Engineering Update - September 2020

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September 2020

Power Connectors

by Murrelektronik

Bringing power to your installation has never been easier!

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Recommended Suppliers

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ENGINEERING PDATE September 2020

CONTENTS Editor

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

September 2020

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

Taylor Owens 01843 448 443 taylor@engineering-update.co.uk

Publishing Director

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September 2020 ENGINEERING UPDATE

Maximum Cut Protection Glove with A Revolutionary Coating.

The CT1065ST is the ultimate cut protection glove.

It offers a unique mix of protective properties and technology which is way ahead of other gloves in this arena.

Maximum Cut Protection CT1065ST achieves cut level ‘F’ in the EN388:2016 test, this is the highest possible rating and qualifies the glove for use in high cut-risk environments.

Featherweight, Breathable and Highly Dexterous Manufactured on 18- gauge needles, the high stitch intensity produces feather-light fabric. The yarn is ultra-fine so the finished glove is light yet, due to the stitch intensity it’s also extremely strong. Fine construction makes for a comfortable, fit, great dexterity and reduced fatigue.

PURATEC | Revolutionary New Coating • Water-based for purity A Water-based coating, completely free from DMF and silicon. This means zero skin irritation and zero odour. Safe dyes guarantee no migration of pigment onto the skin or any other contact surface. It’s also non-allergenic.

• No risk of silicone erosion Silicone is common in glove dips; it atomizes in the air and deposits on surfaces. This can cause erosion which is detrimental in industrial environments. With PURATEC there’s no silicon so no deposits and no erosion.

• All round good grip The feel and appearance of the coating is smooth yet grip is extremely strong.

You’ll get a strong hold on a dry object or surface and you can also securely grip anything wet or slightly oily. PURATEC is tested against nitrile foam coatings and proves to be superior for grip.

• Flexibility and comfort The incredible flexibility of PURATEC means the glove perfectly follows the contours of your hand. It has material memory so when stretched, it returns to the correct fit. With large or small hands, once you have the correct glove size, the comfort is exceptional.

Touch-Screen No need to remove CT1065ST to operate touch-screen machinery or tech. The smooth coating acts like a second skin. Its a great time saving and convenience factor.

Extra Protection where it’s most needed CT1065ST has reinforcement between thumb and forefinger; this area is highly vulnerable to injury. Reinforcement enables the wearer to grip with confidence knowing that extra protection is there.

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Find out more Visit the Product Profile page on MCR Safety’s website or you can make enquiries by phone or via email at: +44 (0) 1922 457 421 sales@mcrsafetyeurope.com

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!

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Monitoring the world

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September 2020 ENGINEERING UPDATE

TF Automation design New Plasma Treat Machines for Automotive Client TF Automation were commissioned by Kostal to design and build two plasma treat machines to address the increase in demand for cleaning new automotive switch products.

Kostal commissioned TF Automation to design two identical plasma treat machines to clean the surfaces of a switch assembly. Under the touch sensitive switch or button there is a capacitive foil and to ensure good performance the bonding between the switch and foil is critical with no moisture or air bubbles. To prepare the switch for capacitive foil bonding, the plastic elements required to be plasma-cleaned to remove any moisture and impurities.

Plasma pre-treatment is the key enabler technology for microfine cleaning, surface activation and plasma coating of nearly all kinds of materials. Conventional industrial pre-treatment methods are being replaced by plasma technology to make processes more effective and environmentally friendly.

TF Automation manufactured the two Plasma Treat Machines to automatically clean and prepare the inner surfaces of the automotive switches. Both machines accept 6 variants; however, they are programmed to accommodate many more variants, if required. The operator places two component

parts into nests on a sliding drawer which is then closed. The drawer is automatically locked which seals the plasma cleaning area and protects the operator. The plasma cleaning of both switches is carried out, allowing the operator to perform other tasks, as required. Once cleaning is complete, the operator then removes the switches and repeats the operation.

The change-over from one variant to another is simple with quick change nests selected from the menu on the HMI screen. The nests are fully pokayoked sensed if variants are selected in error, the machine prompts the operator.

The plasma head is mounted on to a 3-axis servo cartesian gantry and when the operator chooses a variant on the HMI, the correct plasma path is automatically selected. The plasma jet is guided with a defined speed and distance over the surface of the component prior to bonding. As the jet rotates, the plasma provides uniform treatment over a wider area than a non-rotational jet. The treatment is made by a potential-free plasma flume that exits the nozzle at an angle

Tony Hubbert, MD at TF Automation, comments, “TF Automation have worked with Kostal for nearly ten years now and built numerous process automation an testing machines, however this was the first plasm treat machine requirement.” He adds, “We see growth in general in the market for plasma treat machines as the technology can be applied across numerous industries.”

To find out more about plasma treatment or to discuss your next automation project with our design team, contact us on 01274 308005, email us at info@tfautomation.co.uk or visit our website www.tfautomation.co.uk.

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PRODUCT SHOWCASE – ON THE SHELF Stock items available immediately

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

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

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

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

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

www.labfacility.com

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September 2020 ENGINEERING UPDATE

The Importance of Accurate Temperature Measurement for Industrial Processes Advanced Energy owns 100+ infrared pyrometers for exact non-contact temperature measurement Pyrometers are temperature measurement instruments that operate on the principle of infrared radiation, i.e. they detect infrared radiation of objects to exactly determine the temperature without making contact with the process or surface being measured.

In many industry sectors, the use of non-contact temperature measurement instruments is essential. For example, it is used for controlling complete factory processes or measuring even smallest components to ensure a consistent quality level.

With a huge Impac pyrometer product portfolio developed from years of research and customer contact, Advanced Energy provides solutions for nearly every application request.

Our portable IMPAC Series 8 pyrometers are suitable for measuring metals, ceramics, graphite etc. Also, they can be used for special applications such as measuring pouring streams or for temperature monitoring in coke ovens. The focusable optics and compact design allow for easy operation and data capture during the measurement process.

These robust, classically designed handheld infrared thermometers offer small spot sizes, maximum value storage, and temperature indicators.

From AE’s flagship series of stationary pyrometers the Impac ISR 6‐TI Advanced represents the world’s first industrial grade infrared pyrometer with thermal imaging capabilities. It is a pyrometer and thermal imager in a single solution.

It uses two-color (ratio) technology to measure the center spot’s temperature for ranges between 700 and 1800 °C. The built-in video camera’s infrared filter auto-calibrates a thermal image. The video output

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September 2020

Advanced Energy acquired LumaSense Technologies, Inc. in September 2018.

is transferred to your PC via USB and InfraWin software generates the image.

Another versatile infraredmeasurement highlight is the IGAR 6 Advanced as the only pyrometer for industrial applications with Smart Mode functionality. This includes a unique switchover technology that transitions between modes, creating a very long temperature

measurement range from 100 ...

2000 °C. In Smart mode, the measurements in the range between 100 ... 250 °C will be taken in 1-color mode whereas in the range between 280 ...

2000 °C the measurements will be based on the 2-color (or ratio) method. In the range from 250 to 280 °C, a continuous transition from 1-color to 2-color measurement automatically takes place.

The legacy LumaSense solutions in combination with our precision power control technologies enable our customers to precisely control critical parameters of heat and material processes and to significantly improve process performance, efficiency and waste reduction.

Contact: LumaSense Technologies GmbH An Advanced Energy Company LTI-info@aei.com www.advancedenergy.com

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September 2020 ENGINEERING UPDATE

Preparation. Planning. Performance | Aiden Moffat Talks BTCC and his New 2020 Strategy “It was to effectively sacrifice the 2019 season, but the decision had to be made.

We changed the car mid-season with just a shakedown, before heading back out into competition.

The team did a great job to get the new Infiniti Q50 ready in less than two weeks.”

How do you come back from a difficult racing season in motorsport? Aiden Moffat reveals his plan to return stronger than ever for the 2020 KwikFit BTCC season.

2019 was undoubtedly a difficult race season for Aiden Moffat in the BTCC, with the young Scotsman nearly hanging up his racing boots for good.

The development of 2 brand new Infiniti Q50 NGTC racing cars, combined with sessions to visit a sports psychologist, and the addition of new teammate - 2017 BTCC Championship winner Ashley Sutton - sees Aiden Moffat set to return stronger than ever ahead of the 2020 BTCC season-opener at Donington Park. as pro engineering ltd. catches up with Aiden as he reflects on his ‘character building’ 2019 season, and reveals the exciting plan he's put in place for 2020!

Despite a strong start, achieving a fourth place finish at Brands Hatch, frustrations with Aiden's Mercedes-Benz A-Class ultimately resulted in a final season position of only 18th, his lowest in five years.

“It was a really disappointing season, largely down to the Mercedes A-Class just not being on the pace, however, I wasn’t the only driver struggling to get speed out of the package - there were three of us!”

Aiden Moffat’s in-house engineering team made the tough decision to make a risky mid-season car switch, ditching the A-Class in favour of the Infiniti Q50 NGTC car, as the series headed into the summer break.

“We soon realised we had to make a change, and a big one at that,” Aiden reflects.

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While the decision to change to the rear wheel drive Infiniti was the right one, it took time for Aiden to adapt to his new car.

“The Mercedes was a short wheelbase, right-hand, FWD car. The new Q50 has a longer wheelbase, is left-hand and RWD so it's a very different car to actually drive!”

So how does Aiden cope with the frustrations and disappointments that are an inevitable part of the racing experience?

“I’ve been using a sports psychologist for a couple of seasons now,” Aiden explains.

“It’s so important. While we know our racing lines and the braking distances needed, so much about being successful is in your head, as well as the equipment at your disposal.

Racing is hard both physically and mentally, so having this psychological support helps on the days when things don’t go as planned.

There was a stage last year where we were gaining nothing in the Mercedes. We were just turning up and running mid-field, but at least we can now look ahead to the new Infiniti.”

“It was really difficult to make the decision to effectively write-off a season like that, but we were able to use the remaining rounds of the championship to prepare for 2020, and hopefully it will have been worth all the pain and hard work.”

The Laser Tools Racing Team engineers have been working hard on their 2020 car, improving the weight distribution, roll stiffness and mechanical grip, as well as running a full aero development programme at the MIRA wind tunnel, unlocking every 10th of the new car's race pace!

And the exciting news announced at the end of last year is that they've developed not one, but two new Infiniti Q50 NGTC cars for the 2020 season.

For the first time, the 2020 season will see the Laser Tools Racing Team competing with two BTCC cars on the grid, as they welcome 2017 championship winner, Ashley Sutton, and his engineer Tony Carrozza to the team.

Having been good friends with Ash for several years, Aiden is looking forward to working with him more closely, and reaping the benefits of being part of a two-car team.

“It’s great to be teaming up with Ash – we know each other really well and we’ll definitely push each other. He’s an excellent driver, and together we can really drive this programme forward.”

The exciting developments of the Infiniti Q50 and welcoming a new teammate, along with frustrations from his challenging 2019 season, have left Aiden more determined than ever to triumph in 2020.

Alongside its many challenges, the 2019 season saw many memorable performances from Aiden, showcasing his great skill as a racing driver.

“There were positives from the season though – both Brands Hatch and Silverstone were good. I got my first podium at Silverstone for P2. We were very fast there and in the top ten in terms of pace in every session.”

And now with half a season of experience in the Infiniti Q50 under his belt, and further developments on the car over the past few months, Aiden Moffat is in a stronger position than ever for the 2020 season.

“I feel the racing passion and hunger to win again, and that is crucial as we head into this new season!”

Now in our 4th year of support, as pro engineering ltd. are proud to continue our sponsorship of Aiden Moffat and Ashley Sutton in the 2020 KwikFit BTCC Championship.

What are your thoughts on Aiden's plans for 2020? What do you think Ash will bring to the team, and how will the duo fair this year?

Let us know your thoughts & opinions here!

ENGINEERING PDATE September 2020

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

PIEZORESISTIVE OEM PRESSURE

TRANSMITTER 4 LD…9LD WITH I²C INTERFACE

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

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

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September 2020 ENGINEERING UPDATE

Titan Enterprises OG Series flowmeter range

Flow Monitoring in Explosive Atmosphere Titan Enterprises offers special options for its Oval Gear flow meters to ensure safe operation in potentially explosive atmospheres such as are often encountered in the petrochemical industry.

