DPA_21_09

Editorial Comment

04: Springboarding the Olympics into a new technological era

Cover Story

06: Polymer plain bearings make metal pillow blocks more economical

General Feature

08: ABB robots help deliver fast palletising solution for soft drinks maker

Motors & Motor Control

10: Can DC motors be used at high temperatures?

12: Improving standards for sustainability of electric motors

14: Use sensorless vector control with BLDC and PMS motors

18: Why VFDs will be integral to being ‘Fit for 55’

21: Running a brushed DC motor as a generator

Machine Building & Safety

24: Revolutionary underwater diver-safety monitoring system

27: The benefits of using Safety over EtherCAT in your next machine design project

30: Safety constraints are driving innovation in advanced material use

32: Machine safety: is it on or off?

Fasteners & Adhesives

34: Fastener challenges for hybrid and electric vehicles

36: Rapid-response composite wrap repairs damaged chemical tank

38: Investing in adhesives: Why ROI is more than just the payback period

41: How can the use of adhesives in the manufacturing process impact sustainability?

Springboarding the Olympics into a new technological era

Backin 1964, the first Olympic Games to be held in Tokyo marked a technological turning point in the competition’s history: described by one British journalist as the “science fiction” Olympics, it was the first major sporting event to be broadcast live via satellite. Almost 60 years later, the longawaited Tokyo 2020 was one of the most hightech events to date, with groundbreaking advances in robotics, tracking technology, and sustainability.

Here are just a few innovations that were deployed at Tokyo 2020:

• Intel and Alibaba launched 3D Athlete Tracking (3DAT), a cutting-edge tracking technology that combines AI and computer vision to generate 3D motion-capture models, delivering rapid, real-time performance data on the velocity, acceleration, and biomechanics of athletes’ movements.

• The Games also saw advances in clothing technology. Among these were Speedo’s Fastskin swimsuits,

Cover

Group Editor: Paige West paige.west@imlgroup.co.uk

Assistant Editor: Sophia Bell sophia.bell@imlgroup.co.uk

Publisher: Andrew Quenault andrew.quenault@imlgroup.co.uk

worn by the US swim team, who won a total of 30 medals. Working with various partners, including the National History Museum and Formula 1, these innovative lightweight swimsuits were inspired by the hydrodynamics of shark skin, to enhance flexibility and reduce drag. 62 percent of world record-breaking swimmers have worn Fastskin since the line was first launched in 2019.

• The Tokyo 2020 Robot Project was designed to showcase the usefulness of robots in supporting people. AI-powered, self-driving Field Support Robots (FSR) – equipped with cameras and sensors – were deployed to support staff and collect items like javelins and shot puts. Miraitowa and Someity, Human Support Robot (HSR) mascots, welcomed athletes to the venues with handshakes, waves, and a variety of human-like facial expressions. Meanwhile, the T-HR3 was programmed to mirror the movements of its remote human handlers. Controlled by VR and an exoskeleton, this life-size humanoid robot could highfive and even hold a conversation with athletes.

In the light of COVID-19 restrictions, perhaps the most important of Tokyo’s robotic fleet was the T-TR1 telepresence robot, which allowed people to attend events virtually. It projected a near life-size image of the user on its large screen, giving

Production: Nick Jacobs nick.jacobs@imlgroup.co.uk

them the sensation of physically being there, as they moved the robot around the venue and interacted with athletes from a remote location.

• Twice as fast and far more reliable than traditional ID checks, facial recognition technology was deployed for the first time, to improve security and prevent unauthorised personnel from entering the site.

• Finally, with the climate crisis at the forefront of everyone’s minds, sustainability was a key consideration at this year’s Olympic Games. Toyota provided a fleet of driverless electric vehicles (EVs) to ferry athletes around the 44-hectare Olympic Village. In addition, recyclable cardboard beds (designed to withstand weights of up to 200kg) were used in the Olympic Village, medals were made from recycled metals collected from 6.2 million disused mobile phones in Japan, and, for the first time ever, the iconic Olympic torch was lit by hydrogen.

Although it faced several setbacks due to the pandemic, there is no doubt that these innovations helped Tokyo 2020 to make its mark on the global stage and in Olympics history – and will continue to influence technological development for years to come.

Do let us know what you think of the issue and if there are any specific topics you think we should be covering. Email me at sophia. bell@imlgroup.co.uk.

Sophia Bell, Assistant Editor

DRIVING SAFETY, WEG’S CFW500 WITH EMBEDDED SAFETY FUNCTIONS

A very important fact to be considered by designers and users of machinery is the high degree of reliability and robustness of the CFW500. Its safety functions have SIL 3 and PLe rating according to EN/IEC61508 and EN ISO13849-1, achieving the highest levels of reliability as certified by Germany’s TUV Rhineland notifying body.

