 2.4 m with linearity of ±0.1%, E61441 for spans up to 3 m with linearity of ±0.01% and E61442 for spans up to 5 m with a linearity of ±0.01%. Special versions for spans up to a maximum of 15 m can be supplied upon request. For more information please click here.


December 2021 ENGINEERING


Precise machining for smaller diameters Sandvik Coromant launches new grooving tools for lighter cutting action and cutting forces that aid vibration free machining, a rail insert seat for a stable and precise insert position for minimal insert movement. In addition, screw clamped tool holders ensure stability and high process security and inserts with high edge line quality increase tool life and surface quality. “Grooving can be a difficult technique to master,” said Angélica González, Product Manager of the CoroCut® Q platform at Sandvik Coromant. “Long overhangs, difficult chip evacuation and stuck chips are frequent problems when machining internal and face grooves. CoroCut® QI has been developed to tackle these challenges to help achieve optimal results. Besides this, most CoroCut® QI tools have internal coolant channels that deliver coolant directly to the cutting zone to enable efficient chip evacuation with minimum damage to the surface.

Leader in metal cutting, Sandvik Coromant, has launched CoroCut® QI, a range of internal and face grooving inserts designed for smaller diameters. Optimized to enable a lighter cutting action and reduced cutting forces, CoroCut® QI ensures high process security, reliable grooving operations and precise chip evacuation, resulting in high surface quality grooves. he addition of CoroCut® QI completes the CoroCut® Q platform, which already consists of CoroCut® QD for parting off and CoroCut® QF for secure face grooving. CoroCut® QI provides a comprehensive selection of optimized tools for numerous parting and grooving applications, designed specifically for smaller diameters. All inserts fit both internal and face grooving tool holders, making it easier for users to select the right tool. CoroCut® QI is divided into internal grooving and face grooving application areas and is an upgrade of the T-max Q-Cut® 151.3 program. The improved design allows for greater chip control, a 10% productivity increase, 20% improved tool life aided by tighter edge-rounding tolerances and internal coolant for both internal and face grooving tools. Key features of the CoroCut® QI include an optimized tip seat angle


“The smaller the groove, the harder it is to machine. To combat this difficulty, the CoroCut® QI inserts are specifically designed for small diameters that require great precision. For example, the minimum hole diameter for internal grooving is between 12 and 60 millimetres (mm) with a cutting depth of two and eleven millimetres. Face grooving inserts can be used in a first cut diameter between 16 and 102 mm, with a cutting depth of 5.5 to 20 mm.” The insert geometries vary from -GF, a ground sharp insert for internal grooving, -TF with direct pressed geometry for face grooving and internal grooving and turning, plus -RM, ideal for non-linear turning such as internal and face profiling. “CoroCut® QI is the upgrade from our previous grooving system,” continued González. “In fact, performance tests compared with competing tools have demonstrated better process security and chip evacuation for a higher quality surface finish.” To learn more about CoroCut® QI, visit the Sandvik Coromant Website here.


Process precision demonstrating repeatability that is unmatched by human workers. For instance, when properly calibrated, it’s possible for a six-axis industrial robot to achieve a position repeatability of 0.1 millimetres (mm) or better.

Another assessment where automation is beneficial is tensile testing, where the product is pulled and then monitored when it deforms or snaps to measure its resistance to breaking under tension. This is often used on metal alloys to discover how they perform under different loads. Tensile testing devices may be used as part of a quality control system or during material research when developing new alloys.

There are a number of production stages that can benefit from the precision of automated equipment. For example, a torque controlled power screwdriver ensures each screw in the workpiece is turned to the exact same level of tightness, avoiding loose or overtightened screws.

Not only would these testing tasks be highly monotonous for human workers, but they would also take much longer to perform than an automated system. High performance motors can power an automated system to perform these mechanical tests repeatedly at a fast rate with no human intervention.

In addition, an automated dosing pump can supply the exact amount of materials, such as adhesives, lubricants or sealants, required to the target product area. As well as preventing waste and avoiding contamination of other product parts, being able to supply precise amounts helps meet the miniaturisation trend, aiding the assembly of products with ever decreasing sizes.