Based upon a proprietary oval gear design, Titan OG Series flow meters are designed to give reliable, high performance across a wide range of applications. Unlike other types of flowmeter, the measurement accuracy of these oval gear flow meters improves as liquid viscosity increases, from a nominal 1% towards 0.1% of flow rate at higher viscosities. Titan OG flowmeters are also available to pressure in excess of 700bar, where required. Standard versions of these Oval Gear flow meters use electrical pulsed outputs and therefore Titan has developed options to ensure they meet the requirements for safe use in hazardous atmospheres.

Titan offer two options for ATEX compliant operation of its Oval Gear flow meters in explosive atmospheres.

A simple option for monitoring flow in an explosive atmosphere is based upon using a Reed switch that operates via the customers intrinsically safe circuit. Employing this design there is no potential for storage or generation of electricity, allowing the Oval Gear flow meters to fall under the “Simple Apparatus” definition. These units can therefore be used without the need for ATEX certification.

The second ATEX compliant approach uses a fully certified NAMUR Proximity Switch to give the pulsed output from

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Oval gear flowmeter

the oval gear meter. For customers that elect for this option, Titan will install the switch into the Oval Gear flow meter and can supply the appropriate amplifier if required For any installation in potentially explosive atmospheres, operators must ensure that correct standards are maintained for the full electrical installation, but with the two options available throughout the Titan OG range, you have the choice to optimise your installation depending on process and environment requirements.

The OG range is offered with Stainless Steel, Aluminium, PEEK and Hastelloy housing options to provide a comprehensive range of chemical compatibility to suit almost any application.

For further information please visit https://www.flowmeters. co.uk/oval-gear-swept-volumepositive-displacement-flowmeters-overview/ or contact Titan Enterprises on +44-1935-812790 / sales@flowmeters.co.uk.

Power Security & Back-Up

Instruments Ltd

DC UPS

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

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

Power Supplies

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

A H

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

S

Instruments Ltd

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

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

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September 2020 ENGINEERING UPDATE

Radiation Resistant Zoom Lenses Resolve Optics has developed a range of nonbrowning (radiation resistant) zoom lenses for use in environments subject to radiation.

As the market leader in radiation resistant optical systems - all lenses are manufactured to the highest standards of quality and performance and are designed to withstand a total radiation dose of 100 million radians and temperatures to 55°C without discoloration.

Suitable for use in nuclear fuel handling operation, reactor active zones and radioactive waste storage plants, the Model 290 motorised non-browning zoom lens is a direct replacement for the Fujinon 1272mm (6x) non browning zoom lens, which is no longer manufactured.

All functions of the Model 290 are motorised and include slip clutches and electronic noise suppression.

Operating at f/1.8 the Model 290 provides high image resolution and minimum geometric distortion from 400-750nm. This versatile zoom lens can be used with single chip 1/2" and 2/3" CCTV cameras as well as Newvicon and Chalnicon tubes.

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The Model 200 is an extremely compact 3x non-browning zoom lens. Operating at f /2.8 the Model 200 provides high image resolution, a close focus of 50mm and minimum geometric distortion from 400-750nm. Special cerium doped glass is used in Model 200 zoom lenses to avoid browning or discoloration when exposed to radiation.

The Model 192 is a compact nonbrowning 6× zoom lens proven in applications requiring radiation resistance including medicine, academia, space exploration and nuclear power generation plants.

Operating at f/1.8, the Model 192 provides high image resolution and minimum geometric distortion from 400 to 750 nm, and it can image objects from 800 mm to infinity without the use of add-on adapters. When focused at

infinity, the Model 192 achieves high image resolution on-axis at full aperture throughout the zoom range without refocusing (image tracking). The lens is designed for use with CCTV cameras, and with Newvicon and Chalnicon tubes.

The Model 357 is a new generation non-browning 10x zoom lens uniquely able to produce clear, sharp images free of the strong yellow tint that has traditionally been a limiting issue when using radiation resistant lenses on color sensors. Operating at f/3.6, the 2/3-inch format Model 357 provides high image resolution and minimum geometric distortion from 400 to 770 nm, and can image objects from 1.5 m to infinity without using add-on adapters.

When focused at infinity, the lens achieves high image resolution at full aperture throughout the zoom range without refocusing.

In keeping with Resolve Optics tradition of designing application optimised lenses the company is also able to provide non-browning zoom or fixed focus lenses to meet your exact specification.

If you cannot find a lens, within our standard range that meets your requirements, please contact us on +44-1494-777100 / sales@resolveoptics.com to discuss the possibility of developing a lens for you.

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

Fluid Carrying

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel Joints Swivel joints allow pipework to 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.

Tel: 0208 339 7370

Tel:

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

Bingswood Trading Estate Whaley Bridge | High Peak | SK23 7LY | UK

+44(0)1663 735003

E-mail:

we make ideas come to life

RMIG is the world’s largest manufacturer and supplier of perforated metal and its related products.

We know our customers’ requirements for price and quality and meet their demands with uncompromising service.

Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below.

Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.

Cutting We can cut and shape perforated sheet to meet the needs of your final application.

Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements.

Rolling and forming We can roll, bend and form perforated sheets to match your design.

Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.

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

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September 2020 ENGINEERING UPDATE

Fast-track machine installation helps Eastleigh subcontractor deliver demanding project An Eastleigh-based precision manufacturer has turned to Yamazaki Mazak to install new, state-of-the-art machinery in a challenging four-week time window following a project win.

The swift installation and commissioning of a new Mazak HQR-200MSY CNC turning centre has enabled GW Martin & Co. (GW Martin) to expand their machining capacity and fulfil their exceptionally strong order book.

Established in 1959, GW Martin supplies a complete CNC machining service, providing components to the automotive, medical, electrical, vacuum and defence sectors. While the company has traditionally specialised in the production of high-volume, precision parts, it has been driving a strategy to reduce costs and increase capacity over the last five years, with investment in automated production being central to this. This was demonstrated when they purchased their first Mazak MULTIPLEX W-200Y Multi-Tasking CNC turning centre with an automatic gantry loading system in October 2019.

After winning a tender to machine a specific high-precision component in large volumes, GW Martin needed to further increase its machining capacity to complete the order in time. Having been impressed

by Mazak’s work adapting the MULTIPLEX to fit their bespoke component manufacturing processes, GW Martin turned to the machine tool manufacturer to supply an HQR-200MSY. The new unit’s highly efficient twoturret, two-spindle set-up enables reduced cycle times, and, when combined with the long Y-axis stroke, high-accuracy milling required for precision manufacturing.

The machine can perform highaccuracy turning and milling, and crucially for GW Martin, is compatible with a variety of automation equipment, including bar feeders, workpieces unloaders and robots.

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Following the machine’s order at the end of February 2020, Mazak’s Application Engineering team was able to quickly engineer the HQR200MSY off-site to fit into GW Martin’s machining line. This entire process, from order to installation, took only four weeks and enabled the company to manufacture the volume of bespoke parts in line with the project’s demanding schedule.

“Having worked with Mazak in the past, we were aware of their reputation for supplying quality turning centres,” says Richard Blake, Business Development Manager at GW Martin. “So, when we required an automation-capable solution at short notice that could machine highquality components in large volumes, we knew where to turn.

“Our previous experience with the MULTIPLEX W-200Y meant we were fully confident that Mazak could adapt the HQR-200MSY to suit our existing processes. Bearing in mind the time pressures of this project, this was absolutely vital.

Yet as we expected, even in such a short timeframe, the installation was completely seamless and risk free.

“While this all sounds very simple and easy to do, it really isn’t – Mazak’s adaptability and applications engineering proficiency was

already well known to us. We really appreciate how they were able to help us react quickly to this project win, and following this success, we ordered another new MULTIPLEX W-200Y for installation in August.”

Alan Mucklow, Managing Director UK & Ireland Sales & Service Division at Yamazaki Mazak, adds: “General subcontracting is a fast-moving industry, and companies working for customers across a variety of market sectors often require increased machining quality and volume at short notice in order to complete project work.

“The installation of GW Martin’s HQR200MSY is a perfect example of how Mazak can assist organisations working in this demanding sector.

We are thrilled that the quick and effective installation of this machining centre enabled GW Martin to complete their project order, and look forward to working with the company again in the future.”

For more information on GW Martin & Co., please visit: www.gwmartin.co.uk.

For more information on Yamazaki Mazak’s HQR-200MSY CNC turning centre, please visit: www.mazakeu.co.uk/machines/hqr200msy/.

ENGINEERING PDATE September 2020

Forerunner.

Yesterday. Today. Tomorrow.

The Sensor People have been setting technological standards in industrial automation for more than 50 years. This is how we ensure the success of our customers in an industry that is ever evolving.

We have been a forerunner from the start, and we are working on standardizing industrial communication. Among other things, we make sensors that are capable of transmitting data to control systems and the cloud via IO-Link and OPC-UA.

www.leuze.co.uk

Leuze_Kampagne_Wegbereiter_UK-BH_190x130_RZ-oMHW_en.indd 1

23.03.2020 10:50:21

MONITOR MOUNTING •

For monitors, control panels and touch screens up to 25KG

•

Screens can be turned, tilted, swivelled and height adjusted

•

Can be connected to tube or aluminium profile

•

Control centres and workstations

•

Plants and machines

Profile Technology

Linear Technology

Connecting Technology

01296 611 660 rk@pmgb.co.uk www.pmgb.co.uk/rk

Modular Technology

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September 2020 ENGINEERING UPDATE

Preassembled Power Connectors Bringing power to your installation has never been easier!

A

utomation and equipment need a lot of power. As installation concepts become more sophisticated, the number of field devices is increasing, and components such as IO modules, sensors, drives, cameras & lighting are being used everywhere. The influences of Industry 4.0 and IIoT are leading to increased demand for process control and feedback. Even mechanics are evolving from pneumatic to electric propulsion increasing demand for power in the field. Simple solutions are needed to bring energy to power hungry applications, an easy achievement with Murrelektronik’s standardized power connectors.

motors up to 7.5 kW and is ideal for power distribution.

Receptacles are available so you can install MQ15 connections on existing asynchronous and three-phase motors.

Power connectors from Murrelektronik allow you easily feed the required power into the field.

M23 connectors are a proven solution for connecting servo motors.

M12 Power Connectors TIGHTLY SEALED – 63 V/16 A OR 630 V/12 A Murrelektronik’s M12 Power connectors are compact yet have high capacity to transmit energy. They are a safe, pluggable connection for linear drives, stepper motors and for supplying power to fieldbus modules. They are the solution when you need high power density in a compact space. M12 Power is a compact alternative to 7/8” connectors in applications that require high power density.

The connectors are molded with highly-resistant, halogenfree PUR material, which makes them suitable for harsh industrial applications. The integrated anti-vibration lock ensures safe connections, even when exposed to shock or vibration.

MQ15 Power Connectors The MQ15 has a practical quick connection system. A quarter turn is all that is needed to create an IP67 rated connection. This saves time (up to 80 %) during installation.

The MQ15 is suitable for asynchronous and three-phase

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Mini (7/8”) connectors Mini (7/8”) cables have been the established choice for power and signal control. These c(UL)us listed cables are an industry standard in the North American and have been used worldwide for decades powering components and devices. The robust cables are suitable for connecting sensors, actuators and many other components.

Connect your servo-controllers with drives with our overmolded M23 connectors that are available in a wide variety of contact assignments. For the servo- controller connection, you can choose between double or single ended power cables that are designed to meet the Siemens Sinamics specifications.

Did you know…?

All Murrelektronik cables offer superb and verified quality.

Our know-how on power cables is based on many years of experience in manufacturing M8 and M12 cordsets for the sensor/actuator level.

Download the White Paper and receive a M12 Power Connector Sample https://www.murrelektronik.uk/gb/ highlights/power-connectors/ Murrelektronik UK 0161 728 3133 sales@murrelektronik.co.uk

Top Marks!

Because our efficient labelling is top of the class.

Industrial labelling systems from Murrplastik.

In 1986, history was made: Murrplastik developed the first computerised labelling system, including CAD/CAE data integration for single wires, terminals, control and signalling equipment, as well as conduits and systems. Today Murrplastik is one of the world’s leading suppliers of labelling and engraving equipment. Our labelling software will help you produce individual labels with the aid of plotters, engraving machines, printers and laser machines.

We offer labelling as a special service aswell. With an extensive range of high-quality labelling materials, Murrplastik can improve your labelling - so you achieve top marks too!

Cable drag chains

Cable protection conduits and fittings

Cable entry systems and holders

Labelling

www.murrplastik.de Murrplastik is represented in the UK by Murrelektronik • phone: 0161 728 3133 • sales@murrelektronik.co.uk



September 2020 ENGINEERING UPDATE

Smart Position Transmitters for Enhanced Plant Operational Efficiency Maximum process reliability and constant product quality are maxims in the food industry - whether in the manufacture of beverages, sweets and dairy or in meat processing. The increased usage of automation within the Process Industries has had a significant effect on the nature of valves supplied into the sector.

Whilst the functions of the valve and valve actuator are fundamentally the same regardless of whether the automated valve is being used for control (modulating) or for On/Off operation, the equipment that interfaces between the control room and the valve differ depending on the valve function.

Control valves will typically employ a Positioner to initiate a valve movement and a Position Transmitter to confirm valve position matches required position. On the other hand, an On/Off Valve will connect using a Solenoid Valve to allow a change in a digital output status in the PCS to operate the valve and a Limit Switch Box to confirm the valve is in the required position.

In contrast, the Position Transmitter on a Control Valve has been largely overlooked and hence many control valves suffer performance issues solely because of the limitations of the position feedback mechanism and can have a significant effect on both plant productivity and plant safety.

The vast majority of Position Transmitter products currently available utilise a potentiometer, which have a number of limitations when used on valve applications.

Potentiometers are susceptible to vibration, wear and liable to contamination from foreign particles such as dust, sand or water.

These issues, along with those encountered with other transmitter technologies are often not appreciated by the Plant Operator until the product is already in service and performance is not as expected.

A few specialist companies providing Valve Position Monitoring solutions, such as Imtex Controls Limited, have recognised both the potential benefits to Plant Operators for using IVPTs on valves but also the severe limitations of the products currently available. For this reason, new ‘smart’

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solutions are now being offered that solve the traditional issues of IVPTs and enable plant operators to maximise their returns from these devices.

The new generation of smart IVPTs employ more robust feedback mechanisms. For example, the Imtex NC transmitter range utilises inductive sensor technology in non-contact, solid state feedback devices that are both highly accurate and largely impervious to challenges presented by the environment in which they operate.

Traditional IVPTs are often tricky to calibrate, requiring the use of tools or a laptop to complete the setting of zero and span. Smart IVPTs simplify the calibration by allowing the user to calibrate through push buttons built into the transmitter unit. In addition, where the smart IVPT is equipped with the ability to interface with a digital protocol such as HART, the device might also be calibrated remotely.

When mounting a rotary transmitter on a linear valve, a nonlinear output is often generated due to a linear to rotary conversion kit being used. Smart IVPTs have recognised this issue and provide the means to adjust the output from the device. For example, the Imtex NC transmitter is available with the ability to set up to 20 intermediate feedback points to linearise the output.

Another benefit of Smart IVPTs is that they put intelligence in the field device. The ST-4312 NC Transmitter from Imtex Controls analyses the stroking speed of the valve every time it moves and compares this information with a stored ‘as new’ profile of the valve. The device is then capable of sending a warning signal via the HART communication interface, flagging when the valve has started to slow down by a user defined amount.

With the ever increasing need to improve plant efficiency and safety, Independent Valve Position Transmitters provide a simple and cost effective method to deliver these demands. By employing the latest generation of ‘smart’ IVPTs, plant operators are able to dramatically improve their efficiency and safety by gathering information on valves that permits targeted preventative maintenance.

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:

08700 340 002 www.imtex-controls.com



September 2020 ENGINEERING UPDATE

Piping and Equipment Analysis Software for Every Engineer and Designer The PASS Suite offers smart, easy-to-use analysis, simulation, and code compliant sizing tools for every piping and equipment engineer/designer enabling new users to perform piping and related equipment analysis in days rather than months. By embedding its experience from many engineering projects into the PASS software tools and combining this embedded intelligence with powerful capabilities and unsurpassed usability, PSRE makes piping and equipment analysis practical for every engineer and designer while reducing the time, effort, and cost to perform the analysis.

PASS Suite Overview The PASS Suite is in active use by thousands of engineers at more than 2000 customers around the world for efficient analysis and design of process piping and plant utilities, district heat transfer, water and gas networks, oil and gas field gathering piping systems, and other types of pipelines. The PASS Software Suite covers all main aspects of pipeline analysis and is organized into product families to meet the broad range of piping systems analysis and design requirements.

PASS/HYDROSYSTEM provides diameter selection, heat and hydraulic analysis of steady state and transient flow in piping systems of any complexity, including networks with loops, liquid surge (waterhammer) analysis and flow assurance analysis.

Please check out the PASS Suite at www.passuite.com or contact the PASS Authorized Distributor in the UK & Ireland:

PASS/EQUIP provides strength and stability finite element analysis using for horizontal and vertical vessels, columns, storage tanks, as well as shell, tube, and air-cooled heat exchangers under static and seismic loads in order to evaluate bearing strength.

Email: info@pipedesignservice.com

PASS/START-PROF provides comprehensive pipe stress, flexibility, stability, and fatigue strength analysis with related sizing calculations according to the most common codes and standards.

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PASS/INDUSTRY provides comprehensive piping and equipment analysis with related sizing calculations for specific industry sectors according to international and national codes and standards. PASS/ INDUSTRY combines the ease of use and extensive analysis capabilities of PASS/ START-PROF, PASS/ HYDROSYSTEM, and PASS/EQUIP in an organized manner to address the specific simulation requirements for Process Plants, Piping systems, and District Heating.

Pipe design service ltd.:

TEL: 0208 638 5898 www.pipedesignservice.com

ENGINEERING PDATE September 2020

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

Safety Guarding •

Complies with the EU Machinery Directive 2006/42/EC

•

Clamping profiles allow different materials to be installed

•

Minimal effort required in construction

•

Smooth easy to clean outer surfaces

•

Comprehensive range of accessories

•

Quick assembly time

Profile Technology Linear Technology

Connecting Technology

01296 611 660 rk@pmgb.co.uk www.pmgb.co.uk/rk

Tel: 0208 339 7370

Modular Technology

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

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

September 2020 ENGINEERING UPDATE

Colour picking – can it improve Order Fulfillment?

E

fficient and modern order processing is more important today than ever before. Internal processes must be put to the test as new challenges are to be met. For many sectors “on demand” orders with shorter delivery times are becoming the norm. Its no secret that demand fluctuation is also a big challenge for manufacturers and distributors, but this problem has become even more apparent. In fact, many fast-moving consumer goods manufacturers and distributors are experiencing their highest spikes ever. They are facing an unprecedented (and likely unexpected) predicament right now!

How to produce an overwhelming demand for essential (e.g. prepared food, cleaning products, non-prescription medicines, toiletries) while facing a surge in e-commerce sales.

As the world slowly recovers from COVID-19, consumer demand for some of these products might slow down, but experts predict the undistributed shift to e-commerce as a main shopping outlet will remain steady. With a potential second wave on the horizon, we’re finding warehouse managers are searching for ways to manage future demand spikes. The answer starts with an underlying foundation and Kardex is experiencing a surge of requests for a well-organised and efficient production and order fulfillment process.

A few years ago, Kardex developed a new solution, based on the principles of pickto-light technology, Colour Picking guides multiple operators through the picking process using colour as pick-lights. This allows warehouse managers to add or reduce staff based on order demands. It has a proven track record to increase picking throughput, improve performance and optimise labour costs.

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Thomas Lampinen who is the supply chain manager for KICKS cosmetics had this to say, “Before we were ten people picking in one area and we reduced it to four people and they were actually picking faster than what ten people did before and also the stock quality was really improving and the picking quality, because we reduced the amount of mispicks.”

An example of a common Colour Picking work zone includes eight vertical carousel modules (VCM) RS – four on each side facing each other with a pick lane between them. Orders are transferred via a software interface from the host system (ERP/PPS) to the warehouse management software (WMS), Power Pick Global. Power Pick Global dynamically creates batches of orders based on customer criteria (e.g., required delivery date, priority, shipping method, line of business).

When the batch starts, the system automatically assigns a colour to the cart and all units with order lines for that batch show the matching colour and move to retrieve the stored items required. All picking carts consecutively pass through each area. They do not overtake or pass batch carts. The same cart is assigned a different colour in another storage area or in a new batch. The operator follows the pick-to-light colours on the pick locations and batch carts during the entire picking process, picking and putting goods easily and quickly with the correct order (box or compartment in the picking cart).

Kardex has prepared a white paper on the benefits of usage of colour picking with customer user examples as well as an educational on-demand webinar. To learn more, download our free white paper on the benefits of colour picking or contact us at info.remstar@kardex.com



September 2020 ENGINEERING UPDATE

Positivity in Plastic As a business everyone has targets, goals, processes, developments, projects, the list goes on.

T

he main purpose for any business is to be profitable and utilise all aspects of investment.

When you hear investment, instantly your mind is drawn to large pieces of machinery, revolutionary technology, and property, these are factors, however I am taking us back to the basics of the plastics business.

The plastic polymer.

Each polymer has been on a journey, these tiny pellets are created from natural resources, and have a long life. (Plastics are made from natural materials such as cellulose, coal, natural gas, salt and crude oil through a polymerisation or polycondensation process.) Each pellet is a form of investment.

If you think about every product that is created from plastic, it has travelled many miles, has been through hours of processing and production, and then for many it’s life is cut short and has historically been shipped on a journey to China, to landfill, or simply stacked up “as it will have a use.” Millions of plastic pellets have entered our oceans, through sewer systems, polymer creation and simple misuse.

I have worked within the plastics industry, and seen the mistakes made, however credit has to be given to the industry I work with, they are making changes, and creating what many deem a new way of doing business.

Plastic is not evil, it is lifesaving which has been more than proven, within the times of the recent worldwide pandemic. Plastics have simply been dealt a bad hand, and due to some abusing the processes, plastic had ended up in places, that it was never meant to have seen, let alone entering the food stream, or ocean bed.

An example of a business utilising every polymer and plastic off cut is Coral Products PLC, a company that has had to diversify and adapt to change since its days as a supplier of packaging for the entertainment, music, and film industry. The group supply extrusion, blow moulding and injection moulding products into a wide range of industries, including telecoms, automotive, household, food, and beauty.

This business of over 30 years has an experienced CEO, with an eye for detail, which brings onboard projects and innovations that others may overlook or

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deem irrelevant. Bringing staff and teams together to enable a complete in-house project from design to creation, with R and D and recycled polymer as a focus.

This business uses what others deem as waste, or simply sweep away.

An example of this was highlighted

by Operation Clean Sweep, a project supported by the British Plastics Federation. Why are plastic polymers entering the rivers and oceans at this start of its journey if manufacturers are seeing each pellet as a resource and profit for the business?

At Coral Products PLC, every top and tail from blow moulding, every pellet from extrusion and injection moulding, has a place.

If it ends up on the floor, it is a waste a loss of profit for the business and does not support their circular economic business strategy.

Education is the key to success.

Staff need educating, and to be included within your business, in decisions, in processes, in investments, in expenditure, if staff are not part of the business, and are not aware of costs or polymer, how are they expected to respect the cost of that pile of plastic on the floor! Or why it should not be on the floor.

Investment is of course key, the group have invested heavily in processes and structures that can utilise the “waste resource,” a state of the art recycling facility onsite in the North East, has enabled the group to create a circular economic strategy and offer this process to customers, collection and gathering of waste plastics, whilst delivering new product and a cost effective pricing plan, has reduced costs for many LA’s and Councils and has provided an in house resource for development of new innovative products.

There are many misconceptions with regards to what can be recycled and reused as a secondary life plastic, the fable of black plastic not being recyclable, (when it’s usually down to cost,) that recycled plastic can’t be used in food products (when in-fact it can,) and plastic being the most destructive form of packaging in process, (when as it is proven, paper uses many more resources and energy, as do many other alternative polymers.)

Thinking outside of the box, (pardon the pun as Coral Products PLC create many bins, boxes, and caddy’s!) Is what Mick Wood and his team are particularly good at.