Superb motor systems

How motorised equipment aids testing and control in manufacturing PWC’s UK Manufacturing Operations Pulse Survey 2021 found almost half of UK manufacturers are prioritising robotic process automation over the next two years. Automated equipment can perform to exact requirements, making it inherently advantageous in testing and control. Here Dave Walsha, sales manager at drive system supplier EMS, looks at how reliable, high performance micromotors are achieving process precision. Developments in robotics have allowed automated equipment to become increasingly sophisticated, performing tasks with superior speed and accuracy. For instance, a hospital in Oxford found a surgical robot could perform an eye surgery with ten times more precision than a human surgeon alone. However, it’s not just the medical sector that can capitalise on the high accuracy of automated machines - manufacturers can reap the benefits too. Keeping control Meticulous testing Manufacturers who adopt automated production lines gain a high level of control over the assembly process, which minimises waste from defected goods and ensures customers consistently receive a high quality product. These benefits have contributed to the record high of 2.7 million industrial robots operating in factories around the world in 2020. Automated equipment can be digitally programmed to perform tasks to exact measurements,

along a motorised conveyor belt to a vision system.

However, the benefits of precise automated equipment aren’t restricted to product manufacturing, they’re also advantageous in testing. For example, an automated testing rig with a motorised locking mechanism can hold a product in place while it’s subjected to different tests. One of these tests could be scanning the product for defects, such as missing screws, damage or incorrect dimensions, by moving the rig

It’s important that automated industrial equipment are matched with advanced motor systems that deliver reliable power. The FAULHABER brushless motors are ideal for automated systems, as they provide a long life with a wide speed range. They also have a range of compatible motion controllers that create an advanced, programmable drive system with easy and accurate control that is simple to integrate into an automated system. Many manufacturers are focusing on automation in their future development plans. Motorised equipment bring high levels of accuracy and precision to production lines and testing facilities, ensuring only consistently high quality products reach customers.


December 2021 ENGINEERING


OEMSecrets reveals global electronic parts and components market insight and trends New data shows positive and increased opportunities in various industries even with shortage and price uncertainty still affecting the supply chain. With the growing need for stable supply chain networks, business research company OEMSecrets has identified four key trends that reflect a recurring theme in 2021. OEMSecrets analysts have selected these trends, extrapolated the following insights from big data analysed over the past three months in its search engine, for their influence on buyers and their ability to disrupt key functions across businesses.

including microcontrollers, power converters, LEDs and connectors. The price uncertainty has been driven by shortages along the various levels of the supply chain and according to OEMSecrets, it starts way down at raw materials, especially for products driving green technology such as electric vehicles and battery components. The company reckons electronic parts prices are on the up for the foreseeable future. 3.


During the last quarter (Aug-Oct 2021) OEMSecrets has seen an increase in demand for parts with low stock which is an indication that the industry is experiencing continued electronic parts shortages. Semiconductors (diodes, ICs, and sensors) and passives (transistors, resistors, and multi-layer ceramic capacitor) have been the worst hit, with distributors displaying low stock levels with long lead times on additional stock. Although manufacturers have increased capacity and supply to their distributors listed on the OEMSecrets search engine, demand still outstrips supply, which in turn is perpetuating pricing uncertainty along the supply chain. 2.

Revenue insights

Demand insights

Price uncertainty dynamics

There has been a gradual increase in prices for products in various categories

In the months of September and October 2021, OEMSecrets saw strong demand for semiconductors and passive. The revenue data reflect an increase based on estimated figures shared with the company by top distributors over those two months. Restraints such as shortages barely affected revenue growth as suppliers also increased their capacity. These revenue insights are backed by research undertaken by Market Research Future who expect the electronics components market to be worth more than $355 billion by 2022. 4.

The above insights have been derived from major suppliers including Abracon, Analog Devices, Diodes Inc., FTDI, Infineon, Kyocera AVX, Littelfuse, Maxim Integrated Products, MEAN WELL, Microchip Technology, Molex, Murata Power Solutions, Nordic Semiconductor, NXP Semiconductors, Omron, onsemi, Schurter, Sensirion AG, STMicroelectronics, Taiwan Semiconductor, TE Connectivity, Texas Instruments and Vishay. “During the past three years the global market has been affected by various factors and as a result, we are seeing trends consistently shift with an increase in demand and shortages of various product types”, said Sam Cowley, founder of OEMSecrets. “As a result, we recommend that buyers and engineers in the electronics components industry supply teams should consider the following: •

Technology insights

The data effectively highlighted that there has been an increased shift of preference to touch input technology which has pushed up the demand for display devices as consumers prefer information in visual form. Touch screens have become the gold standard on devices used today. The adaptation of IoT & Industrial IoT technology has increased demand for sensors and Wi-Fi components which have created opportunities for growth in industries like medical,


automotive, industrial, security and aerospace, among others.

• •

Work with suppliers to identify indicators of demand surge and develop fallback solutions for smooth project continuity in case of shortages Create price uncertainty pointers that will help buyers prioritise parts acquisition for their projects Use comparison websites as research tools and analyse markets behaviours.”