Using plastic on site keeping polymer in production, using automation and cobots to enable the up skilling of staff, innovative ideas and a fresh approach to supporting other business, all of these ways of doing business can be implemented in any business.

What do you have?

Do you have a tool that is lying dormant, that could be used to create a different product?

If you made that product in a different colour could it be used in another industry?

Is there a pile of plastic, waiting for collection that you are paying to be removed, as it simply is no use?

Why can’t your machine run another tool, be adapted, support a different industry?

Is it because change is not discussed, is the focus on the government guidelines, restrictions, boundaries being implemented?

Or is it simply due to a mindset that needs changing?

Plastic is not a dirty word, it is not a product that has no use, it is part of our everyday life, and has its place in society (although many disagree.)

We should always see our best in everything, find and use what we have to the best of our advantage, and do the best by others.

I believe the plastics industry are endeavouring to do this, it is time to show support, change minds and educate. (Oh, and market your business, I am here to help with that! - Emma Varney - Long info@vsmm.co.uk)

www.coralproducts.com

Engineered to last, designed to work The knee-operated wash trough

Hygienic sloping top

Dirt traps removed and reduced horizontal surfaces

Sloped self-draining bowl with minimal splashback

Handsfree design prevents contamination

For more information get in touch today W: teknomek.co.uk T: +44 (0) 1603 788 833



September 2020 ENGINEERING UPDATE

DeviceConfig

– Set valve parameters and run diagnostics at the press of a button With the “DeviceConfig” software you can set the parameters for the 8049 positioner (Ex, 2-/4-conductor) and the 2030 and 2032 motor actuators from Schubert & Salzer in just a few simple steps and then obtain valuable diagnostic data for optimization of the process.

valve travel, or the number of switching operations of the pulse valves.

Due to the acquisition of the temperature and way classes (corresponds to the amount of time in defined temperature and stroke ranges), valuable data for optimizing the control is generated. This data can serve as a basis for changing the nominal size and/or the Kvs value of the valve.

Furthermore, the software contains numerous additional diagnostic functions such as live monitoring of the signal stability and the control response of individual valves. They can be viewed after starting the program in the “Demo mode”, for example.

The Demo mode allows you to test and/or preview the software even when it is not connected to a positioner or motor actuator.

All maintenance data and settings of the connected positioner or motor actuator can be exported to a file in the PDF format for troubleshooting or maintenance purposes or for long-term to documentation and storage purposes.

T

o make setting and changing the parameters for the valve characteristics easy, DeviceConfig contains a separate setup file for each type of valve.

The file can then be easily loaded into the software and then downloaded to the positioner or actuator. It allows you to adjust the accuracy, and for motor actuators even the control and/or actuation speed.

Using DeviceConfig, it is even possible to create split range settings, i.e. set the parameters of two devices so that they receive a common control signal and operate as a unit. The parameters of the corresponding valves can then be set so that they interact, e.g. for temperature control or for even higher control qualities.

Valuable Diagnostic Information DeviceConfig also provides a variety of useful diagnostic data for quick and easy troubleshooting or for control optimization. Among other values, you can read the hardware and software version of the connected device, e.g. the total number of hours of operation, the total operating time, the previous

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Bluetooth connection with up to 255 devices: Up to 255 devices can be read out wirelessly via Bluetooth module (separately available for 8049-4, 2030, and 2032 only). A separate USB connector is available as an alternative.

Intelligent Drivesystems, Worldwide Services

NORDAC PRO FREQUENCY INVERTER

4.0

The next generation of frequency inverters with on-board PLC, positioning software and seemless connectivity to industrial ethernet-based bus systems.

READY

We‘ll talk to anyone...

Integrated multi-comms ethernet interface, parameter selectable, with no hardware changes.

NORD Gear Limited | Tel +44 1235 534404 | GB-sales@nord.com

www.nord.com



September 2020 ENGINEERING UPDATE

TR Fastenings has an engineering team ready to help with your sheet metal requirements Whether you are looking to press, rivet or weld during manufacturing or assembly processes, choosing the right product is critical. With over 45 years’ experience and a comprehensive range of fasteners for sheet metal, TR Fastenings has an expert engineering team ready to assist.

Installation by pressing TR manufactures its own branded Hank® Self Clinch fasteners, Hank® Rivet Bushes and K-Series® nuts that are pressed into pre-punched holes.

Hank® Self Clinch Fasteners Designed to offer a permanent female or male thread across a wide range of critical applications, TR’s Hank® Self Clinch products come in a range of shapes and sizes, including threaded clinch studs, clinch nuts, standoffs, panel fasteners and pins. High pull-out and torque tolerance and available in various materials and plated finishes.

Hank® Rivet Bushes TR’s own Hank® Rivet Bushes are designed to add load bearing female threads in thin sheet metal. Offering the best torsional and pull-out resistance, this range includes round, hexagon, standoffs, mini round, Tank and Swage manufactured in a variety of materials.

Only TR Fastenings manufactures the genuine Hank® Rivet Bush.

K-Series® Nuts The company’s K-Series® nuts provide a strong and permanent female thread for

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sheet metal and some plastic applications too thin to be tapped by usual methods.

The K-Series® standard and thin nuts can be installed using a standard press.

Once fixed, they offer a strong fixing and permanent thread with a high prevailing torque and pull-out resistance.

Installation by Capacitor Discharge welding

Installation by riveting

Weld Nuts

Sheet metal blind rivets and blind rivet nuts can be assembled on or off site, with access required from one side only and are installed using manual, electric or pneumatic tools.

TR’s Weld Nuts provide a strong female thread and are suitable for thin sheet metal, available in steel and stainless steel, in hexagon (DIN 929) or square (DIN 928) styles.

Blind Rivets

Weld Studs

The range includes open, sealed, multigrip, peel and grooved blind rivets.

The CD Weld Studs, installed using a CD gun, provide a strong male thread in thin sheet metal.

The installation tool is used to draw the mandrel into the rivet, which expands the blind end and causes the end of the mandrel to snap off. Subsequently, the stem ejects to form a tight joint.

Blind Rivet Nuts Available as reduced, flange head and countersunk types with either a knurled, plain or hexagon body, TR’s sheet metal rivet nuts offer strong female thread in blind applications and high push-out and torsional resistance.

TR’s weld products are welded to sheet metal using an electric Capacitor Discharge (CD) gun with access required from one side only.

Pin welding adheres the stud to the sheet metal without the requirement of a prepunched hole.

Weld studs are installed on one side of the metal fabrication and offer quick installation, high joint strength and a permanent fixing.

TR Fastenings Ltd sales@trfastenings.com T: 08454 811 800 www.trfastenings.com

FOR MORE THAN

60 Y E A R S

®

BÜLTE Plastics (UK) LTD 8 Basepoint Centre, Harts Farm Way Havant - Hampshire PO9 1HS United Kingdom Tel. : (+44) 023 9244 9606 sales@bulteplastics.co.uk / www.bulte.com



September 2020 ENGINEERING UPDATE Neil Sandhu, SICK’s UK Product Manager for Imaging, Measurement and Ranging explains: “The modular concept of SICK IntegrationSpace allows you to subscribe only to the services you use. You can connect your SICK devices in three simple steps: Firstly, create a virtual representation (digital twin) of your device, then pair the real device with the virtual representation.

Finally, via the virtual device, manage how the data is routed and forwarded to other SICK data applications, such as individual dashboards, digital maintenance services, as well as to your thirdparty dashboards or business improvement systems.”

SICK Launches its IntegrationSpace Digital Services Platform SICK has established a new web-based platform, SICK IntegrationSpace, to be the home for its growing data-based digital software and services portfolio. Seen as a key strategic development for the company, its aim is to align the operating efficiency goals of its customers in automated factory, process and logistics with enterprise-wide business improvement systems.

As the distribution channel for a modular portfolio of digital tools, services and cloud-based applications, SICK IntegrationSpace will enable users to vertically integrate sensor data from device through to the Cloud, creating transparency for users both to the sensors themselves, and the data they generate.

Though SICK IntegrationSpace, data from SICK sensors and other third-party devices becomes a valuable raw material to be collected, represented and manipulated using the appropriate web-based service.

All SICK IntegrationSpace modules are non-sector specific and are designed to work seamlessly with SICK’s sensor technology portfolio and its AppSpace software framework to serve the company’s wide-ranging customer-base across factory, process and logistics automation.

A range of asset-focused digital services are among the key foundation modules included in the initial launch: •

The SICK Installed Base Manager database smartphone app

•

The SICK AssetHub digital-twin asset management system

•

The SICK LiveConnect real-time access capability from sensor to cloud

•

The SICK Monitoring Box real-time analysis and condition monitoring tool.

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Customers may choose to start their IntegrationSpace journey by using the SICK Installed Base Manager smartphone app to build a database with fingertip access to information about both SICK and third-party installed devices. By simply tagging the 2D code label on the SICK device, users can collect data on their entire installed sensor inventory. The SICK Installed Base Manager also enables non-SICK devices to be added.

For every SICK device, the App will automatically detect and log the serial number and its age, assign it to the machine and plant, with the option to add photos and the exact GPS location.

Individual sensors can then be located quickly using the search function, with quick access to technical data and product manuals. All stored device data can be exported for use in the customer’s own systems.

A key foundation of the IntegrationSpace platform, the SICK AssetHub is a web-based enterprise asset management (EAM) that enables users to manage a digital twin of their assets along their entire life cycles. The AssetHub presents a feature-rich and interactive view of all sensors, systems and other devices.

The SICK AssetHub evaluates device data so that maintenance happens at the right times, software and firmware are up to date and that inventories are well planned and optimised. The AssetHub also provides transparency for SICK field services to support customers effectively and enables maintenance programmes to be optimised.

In order to access the virtual representation of the sensor and its data, SICK uses LiveConnect to deliver a standardised connection from an edge gateway, such as the SICK SIM1012 or the TDC-E, to the SICK Asset Hub. This visualises the sensor status, thereby providing a foundation that opens up new opportunities for optimising plant availability and process efficiency. The LiveConnect service creates a digital trail linking hardware to SensorApp, and to the Cloud.

The SICK Monitoring Box allows for the early detection of status changes in sensors, machines, and plants. It enables visualization of data in a browser-based dashboard for condition monitoring and real time analysis. Integration with sensors is facilitated through standard SensorApps for SICK devices and implemented via the SICK cloud, or at a customer’s premises.

Process changes can be tracked directly from devices and users have real-time access to sensor parameters, for example whether pre-set limits have been exceeded. Alarms and notifications can be set up, and historical data and events are presented clearly in a log book format, so they can be used to make application-specific predictions.

Guided by the principle of standardised, secure, open frameworks, and easy customisation for individual business processes, SICK IntegrationSpace promises to add value to many business processes. SICK plans to release further modules for the IntegrationSpace platform at a rapid pace supporting assetfocused digital value adding services, as well as cloud-based processes and applications. www.sick.co.uk

SAFETY LIGHT CURTAINS WITH BLUETOOTH INTERFACE

SAFETY LIGHT CURTAIN APP MAKES COMMISSIONING AND SERVICE EASY The first safety light curtain from Schmersal with a built-in Bluetooth interface. The SLC440/COM with Bluetooth BLE is an active optoelectronic protective device that makes all status and diagnostic data on the operating status of the device available on smartphones or tablets via a Bluetooth interface on a real-time basis.

In combination with the Schmersal App "SLC Assist" the operator uses this diagnosis tool for a safe operation, setup and documentation of a Schmersal AOPD by using a smartphone or tablet.

THE "SLC ASSIST" APP

INNOVATIVE TECHNOLOGY

The “SLC Assist” App gives information about:

The light curtain with Bluetooth interface and the Schmersal App gives optimal support for:

• • • • • • •

Operating mode Beam signal level OSSD status Status of the protective field Number of OSSD switches Supply voltage Operating time

• • • •

Condition monitoring Optimal alignment Preventive maintenance Documentation according to industrial safety regulations

The App "SLC Assist" is available for Android and iOS devices.

Scan the QR code below for info, videos and App downloads.



September 2020 ENGINEERING UPDATE

ACS Motion Control launches new website ACS is excited to announce the launch of its new website for OEM system designers who need high-performance motion control capabilities. The new site makes it easier to find the right combination of motion controllers, servo drives and software tools that will enhance the performance of your precision machine design.

Whether you're searching by product category, capability or industry, the new layout streamlines navigation to quickly identify what you need, putting ACS solutions at your fingertips. The website content will be continuously updated with cuttingedge technology developments, company announcements, and useful technical resources, including new tutorial videos.

New users can also register to download datasheets, manuals and software tools.

ACS prides itself in providing customers with clear and concise information about motion controller and servo drive products, software tools, and training services. Your feedback on how this new website could be improved to better meet your needs is always welcome.

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Check out the new acsmotioncontrol.com

IF ONLY AMAZON COULD DELIVER MOTORS...

Quantum Controls have partnered with OSE Logisitcs Company to provide you with 24/7 instant access to ABB & WEG Motors. You get access to UK's largest stock of 2 and 4 pole motors, foot and flange mounted up to 250kW.

No Order Numbers needed 24/7 Direct Telephone access to expert motor engineers Order placed direct with logistics company Motor will be in transit within 30 mins, guaranteed

G ET YO UR UNIQ UE L O GI N DE T A I L S FO R I NST A NT A CCES S T O O UR ON L I N E MO T O R S T O C K. EMAI L US AT : M O TO R S@ QU AN TU M - C O NT R OL S . C O . UK



September 2020 ENGINEERING UPDATE

Innovative no compromise basic DIN-Rail power supplies offer cost advantages Ultra-compact, high efficiency and reliability with 36W, 60W and 90W output power

PULS

Power, the specialist manufacturer of high reliability DIN-Rail power supplies, introduce the latest models in their market leading PIANO series. The PIANO-PIM family have been designed for use in the many industrial applications which only require a basic power supply so that customers do not have to pay for unnecessary control and communication facilities.

The new PULS PIANO-PIM series offer a cost effective, space-saving, efficient, reliable and durable DIN-Rail mounted AC/DC converters. The 100-240VAC wide range input, 24VDC output units are available in three versions: PIM36 (36W), PIM60 (60W) and PIM90 (90W). With these additions to the already very successful PIANO power supply range PULS now provides users with a complete, cost-oriented, product family with outputs from 30-480W. At ambient temperatures between -10°C and +55°C, the devices work at full power without derating. The PIM90 is also available as an NEC Class 2 version for the US market.

The PULS PIANO-PIM range use innovative technology to make savings in cost and space. The single PCB design uses a reduced number of high-quality components, lowering cost, simplifying manufacture and improving reliability. The PIM90 is currently the smallest 90W DINRail power supply on the market. The compact design saves space on the DIN-Rail in the control cabinet and makes them ideally suited for decentralised use in cramped systems or spaces – e.g. building automation.

of a plastic housing means the small, low power PIANO power supplies can be operated without grounding, saving additional installation time and cabling costs.

The PIM60 and PIM90 power supplies are available with either screw terminals or time saving push-in terminals.

PULS devices are optimally prepared for automated wiring processes. The PIANO-PIM range meet all international safety agency approvals and are CE marked.

The high efficiency synchronous rectifier design based on MOSFET technology (90W PIANO achieving over 93.8% at full load and +40°C ambient temperature) reduces the need for system cooling and further increases reliability.

With exceptionally low losses even in idle or standby mode at < 0.5W, the PIANO-PIM range particularly is useful for applications in building automation. In building safety systems power supplies often remain in standby mode for days or even weeks. Due to the very low no-load losses in the idle state, considerable energy costs can be saved over the long term.

Marco van der Linden, UK Country Manager for PULS Power, comments,” Our PIANO range continues the PULS philosophy of offering our customers “more with less”. Our new PIANO-PIM range of power supplies are ideally suited for worldwide applications requiring a simple, basic, cost effective power supply with no compromise on quality. The compact size of the PIM36, PIM60 and PIM90 allows more flexibility in system design while the simple installation provides significant time and cost savings. PULS power supplies continue to set new records in their respective performance classes in the quality-critical functions such as efficiency, lifetime and size.”

The high efficiency and optimised thermal design allow polycarbonate housings to be used, reducing weight and providing a robust impact resistant enclosure. The use

For more information on PULS PIANO-PIN DIN-Rail power supplies call +44 1525 841001, email sales@puls.co.uk or visit www.pulspower.com

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

Setting the benchmark...

Faster, compact, energy saving and affordable...

Kawasaki’s latest robots increase one of the largest robot ranges available today. They are more compact, provide smooth control and give increased all round performance.

For assembly the new collaborative duAro; for palletising the CP Series; the general purpose CX Series and the high-speed spot welding BX Series. Check out the new robots and see just how affordable they can be....

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

Kawasaki Robotics (UK) Ltd

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

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

September 2020 ENGINEERING UPDATE

Industrial Machine Vision cameras At ALRAD IMAGING we know selecting the correct camera for a Machine Vision application can be a daunting task.

In this article we feature just a few of our extensive range of cameras that can be used for industrial applications.

The Imaging Source range of cameras offer users many different types of area scan cameras for Machine Vision with either colour or monochrome sensors and a variety of resolutions ranging from VGA to 42 MegaPixels. Camera outputs on offer are USB2, USB3, USB3.1, and GigE. Most models use Sony CMOS sensors: Starvis with rolling shutter, and Pregius or Pregius S with global shutter, offering frame rates of up to 539 fps (using an 0.4 Mega Pixel sensor).

The cameras with GigE interface allow for cable lengths up to 100m and multi-camera set ups, while maintaining data rates of up to 100MB/s; the GigE Vision standard ensures rapid integration of hardware and

ix Industrial® Ethernet interface which uses an integrated locking system to deliver high shock and vibration resistance in industrial environments. Details of all the cameras in this series can be found at by clicking here In addition to cased cameras, there is also available a selection of OEM board cameras with USB2, USB3 and GigE interfaces.

These are ideal for customers who want to build a high quality machine vision camera into their own equipment.

OMRON Sentech offer a truly extensive range of products for Machine Vision applications. In addition to cameras with outputs similar to The Imaging Source, they also offer industrial cameras with CameraLink, CoaXPress and DVI/SDI, as well as analogue outputs. Resolutions range from 0.3 to 25 MegaPixels.

High output speeds can range from 520 fps image processing software, for a 0.3 making the cameras ideal for MegaPixel applications in production, inspection and quality assurance. camera and up to A variety of input, output, strobe 180 fps for a and trigger options are available 4 MegaPixel via the Hirose port. The newest "38 Series" camera.

CameraLink and cameras feature the GigE Linescan cameras are

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also available. With such a comprehensive range of cameras, Alrad can cover a wide variety of applications by offering a suitable sensor, interface, optic and lighting solution for your particular machine vision application.

Alrad has available frame grabbers and cabling to interface to any of the cameras mentioned above but there is no substitute to discussing your exact requirements with one of are experienced sales staff.

Turnpike Road Industrial Estate, Newbury, Berkshire RG14 2NS, Tel 01635 30345, Email sales@alrad.co.uk Web www.alrad.com



September 2020 ENGINEERING UPDATE

The Importance of Accurate Temperature Measurement for Industrial Processes Advanced Energy owns 100+ infrared pyrometers for exact non-contact temperature measurement Pyrometers are temperature measurement instruments that operate on the principle of infrared radiation, i.e. they detect infrared radiation of objects to exactly determine the temperature without making contact with the process or surface being measured.

In many industry sectors, the use of non-contact temperature measurement instruments is essential.

For example, it is used for controlling complete factory processes or measuring even smallest components to ensure a consistent quality level.

With a huge Impac pyrometer product portfolio developed from years of research and customer contact, Advanced Energy provides solutions for nearly every application request.

Our portable IMPAC Series 8 pyrometers are suitable for measuring metals, ceramics, graphite etc.

Also, they can be used for special

applications such as measuring pouring streams or for temperature monitoring in coke ovens. The focusable optics and compact design allow for easy operation and data capture during the measurement process.

These robust, classically designed handheld infrared thermometers offer small spot sizes, maximum value storage, and temperature indicators.

From AE’s flagship series of stationary pyrometers the Impac ISR 6‐TI Advanced represents the world’s first industrial grade infrared pyrometer with thermal imaging capabilities. It is a pyrometer and thermal imager I a single solution.

It uses two-color (ratio) technology to measure the center spot’s temperature for ranges between 700 and 1800 °C. The built-in video camera’s infrared filter auto-calibrates a thermal image. The video output

Enclosure Climate Control Whatever the scale...... ......we have the solution ENCLOSURES

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ENGINEERING PDATE September 2020

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

September 2020 ENGINEERING UPDATE

How DO you flex your manufacturing to respond to Covid-19 and reshoring needs?

Industry hasn’t really seen anything like the sudden changes the pandemic has thrust upon it, and there is now a massive need for manufacturing to be more flexible and rapidly adapt to a changing economic picture.

H

orizontal innovation, where we take core technology and processes developed in one sector and transfer them to deliver a solution in another, is very much in demand.

MetLase, which is part of Unipart Group, alongside Instrumentel and Park Signalling, specialises in the manufacture of world-class tooling, intelligent fixturing and components, bringing lead times of months down to hours or days. Faster, more intelligent manufacturing that delivers data is what industry is demanding and MetLase is at the forefront of how we can turn a traditional fixture or tool into an intelligent component, using unique, patented innovative technologies that are transforming manufacturing.

Completed Projects MetLase has already completed a number of high-profile projects using its rapid tooling development.

This includes creating an aerospace pipe fixture in less than 24 hours, using parametric CAD modelling to modify a composite wing fixture for F1 in just 12 hours and responding quickly to a premium British automotive

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manufacturer’s styling department change that saw it accommodate quad pipes instead of twin, on an rear exhaust assembly automated laser welding fixture.

The company, which played a key role in the VentilatorChallengeUKConsortium, has also just delivered its largest ever tool, measuring 4 metres in diameter and 2 metres tall.

Despite the scale of the project, manufacturing sign-off and delivery was completed in just one month. Previously, the client would have expected it to take half a year.

Through a series of Manufacturing Masterclass Webinars, MetLase is demonstrating that there has been a huge shift in how tooling and manufacturing is undertaken - and showing that it is possible to re-shore manufacturing using new approaches. To view the first two webinars and sign up for the rest of the series, visit the website.

The company currently employs 30 people at its facility on the AMP Technology Centre in Sheffield and works across automotive, aerospace and, increasingly, in scientific equipment and pharmaceuticals, with over £1m of new contracts secured in the UK, Australia, the EU and the US.

ENGINEERING PDATE September 2020

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

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

September 2020 ENGINEERING UPDATE

nPB solvent for vapour degreasing has been banned from July 2020 EnviroTech Europe have low cost alternatives.

If you are interested in the history, it is all explained in detail on our website.

Bad news for your business. Coronavirus, Brexit, redundancies, social distancing reduced cash flow.

No new equipment needed, guaranteed results and no extra costs to worry about.

If that is not enough and you are using nPB solvent for vapour degreasing that’s another problem to worry about as it cannot be used after 4th July.

We can’t guarantee that more changes will not happen in the future, but you will then have time to evaluate whether the new generation of wonder products which reduce global warming a smidgeon is worth the enormously increased costs.

Don’t panic it’s not too late to change and comply, as we have replacements which are guaranteed to give the same results at no increase in your costs of usage. It is late but we can give you the information to easily make the change in a day without fuss.

You have questions - of course: How can it be so simple?

The EnSolv range of stabilised nPB based vapour degreasing solvents is the market leader in this field worldwide. EnviroTech Europe, the manufacturers, know this product inside out with hundreds of satisfied users. We have been fighting the EU authorities for 20 years regarding classification, but with limited resources and the corporate giants with money to lose as EnSolv gained more and more of the market. Money talks so the Commission ignored the evidence and banned nPB for use as a vapour degreasing solvent with the sunset date in July 2020.

With our extensive knowledge of user needs EnviroTech Europe, during the intervening years, have developed new compliant solvent formulations which are simple “drop-in” replacements.

Talk to us about whether EnSolv CC-A or ProSolv will be the best choice for your application. Advice, literature, changeover instructions are all available to make the change quickly, easily and at no extra cost of usage.

For more information about replacing nPB please visit: https://www.vapour-degreasing.com/npbreplacement/

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September 2020 ENGINEERING UPDATE

Let your bearings grow old gracefully

Without any adverse conditions, the time it takes for a bearing to reach its fatigue life can take years. However, predicting when this will happen is very difficult.