The company’s latest global market insight indicates that the compound annual growth rate in 2020 was 0.7% but, based on the current market climate, expect a 6.4% increase by the year 2025 with a market value of US$367 billion. For further information, please visit


Brandauer taps into Bruderer technology to deliver Middle East contract A significant £1.5m investment in a new high-speed production cell is helping a 159-year-old metal stamping specialist deliver a major contract to the Middle East. He continued: “We haven’t been disappointed. The control technology provides automatic ram shut height adjustment while the press is under acceleration and deceleration load for guaranteed process stability and pinpoint repeatability. “This is essential when you are working with high tensile stainless steel that is just 0.15mm thick and utilising a progression tool that cost in excess of £100,000 to manufacture.” The Bruderer BSTA 410-110 B2 was selected, customised and commissioned in a uniquely competitive eight-month window to meet the stringent delivery requirements of the global client. Brandauer, which employs 63 people at its Birmingham factory, has strengthened its long-term partnership with Bruderer by installing a BSTA410-100, which is capable of up to 41 tonnes, 1600 strokes per minute and features a large 1110mm bed. The machine will be used to manufacture stainless steel substrate frames for a male grooming product that is exported all the way to Israel and was chosen for its ability to achieve repeatable quality and parts in their millions. Secured against intense international competition, the project underlined Brandauer’s ability to take the customer through the entire journey, from developing the complex tooling to producing these parts in extremely high volumes. “We needed technology that could give us the tolerances and speed required by the customer to meet the order quantities, quantities that have more than doubled since winning the work,” explained Rowan Crozier, CEO of Queen’s Awardwinning Brandauer. “The Bruderer was our 26th press of theirs. We know the level of performance and reliability it can deliver and we knew we could work with their engineers to spec the machine so that it not only gave us the control we wanted for this project, but could also be deployed to pick up other high volume contracts we might be managing in the future.”

Teams from both companies worked closely together to make this happen and to also ensure the machine was set-up to be fully automated to include post-production cleaning and re-reeling. This means the press, alongside another Bruderer BSTA 510110 B2, can produce up to 100 million parts for the customer every year. “You just can’t beat the precision and speed of this technology and the £1.5m dedicated cell we’ve created for this is one of the best-performing in the business,” added Rowan. Adrian Haller, Managing Director of Bruderer UK, concluded: “We’ve been helping Brandauer produce precision parts since 1976, so it’s great that the firm has once again turned to our presses for its latest product introduction. “The tri-modular progression tool has more than twenty different stages and is one of the most complex the company has ever created. Our ram guidance system – exclusively at strip level, helps eliminate displacement between the punch and the lower die giving engineers the ultimate control over the quality of the component. “It also plays a big role in reducing tool wear, which I know Rowan and the team were very keen on.” For further information, please visit




T&D Corporation Mr Minoru Ito, European Sales Office, Gronauer Straße 1, 61194 Niddatal, Germany 0049 (0)6034 930970

Unit 3A, Whitworth Court, Manor Park, Runcorn WA7 1WA. Tel.: (0044)-330 002 0640,

Curtiss-Wright Surface Technologies

TR Fastenings LTD

European Corporate Office, Hambridge Lane, Newbury, Berkshire, RG14 5TU 01635 279621

Trifast House, Bellbrook Park, Uckfield, East Sussex, TN22 1QW Free phone: 08454 811 800 E-mail:

Phoenix Mecano Ltd

Blackfast Chemicals Ltd

26 Faraday Road, Aylesbury, Buckinghamshire, HP19 8RY +44 (0)1296 611660

Unit 5 Russell House , Molesey Road, Walton-onThames, Surrey, KT12 3PE 0207 339 7370,


Ecopac (UK) Power Ltd

Monitran Ltd, Monitor House, 33 Hazlemere Road, Penn, HP10 8AD, UK T: +44 (0)1494 816569 E:



Unit 4, Ridgeway, Crendon Industrial Area, Long Crendon, Bucks, HP18 9BF Tel: +44 1844204420



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:

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: Tel: +44 (0)1923 232 335

T +44 1935 472376

Mecmesin Ltd Newton House, Spring Copse Business Park, Slinfold, West Sussex, RH13 0SZ w: t: +44 (0) 1403 799979 e:

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

Wood Automated Systems UK (ATG – Systems) Tenter Road, Moulton Park Industrial Estate Northampton, NN3 6AX +44 (0)7827 327231

Lascar Electronics Ltd UK Module House Whiteparish, Wiltshire SP5 2SJ +44 (0)1794 884 567

Rotech Machines Limited


Power Security & Back-Up

Instruments Ltd


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