Contrastingly, it’s easy to identify a bearing that is approaching the end of its life, as cracks begin to appear in the steel raceway and the balls and the surfaces will begin to flake. This creates a build up of debris in the bearing, which leads to friction and there is usually an increase in noise and vibration when the bearing is in use.

This process is known as spalling. It occurs because non-metallic inclusions in the steel begin to crack under repeated pressure and these cracks grow and work their way to the surface. There’s nothing that can be done to avoid this.

However, the first step to extending bearing life is to make sure you select a manufacturer that can be relied on to use high quality steel that will have fewer non-metallic inclusions.

the steel raceway and balls, changing the geometry of the bearing. This will reduce the bearing’s efficiency and increase the levels of noise and vibration, which will have a detrimental impact on surrounding components, so it is important to maintain clean work areas and use clean lubricants.

When contamination is in the form of water entering the bearing, or precipitating water accumulating in the bearing when the machine is cooling, you will certainly get corrosion if the bearings are made from standard steel. The areas where rolling elements are in contact with the raceway are most vulnerable because the pressure of the balls during idle periods may force lubricant away from the area of contact.

Contact type bearing seals may prevent corrosion and a lubricant with a corrosion inhibitor will also help. However, in some cases you may need to invest in bearings made from corrosion resistant materials.

Installation mishaps

Abrasion and corrosion Allowing contamination of bearing lubrication is one of the fastest ways to kill a bearing. There are several ways abrasive dirt can enter a bearing. If the seal is damaged or tampered with during installation or routine maintenance, dust will be able to enter the bearing. If the seal is not replaced, it remains vulnerable to debris from any nearby processes. It is also possible to introduce abrasives by selecting a sub-standard bearing lubricant.

However small the particles of grit may be, the motion of the bearing grinds the foreign material across the surface of

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Bearings are delicate components, so something as simple as applying too much pressure during installation can cause you serious problems down the line. For example, poor mounting practices or dropping a bearing during installation often results in true brinelling.

This is where dents appear in the raceway which cause excessive vibration during rotation. This can be avoided by simply applying pressure only to the part to be press fitted at installation.

Another easily avoided phenomenon is electrical fluting. Electrical fluting presents as a regular pattern over the bearing. This

It’s easy to believe that something made of steel will last forever. However, no matter how well you care for bearings in your plant equipment, they will eventually wear and need to be replaced. This is because they have what’s known as a fatigue life. Here, Chris Johnson, managing director of steel bearing specialist SMB Bearings, explains how to avoid shortening their lifespan. results from an electrical current passing through the bearing, which is often caused by static electricity from conveyer belts and current from unsatisfactory welding setups.

If you ensure that welds are grounded and that there is a grounding strap on nearby conveyors you can easily avoid this problem.

Loads and over-heating When you combine heat with heavy loads you get a whole new pool of problems. Any process that involves high temperatures creates the risk that bearings will overheat. When a bearing exceeds its maximum temperature, the load capacity of the steel rapidly reduces, and the bearing is easily deformed, often resulting in complete, catastrophic failure.

In addition, heat will cause bearing lubrication to evaporate and deplete. If your bearings are operating at more than the rated temperature of the lubricant, life is drastically decreased so it makes sense to specify a lubricant that will cope with more than the expected maximum temperature.

Whatever the application, if you want to keep your bearings rolling right on up to their predicted fatigue life you need to take care of them.

If bearings keep failing, it is probably because the size, shape, type, material or lubrication is not suitable for your application. In these instances, you should approach a bearing specialist, like SMB Bearings, that can advise you on the most suitable and cost-effective replacement.



September 2020 ENGINEERING UPDATE

Choosing the right heat exchanger for wastewater applications

By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers Heat exchangers are crucial to many processes in the water industry, whether as part of an aerobic or anaerobic digestion plant, for cooling or evaporation, and for sludge concentration.

There are a number of different types of heat exchanger available and choosing the right one can appear daunting. For both economic and environmental reasons, maximising productivity is essential in order for companies to remain competitive, and correct heat exchanger selection is key to this.

What is productivity?

Productivity is measured by the ratio of output per unit of input. Many water companies see it as a balancing act – how can they increase their output without increasing their costs? It is closely linked to efficiency, ensuring that every piece of equipment and every part of the process is optimised, delivering greater value for money to the operator.

Understanding the process The most important criteria when specifying a heat exchanger is to ensure that it will be fit for purpose. To do this, it is important to understand both the material being treated, the heating (or cooling) medium, and the process involved. Is the material in question liquid (dirty or clean water) or semi-solid (sludge)? Is it viscous? What is the extent of the temperature difference required?

Other information must be provided for correct heat exchanger selection, too.

For example, does the product contain solid particles? Consider also whether it is shear sensitive, if the process needs a scraped surface heat exchanger (SSHE), or whether well-designed corrugated tubes will be enough to prevent fouling.

Also bear in mind the space available for the heat exchanger, and the connection pipework and fittings. The more information an operator can provide, the more likely they are to get the right heat exchanger for the job.

Avoiding a false economy After thoroughly researching the options available, it may be that that more than one type or model of heat exchanger is suitable for the purpose. In

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order to ensure optimum productivity, it is important to consider the total cost of ownership (TCO). Although some operators can be swayed by the initial purchase price, this can be a false economy. The lifecycle cost of a heat exchanger, particularly one used to process difficult materials such as sewage sludges, heavily depends on the costs of cleaning and maintenance – buying a cheaper design which is more prone to fouling can quickly become more expensive to operate. To keep productivity high, it is therefore essential to consider the TCO of a heat exchanger, not just the purchase price.

Energy efficiency The running costs of a heat exchanger also have a large effect on its overall financial viability, so selecting a heat exchanger which is energy efficient is key to enhancing productivity. HRS Heat Exchangers have developed a number of features which are specifically designed to improve the operational energy efficiency of both their tubular and scraped-surface heat exchangers. These include the use of corrugated tubes specifically designed for high fouling sludges, such as the DTI Series of Double Tube Heat Exchangers, and unique SSHE designs including the Unicus Series.

The Unicus Series is based on traditional shell and tube heat exchangers, with the addition of a patented stainlesssteel scraping mechanism which is hydraulically moved back and forth within each interior tube. This movement minimises potential fouling of the product by keeping the tube wall clean, and also creates turbulence within the material.

Both of these actions help to increase heat transfer rates and together, they create a highly efficient heat transfer process ideal for high fouling viscous materials like sludges.

Maintenance matters Using the wrong heat exchanger can soon prove costly in terms of maintenance and spare part costs. In fact, HRS have been asked to replace a

number of alternative heat exchanger designs in the wastewater sector when they have become too expensive to clean and maintain. All HRS heat exchangers are designed to make cleaning and maintenance as easy and flexible as possible, while their clever design reduces cleaning and maintenance intervals.

The fact that HRS equipment can be remotely monitored also makes it easier to anticipate problems, enabling predictive maintenance. Being able to quickly identify issues helps to keep efficiency high and provides more time to plan for maintenance, resulting in less downtime for operators.

15th International Exhibition of Railway Equipment, Systems & Services

F 1 WS

O H S AT

E R G 2

S A T AN

T

IL A R IC

T N E EV

CONNECTING THE INDUSTRY 13TH INTERNATIONAL RAILWAY INFRASTRUCTURE EXHIBITION

In 2021, Railtex will play host to Infrarail at the NEC, Birmingham from 11-13 May. The UK’s most important events in the rail calendar will come together to form the ultimate show for the rail industry.

To be part of the most comprehensive rail exhibition of 2021 contact the team on +44 (0)1727 814 400 or via email railtex@mackbrooks.co.uk

T H R E E S H O W S | T W O D AY S

B R O U G H T TO YO U B Y D ATAT E A M B U S I N E S S M E D I A

Sensors & Instrumentation live

WHEN

29-30 JUNE 2021

WHERE

NEC, BIRMINGHAM

CO-LOCATED

In June 2021, the NEC Birmingham will host an industry event like never before as three leading exhibitions Sensors & Instrumentation Live, Electronics Industry Live (formerly known as What’s New In Electronics Live) and Future Robotics Live - join forces for the first time.

This exciting new partnership will also offer a one ticket policy with co-located events, Interplas, Med-Tech Innovation Expo and TCT 3Sixty opening the doors to thousands of visitors and potential clients for your business.

Get in touch to find out how your business could benefit from exhibiting and secure your bespoke package today!

DESIGN, EMBEDDED, ENGINEERING & MANUFACTURING www.electronicsindustrylive.co.uk WANT TO GET INVOLVED? Contact Harriet Campbell on T: 0844 381 4235 or at E: hcampbell@datateam.co.uk

ROBOTICS, MOTION CONTROL, VISION & AUTOMATION www.futurerobotics.co.uk WANT TO GET INVOLVED? Contact Aamir Rashid on T: 01622 699 188 or at E: arashid@datateam.co.uk

Sensors & Instrumentation live

SENSORS, TEST, MEASUREMENT & CONTROL www.sensorsandinstrumentationlive.co.uk

WANT TO GET INVOLVED? Contact Louise Pudney on T: 01622 699 104 or at E: lpudney@datateam.co.uk



September 2020 ENGINEERING UPDATE

Three shows in one location an opportunity not to be missed!

As lockdown restrictions ease, we look ahead to see what the post COVID-19 resurgence looks like, and we are excited by the trio of events that Rapid News Group are organising at the NEC from 29 June – 1 July 2021. After months of uncertainty this critical period of economic rebound provides opportunities.

TCT 3Sixty, the event for 3D printing and additive manufacturing will be co-located alongside Rapid News Group's other highly successful industrial events: Interplas, the UK's no.1 plastics show and Med-Tech Innovation Expo, the UK’s leading medical design and manufacturing technology event.

TCT 3Sixty – The event for 3D Printing & Additive Manufacturing Intelligence www.tct3sixty.com As a leading authority in additive manufacturing, 3D printing, design

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and engineering technology for the last 30 years, The TCT Group are excited to lead the way with their re-imagined event TCT 3Sixty.

TCT 3Sixty will deliver business critical intelligence with a comprehensive conference programme delivering world-class content across multiple stages, each offering innovative and interactive 360-degree insights into how to get the best from existing additive technology or how to invest and choose the most appropriate new 3D printing technology.

The event will connect the additive community, using a rich mix of interactive features, pavilions and networking events including a meetings programme and learning seminars that will provide tangible value to an attendee, providing a return on investment immediately.

By focusing on cutting edge applications, expert analysis and commentary, TCT 3Sixty will help designers, engineers and buyers evaluate, adopt and optimise their additive requirements.

ENGINEERING PDATE September 2020 The TCT Group mission goes beyond simply raising awareness; it is focused on developing a 360-degree understanding of the potential of additive manufacturing and 3D printing technology to increase utilisation at all stages of design, engineering and manufacturing.

MED-TECH INNOVATION | expo

Med-Tech Innovation Expo: Medical Engineering www.med-techexpo.com Med-Tech Innovation Expo is the UK and Ireland’s leading event for medical device design and manufacturing technology.

Interplas –Innovation Happens Here www.interplasuk.com Interplas is the UK's leading plastics industry event and an exciting showcase for the manufacturing processes, technologies and services essential to the plastics sector. In its 70th year, Interplas 2021 will see more than 500 exhibitors present solutions, products, machines and ideas from across the entire spectrum of moulding and forming machines as well as materials, automation, contract manufacturing and supporting technologies including software, testing, inspection, surface treatments and much more.

Over 12.000 attendees from the UK manufacturing community will attend to discover solutions to their challenges, to make connections and source the latest technologies and innovations.

Alongside the show floor an engaging three-stage conference programme is scheduled, with key themes of Advancing UK Plastics, Sustainability and Extrusion.

These learning opportunities alongside a matchmaking programme and networking opportunities will ensure a visit to Interplas offers tangible value to an attendee immediately with intelligence and contacts that will continue to pay dividends long after the show closes.

At Med-Tech Innovation Expo the show floor will host a wealth of exciting features including cutting edge technology zones, association member and country pavilions, a VIP meetings programme, and the ever popular Start Up Zone.

Visitors from the medical engineering and manufacturing community will be able to see the entire spectrum of advanced technology, materials and solutions for concept, design, validation and manufacture. The showcased solutions will help attendees design and manufacture the next generation of medical and healthcare devices.

Med-Tech Innovation Expo 2021 is further enhanced by three conference stages. Each one presenting content of the highest calibre for every type of stakeholder in the Medtech supply chain – from solving design and engineering challenges through to market access.

This trio of shows will create an engaging and useful experience for the attendee which means better educated prospective buyers and therefore the events will deliver exhibitors and sponsors greater commercial opportunities both in the short and long term. Registration does not open until the autumn but if you want to be part of these amazing events please contact organisers Rapid News Group or visit one of the show websites:

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

September 2020 ENGINEERING UPDATE

RSS Engineering Division Opens FAAC Doors Rope and Sling Specialists Ltd. (RSS) has been named an installer of FAAC’s range of automatic commercial and industrial doors.

The partnership fits within the recently expanded engineering services division at RSS, whose core business remains in the lifting and rigging sector. The agreement will see the company provide a full range of automatic pedestrian, swing, sliding, folding and revolving doors from six strategic locations across the UK.

it for continued growth. Ongoing diversification is key to that, typified by the FAAC installation agreement.

We have an existing working relationship to build from and, while we might not be a typical installation partner, we’re enthused about working with the outstanding brand in the auto-door sector.”

FAAC is a business unit within the Italy-headquartered FAAC Group, which specialises in modular automation solutions for vehicle access and pedestrian entrances, for houses, offices, hotels and industrial facilities. Other divisions within the group cover access control and parking, for example, but they are not covered within the RSS partnership.

Richard Weeks, regional sales manager at FAAC, explained that the company’s supply chain works exclusively through such installation partnerships, of which it has approx.

400 in place in the UK alone.

Steve Hutin, managing director at RSS, said: “The recent climate—which needs no explanation—has given us cause and motivation to look at our business as a whole and prepare

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Those partners provide specifications to the manufacturer, which delivers the modular products for installation at the end user via a UK-based workshop—one of 13 such FAAC sites globally.

Weeks said: “The concept with RSS is the same as with our other partners,

although they give us access to different markets because of their diverse customer base.

"Our products stand out in the level of service we provide, combined with quality of manufacture and longevity of use. However, the business model is based on selecting the right partners to promote and install our product at the point of use; in RSS we’ve chosen wisely again, I’m sure.”

Hutin said: “All potential enquiries are handled directly by our engineering services division from concept to commissioning. We have a three-year strategy that will support growth across all areas of the organisation and we will be announcing further, similar partnerships as they are finalised in the near future.”

The FAAC range is suited to retrofit and new-builds.

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

September 2020 ENGINEERING UPDATE

JET PRESS uses Furniture Fittings to Save Lives JET PRESS is working with Rolls-Royce, Aston Martin, Multimatic, the Manufacturing Technology Centre (MTC) and the NHS on a revolutionary new Aerosol Generating Procedure (AGP) Shield. Fir Tree Buttons and Plastic Screw Cover Clips – more often found in furniture - play an important role in the finished product.

The AGP Shield provides a high level of protection to medical teams in Intensive Care, protecting them from airborne particles. Following trials in various hospitals, medical teams are happy they can use the AGP shields for patients on ventilators.

Rolls-Royce and MTC engineers worked with NHS teams to develop the prototype. After the initial trials engineers from Aston Martin and their supplier Multimatic were brought in to refine the design.

This next iteration was made from strong, lightweight, vacuum formed PET G. Silicone sheets over apertures allow the medics to get their hands inside the shield so they can care for the patient without significant exposure to the virus.

make the shield heavy and difficult to clean so we have been hunting for solutions. We have tried bonding the silicone directly to the shield, and have also tried various plastic fasteners but unfortunately all of our current attempts have failed for various reasons

The Challenge of Fixing Silicone to PETG

The fastener needs to be simple and quick to use, and needs to have a smooth finish on the inside to allow for easy cleaning. It must be able to cope with varying thicknesses of material as the shield itself is vacuum formed and therefore the material thickness varies

This is how Alan Pardoe explained the challenge to JET PRESS. “The design started off by using metal nuts and bolts to hold the silicone sheets in position; however these 56|

ENGINEERING PDATE September 2020

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from around 5mm to 2mm. It can be single use, but the main requirement is that once used it must provide a tight fit. Some of the plastic fasteners we have tried pull apart too easily and so when the medics have lifted the shield by the front silicone flaps the fasteners have “popped” apart, which is obviously not a good solution.”

Fir Tree Fasteners to the rescue For the AGP shield Fir Tree Buttons are an easy to use, reliable, lightweight and cost effective solution. The only problem was that the sharp end of the Fir Tree button was exposed inside the shield. So, JET PRESS paired the Fir Tree Button with a Screw Cover Clip to provide a smooth finish inside. |57



September 2020 ENGINEERING UPDATE

A clean connection for the food and beverage industry The newest addition to the HARTING Han® portfolio is the Han® F+B, a range of connectors which have been specially designed for the requirements of the food processing, bottling and packaging industries.

Within these sectors, hygiene and safety are key considerations, meaning machines and equipment must be both easy to clean and designed so dirt pockets and bacteria cannot accumulate.

The Han® F+B has been specifically developed as a suitable product for the food zone and splash zone and there are several innovations which make it the ideal solution. Firstly, all hoods, housings and seals are IP69K rated, so the connections are fully protected and resistant to the water jets used to clean equipment.

They also have large nooks and surfaces in accordance with the guidelines of the European Hygienic Engineering & Design Group (EHEDG), which allows cleaning and disinfecting agents to flow unhindered.

The range is Ecolab approved, so it is resistant to the highly aggressive cleaning agents used in the food and splash zones. As the housings are constructed from polypropylene, they conform to the directives of FDA 21. All surfaces also have a smooth finish, which prevents impurities and bacteria from accumulating, whilst the portfolio can function in a wide temperature range from -40 to +125° C. As well as hygiene and safety concerns, HARTING have also considered the impact of machine downtimes, designing in features which keep disruptions on the production line down to a minimum.

With the Han® F+B, operators do not need to open any cable glands on the control cabinet in order to decouple field devices, eliminating the complex disconnecting and reconfiguring of fixed wiring. This solution also allows for fast replacement of defective components and a more efficient configuration when changing components, allowing businesses to shorten set-up times and reduce production stoppages.

The housings can be used with hybrid contact inserts for all types of industrial transmission, including data, signal and power, a versatile connector concept which makes it possible to configure future-proof machine design for processing units, including Ethernet. With the use of an adapter, the user can integrate a selection of Han® 3A inserts, including RJ45 interfaces, signal inserts with up to 21 poles as well as power contacts for currents up to 40 A. To learn more about the Han® F+B and download our FREE whitepaper, which gives more detailed information about using connectors in food and beverage facilities, please visit www.harting.com/UK/en-gb/connectors-food-industry or email salesUK@HARTING.com. www.youtube.com/watch?v=ljrPj-MHyAc&feature=emb_logo

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“

Hygiene and safety are top priorities.

„

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One Range. No Limits: www.HARTING.com/UK/en-gb/connectors-food-industry



September 2020 ENGINEERING UPDATE

Renishaw joins project to automate additive manufacturing post-processing Global engineering technologies company Renishaw is collaborating with UK startup business Additive Automations, as part of a project to automate metal additive manufacturing (AM) post-processing, which involves using collaborative robots (cobots) to perform support structure removal.

The project could reduce the average cost per part by 25 per cent, furthering AM’s potential as a costeffective option for large volume production lines.

Additive Automations is a Sheffieldbased start up that creates robotic systems to automate additive manufacturing. After obtaining funding from UK and Canadian bodies, its founder and CEO, Robert Bush, collaborated with both Renishaw and the University of Sheffield Advanced Manufacturing Research Centre (AMRC). Since August 2019, Renishaw has been assisting Additive Automations’ progress by providing its industry leading AM expertise.

Renishaw provided four examples of AM builds, so the start-up could demonstrate its support structure removal system. The four AM parts were designed for medical, oil and gas, automotive and mechanical engineering applications. Testing its robotic system on parts already being used in industrial applications will help Additive Automations

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demonstrate the potential of its product.

The project, named Separation of Additive-Layer Supports by Automation (SALSA), aims to use robotics and deep learning to digitalise some of the few remaining manual processes left in AM. Cobots were chosen for their high payload-to-size ratio and integrated force sensors, which collect data to determine the geometry of AM parts. Software then analyses the data, using digital twin technology.

The output is then used to determine where the support structures are so that they can be removed using an end-effector tool.

“Automating support removal and finishing in AM completely changes the economics when scaling up AM, and for the first time makes it feasible for manufacturers around the world to adopt this technology in rapid production,” explained Robert Bush.

“The digitalisation of AM also comes with an increase in quality, traceability and repeatability. Given that on average almost two thirds of post-

processing costs are from finishing and support structure removal, we believe automation can reduce costs by an average of 25 per cent per part.”

“Improvements in post-processing could bring AM to the forefront of new applications in medical and aerospace applications,” explained Bryan Austin, Director of AM Sales at Renishaw. “An automated manufacturing process could make AM adoption more appealing to manufacturers operating large volume production lines.”

Renishaw is a leading global manufacturer of metal additive manufacturing systems, and is at the forefront of AM development. The company has worked to innovate additive manufacturing technology and develop new applications in sectors as varied as aerospace, motorsports and dental care.

For further information on the latest advancements in additive manufacturing, visit www.renishaw.com/additive

THE FUTURE OF DIGITAL PRESSURE MONITORING The GD4200-USB



September 2020 ENGINEERING UPDATE

Elta Fans Bolsters BSI Certification for Smoke Fans with VSDs Testing is now complete for Elta Fans’ Applied Technology division, meaning ventilation specifiers can access fully compliant high-temperature fan packages complete with a variable speed drive (VSD).

By testing its high-performance smoke fans alongside various VSDs in accordance with BS EN12101-3:2015, Elta Fans Applied Technology aims to offer the market a more competitive holistic solution. In addition, Elta Fans’ BSI certification is now issued from the Netherlands to ensure its products can be CE marked irrespective of the outcome of Brexit negotiations.

With the construction industry tackling a balancing act of declining budgets alongside improved sustainability and safety targets, Elta Fans strives to develop highly efficient impellers that provide an economic way of moving high volumes of air at low to medium pressures.

By incorporating the VSD with the fan itself, system specifiers and designers are offered a streamlined approach to compliance.

running with VSD during the test means that the fans and VSD can be used together without the need for bypassing or fitting filters to the VSD in fire mode.

Elta Fans Applied Technology’s specialist production plant is based in Fareham, Hampshire. The division designs, manufactures, and supplies fans for a variety of specialist OEM applications, including power generation, offshore oil and gas, agriculture, and marine. Capable of delivering

unrelenting trend across Europe, the limitation for space is leading to the construction of more mid-rise to high-rise buildings.

"In turn, this is driving an increase in demand for high-performance equipment compliant with stringent government regulations to ensure the safety of people and property.

The highly bespoke and precisionengineered fans were tested at BSRIA’s testing facility in Bracknell, for F300 (300°C 2Hr) and F400 (400°C 2Hr). Having the fans

both standard and bespoke products, the company utilises expert knowledge and the latest technology to develop solutions for customers across the globe.

The Fareham site processes raw materials to produce fan casings and ancillaries, before assembling them and selling to these customers.

Bradley Crisp, Applied Technology Sales Engineer at Elta Fans Applied Technology said: “With urbanisation becoming an

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"While there are different ways to ensure the systems are compliant, the most effective and optimal way for our customers is for our fans and VSDs to be tested together, hence why we have sought the BSI accreditation.”

For more information on the testing process and Elta Fans’ updated certification, contact the Elta Fans Applied Technology Division on 01489 566 500.

For more information on Elta Fans Applied Technology, visit: www.eltafans.com/divisions/ applied-technology/



September 2020 ENGINEERING UPDATE

West Yorkshire SME eyes electric vehicle revolution with new workholding innovations A family-owned engineering company in West Yorkshire is aiming to establish itself as the experts in workholding devices for the production of machined components in electric vehicles.

C

raftsman Tools is one of only a handful of British companies that specialises in workholding for machining processes (the device that locates and clamps components while they are machined), and the only one that designs and manufactures all of its own products. As a result of partnerships built up over several years, Craftsman Tools already produces a workholding device used by almost all major automotive manufacturers in the machining of camshafts, and is familiar with the unique challenges faced by the industry.

The initial developments are for a friction welding process to bind two parts of the CV shaft and then machine the joint in situ. Critically, Craftsman Tools will use its expertise to develop workholding equipment that will last in the harsh manufacturing environments of a fiction welder to ensure that the required geometric tolerances can be achieved. Craftsman Tools already has supply chain partnerships with companies targeting major electric vehicle companies, such as Tesla.

Electric engines have considerably fewer moving parts than internal combustion engines (20 vs 2,000) therefore the market for machined components is considerably smaller and there is an even greater emphasis on producing the remaining parts more accurately with tighter tolerances. The initial concept is for a modular design which can be adaptable to different CV shafts and similar components, increasing its versatility with a host of automotive manufacturers.

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Managing Director, Robert Johnson, said: “This is a very exciting project, and one that plays to all of our expertise and knowledge. Sales of electric vehicles increased by 25% last year, and an increase in the uptake of electric vehicles is crucial to the UK achieving its net-zero carbon goal by 2050. It will be a large step towards Craftsman’s own goal of moving away from carbon-intensive industries and towards the green economy.

“Through this project Craftsman Tools’ workholding can become a standard item in automotive factories around the world, each of them proudly made in our factory here in West Yorkshire.” craftsmantools.com

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

September 2020 ENGINEERING UPDATE

New approach to equipment and process efficiency key to industry recovery The impact of COVID-19 on UK industry and manufacturing means a new approach to sourcing processing equipment is required, says Aggreko.

As capex constraints tighten in the wake of the coronavirus’s impact on supply chains, companies are under more strain than ever to ensure their equipment is as efficient as possible.

Yet businesses can circumvent financial obstacles and limitations by thinking outside-the-box when it comes to equipment maintenance and purchasing, say the leading temporary power, cooling and heating solutions supplier.

The disruption caused across industry supply chains has been pronounced and prolonged, affecting logistics, workloads and business cashflows, leaving businesses without the capital to upgrade or update their existing equipment and processes. Companies are therefore more reliant on older and less efficient solutions which lead to escalating operational costs due to breakdown-induced disruption.

Others may find themselves with permanent installations that are inappropriately sized for currently reduced demand, and also ill-suited to the predicted, pronounced spike in activity predicted when the economy rebounds.

Aggreko’s latest campaign, ‘Hire Efficiency Expectations,’ aims to encourage companies to take an innovative approach to optimising their processes and equipment, so they can do more with less in these testing times.

“There’s no getting away from the fact that industry has been massively disrupted by COVID-19,” says Matt Watson, Manufacturing Specialist at Aggreko. “In this altered business landscape where purchasing permanent installations may no longer be possible, it becomes even more vital to improve process efficiency. By taking an innovation approach to applications and solutions, process, production and operations managers may be

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surprised by what savings can be achieved.”

A survey of 200 energy managers conducted by Aggreko in 2019 demonstrated the ‘capex crunch’ problem, with 59 per cent of respondents saying their requests for new equipment to reduce energy consumption had been turned down.

The company expects this figure to increase post-pandemic, and with 59 per cent of those surveyed also saying they did not use hire to avoid capex restrictions, different perspectives may be needed.

“Industry needs to consider new strategies when it comes to purchasing equipment and improving process efficiency,” says Matt. “By looking at strategic hire as a viable method of financing new installations, companies can avoid the further capex constraints caused by the coronavirus.”

Matt concludes: “Equipment rental gives businesses a route out of being reliant on ageing, unreliable installations that provide diminishing returns. Additionally, hired solutions are ideally placed to guard against the volatility inflicted by the pandemic.

The modular and scalable nature of such solutions allows businesses to react quicker to changing circumstances and the peaks and troughs of demand, while maintaining excellent process efficiency throughout.”

For more information on how to improve efficiency in the food and beverage industry following the COVID-19 pandemic as part of Aggreko’s latest ‘Hire Efficiency Expectations’ campaign, visit: www.aggreko.com/en-gb/ news/2020/noeur-articles/hireefficiency-blog-manufacturing

EXPERTS IN PUMP TECHNOLOGY Our progressive cavity pumps, macerators and control systems are used across all industry sectors wherever thin to highly viscous, shear-sensitive, aggressive or abrasive media must be conveyed at low pulsation rates.

SEEPEX’s portfolio also includes digital solutions, consulting, spare parts and after sales services.

“SEEPEX stands for technological leadership, excellent management and outstanding product and application expertise. Focusing on our core competencies and know-how enables us to take the best, most forward-looking course of action for each part of our business. We identify innovative approaches that bring about positive changes for the entire industry.”

PETER MCGARIAN MANAGING DIRECTOR, SEEPEX UK LTD.

SEEPEX UK Ltd. | sales.uk@seepex.com | www.seepex.com



September 2020 ENGINEERING UPDATE

West Wales Company is a Trailblazer With New Kerf Machine Founded over 30 years ago in a small ‘shed’, CLH Trailers has grown into one of the UK’s leading manufacturers of trailers for the agricultural, fishing, marine, sport, leisure and farming industries.

As the product range has grown, so has the factory, staff levels and investment in technology – with the latest addition to the plant list being a plasma cutting machine from Rochdale manufacturer Kerf Developments.

Located in the picturesque village of Saint Clears, between Camarthen and West Wales holiday hotspot Tenby, the 15 employee business manufactures hundreds of trailers every year; and with anything from 50 to 200+ components in each trailer, productivity and precision are critical for CLH Trailers. With a burning desire to keep moving the business forward, Managing Director Mr Chris Hussell and shop floor foreman of over 20 years, Mark Reynolds started looking at available options for cost savings and productivity enhancements.

Taking up the story, Mr Reynolds says: “First and foremost, we wanted to buy British. We looked for a viable option and we realised that laser cutting wasn’t suited to our business whereas plasma was a perfect fit. We found several vendors and we then spoke with customers for their testimonials. Out of the UK manufacturers, it was Kerf that had a reputation above all others.

This reputation was backed by their customer approach and of course, the quality and productivity of their demonstrations. We were about to purchase a RUR 2500p plasma

machine with a 4 by 2m bed – and then the pandemic hit. We initially put the order on hold, but as the lockdown continued and we retained a steady level of business, we realised that the potential benefits of the Kerf plasma would send our business on a forward trajectory, so we finalised the order during the pandemic and the machine was delivered in July.”

Primarily cutting black steel and aluminium in thicknesses from 1.5mm to 25mm, CLH Trailers specified the RUR2500p machine with the user friendly Burny 10 LCD CNC controller, the powerful 275amp Lincoln Spirit II 275 plasma unit and Lantek software to drive the high-definition Ultrasharp cutting technology. Building a new factory unit specifically for the new Kerf machine, Managing Director, Chris Hussell says: “I wanted a machine with a robust build quality that is capable of running all day, every day. The Kerf machine certainly gives us that. The plasma unit can cut steel beyond 60mm thick, which is more than we need and the precision, repeatability and edge finishes are exceptional. We predict that the machine will pay for itself in less than 2 years.”

Creating Savings Everywhere Looking closer at how the new Kerf plasma will create such significant savings, Mr Reynolds continues: “As a business, we typically have 6 staff manufacturing

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parts to complete an average throughput of two trailers each day. The majority of parts require guillotining, notching, drilling, grinding, corner rounding, bending and welding before galvanising. Each of these processes can be slow and labour intensive; and with each subsequent operation, there is an increased opportunity for error and potential scrappage. With the Kerf machine, we can do many of these operations in a single set-up. Going forward, this will free-up at least two employees for other tasks. A labour saving of at least £40k is great; but equally important for a company in a rural area is that the plasma allows us to grow the business whilst redistributing the highly skilled staff we have.”

Providing a practical example of savings, the mudguards on each trailer are processed in quantities of 6 to 8 from an 8 by 4ft sheet of 1.5mm thick black steel. “The batch of mudguards would take 10 minutes to cut on a guillotine, then another 10 minutes on our variable angle notching machine followed by another 10 minutes for marking and subsequent drilling with the final process before bending being the grinding and rounding of the corners, which takes another 5 minutes. If you add to this total of 35 minutes additional time to move the mudguards from machine to machine and position the parts in jigs, you’re looking at over 40 minutes. The Kerf plasma will profile and cut the holes in less than 10 minutes with far superior precision. Not only does the Kerf machine reduce our cycle times by more than 75%, but it also removes the opportunity for operator error, improves quality and consistency, eliminates hand finishing and freesup capacity from existing machines.”

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

September 2020 ENGINEERING UPDATE

MetLase’s rapid tooling offer in demand as largest ever tool delivered to aerospace giant One of the UK’s leading engineering specialists has just completed its largest ever rapid tooling project as demand for shorter lead times intensifies.

MetLase, which is a joint venture between Rolls-Royce and Unipart, has designed and manufactured a stainless steel tool measuring 4 metres in diameter and capable of holding a component 2 metres tall.

The company met the challenge of the major aerospace customer head-on, with manufacturing signoff and delivery completed in just one month…150 days quicker than the client would have previously expected.

It’s just one in a long list of notable successes from the Yorkshirebased firm, who is rewriting the rule book when it comes to rapid tooling development by harnessing the design skills of a 25-strong engineering team and unique joining solutions that replace the traditional welding process.

“Typical conventional tooling approaches often take a massive block of material and then you machine away the bits you don’t want to form the tool,” explained Richard Gould, Business Development Manager at MetLase.

“We take a different stance, basically laser cutting sheet metal, usually

stainless steel or titanium, into lots of different elements. These are then joined together to form the tool using our very own manufacturing technique, removing the need to weld them together and the distortion that usually comes with this approach.”

modify a composite wing fixture for F1 in just 12 hours and responding quickly to a premium British automotive manufacturer’s styling department change that saw it accommodate quad pipes instead of twin.

He continued: “Everything is controlled ‘in-house’ at MetLase and that’s another big benefit as we control the entire process. We have all the technology we require, we have the engineering talent and we are always adding to our standardised feature library and parametric modelling system that will allow us to instantly access formula for creating tools for specific applications."

Interest has come from automotive and aerospace initially, but the firm is now seeing other sectors, such as construction and medical, exploring rapid tooling and the benefits that can give them.

“All of this means we are able to work with customers to reduce lead times to weeks if not days, meaning the client has more time to iterate their component design before signing off the tooling."

“As well as the time saving, our service can also help mitigate massive financial costs associated with last minute changes.”

MetLase, which employs 30 people at its AMP Technology Centre base in Rotherham, has already completed a number of high-profile projects using its rapid tooling development.

This includes creating a pipe fixture in less than 24 hours, using parametric modelling to

Richard concluded: “The MetLase approach means the design engineer you first talk to will actually oversee the entire project, often completing the manufacturing of the tool themselves.

Unlike traditional processes, we can also test ideas out relatively quickly by developing prototype tooling at little cost before agreeing full production.

“It can also be a crucial lifeline for companies looking to ramp up production or create new manufacturing cells quickly. Our rapid tooling service means we can take that headache away from them, leaving them free to concentrate on other business critical activities safe in the knowledge their tool or tools will arrive weeks ahead of when they were initially expecting.”

MetLase will be hosting the latest in a series of best practice webinars on Thursday at 3pm, this time covering in-line testing and validation for technical manufacturing.

Experts will explore how advances in digital quality checking will improve and shorten the quality checks using systematic, standardised techniques.

For further information, please visit www.metlase.com or register for the webinar -https://bit.ly/testing-andvalidation

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Renold Gears OQSx Oil Quality Sensor

The Renold Gears OQSx Oil Quality Sensor is your ideal solution for accurate real time gearbox oil condition monitoring.

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

Directory

September 2020 ENGINEERING UPDATE

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

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

ECi Software Solutions

TR Fastenings LTD

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

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

Phoenix Mecano Ltd

Blackfast Chemicals Ltd

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

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

Monitran

Ecopac (UK) Power Ltd

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

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ODU-UK LTD.

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

Directory

ENGINEERING PDATE September 2020

Foremost Electronics Ltd

Seepex UK Ltd.

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

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

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

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

Ilapak Ltd 29 Riverside Way Uxbridge UB8 2YF

1 Brownfields Court Welwyn Garden City Hertfordshire AL7 1AJ

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

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

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

Rotech Machines Limited

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