• Proof test interval of 20 years eliminating high “re-testing” costs.

• Fewer components, no need for additional wiring, saving space and installation costs.

• Easier installation, commissioning and maintenance.

• No mechanical components allowing for faster response for higher productivity,

• 24 Vdc available to power external circuits.

Complies with (EU) 2019/1781 for VSD

www.weg.net

For further details download our Built-In Safety Features for Variable Speed Drives Guide at www.weg-automation.com

Hybrid power: Polymer plain bearings make metal pillow blocks more economical

Many plant operators shy away from switching from classic metal bearings to polymer plain bearings, despite the obvious advantages. The conversion appears to be too cumbersome. igus responds with low-cost spherical balls, made of highperformance polymers, that can be inserted into metallic pillow blocks in seconds to create a cost-effective and highperformance hybrid.

Metallic pillow blocks are an indispensable part of mechanical and plant engineering, but the problem comes to the forefront in environments with heavy contamination. Additional dust combines with a high load, so that maintenance staff must lubricate the bearings regularly just to keep them moving. That costs a lot of time and money. Yet, a change is often due after just one year.

Is there an alternative? Yes, bearings made of high-performance polymers that allow dry operation without lubricating oil. “Such polymer plain bearings have been available on the market for a long time. However, many users shy away from changing over because they assume they would have to integrate new housings with different dimensions into the machines, which would be time consuming and costly. In most cases, this is unnecessary,” explains Dean Aylott, Product Manager for igubal spherical bearings. “Our JEM-SP spherical balls, made of highperformance polymer, can be fitted into metallic pillow blocks in just a few seconds. This creates a powerful hybrid that totally dispenses with lubricating oil.”

Hybrid solution reduces costs by a factor of 20

Behind the secret of dry operation is a high-performance polymer called iglidur. It consists of a thermoplastic base material, enriched with an embedded solid lubricant, which makes additional lubrication superfluous. “This means enormous cost savings for users,” says Aylott. Until now, many companies have used external lubricators, which cost around £30 per year, per bearing. Additionally, they usually have to replace the bearing’s wear-resistant parts annually and invest an additional £30 per bearing. “Spherical insert bearings made of high-performance polymer[s], on the other hand, are injection moulded, cost around £3, and do not require any external lubricants. Thus, the hybrid solution is 20 times more cost-

effective.” They are also more durable, since a JEM-SP series spherical ball will often operate for more than a year, due to fibres and fillers that make the spherical balls exceptionally wear resistant.

Lubrication? Not necessary with plastic!

Users also save on maintenance. “Lubricating a bearing by hand takes about three minutes. For large plants with 1,000 bearings that need to be lubricated every fortnight, a workload of 1,200 hours per year is eliminated,” emphasises Aylott. In addition, spare parts costs are reduced because shafts wear out less. Finally, polymer spherical balls are 80 percent lighter, lowering the drive power of machines and saving money and energy. They can also strengthen the reliability

The JEM-SP spherical balls made of igus high-performance polymer can be integrated into metal pillow blocks in just a few seconds. (Source: igus)

of machines and systems because inadequate, incorrect or contaminated lubrication is the reason for rolling bearing failures in most cases.

The fact that the polymer spherical balls are lubrication free means that maintenance staff no longer need to lubricate hard-to-reach places, expose themselves to risks of injury, or stop machines. Users only need to replace the spherical insert bearings at the end of their service life, which is two to three years or more, for little money and with little effort.

Assembly in a few seconds, without conversion costs

Spherical balls of the igubal series are currently available in five dimensions for low-cost sheet metal housings and eight dimensions for cast-iron housings. “Thanks to uniform sizes, the spherical insert bearings can be installed, regardless of the manufacturer, and can be used, for example, in 2-hole and 4-hole fixed flange bearings, as well as pillow block bearings,” explains Aylott.

More and more plant operators and machine builders are switching to hybrid technology. Users benefit from the durability, wear resistance and chemical resistance of the standard materials, iglidur J and J4. For special requirements beyond the standard application, igus provides further iglidur materials: from the hightemperature-resistant variant, iglidur X, up to the FDA-compliant alternative, A350, for the food sector.

“Companies improve their eco-efficiency”

If companies decide to replace lubricated metal bearings with polymer plain bearings, they improve their eco-efficiency because they help to save lubricants – not only pillow block and fixed flange bearings, but also other bearing types can be replaced by polymer variants. “With polymer plain bearings, the continuous structure, without layers, ensures an almost constant coefficient of friction and wear rates over the entire product life cycle. Due to the homogeneous structure, the entire wall thickness is theoretically available as a wear zone,” clarifies igus.

Polymer plain bearings as an alternative

Users of needle roller bearings can also benefit from an exchange. The problem here is that rolling bearings have a high Hertzian pressure, due to the line contact between needle rollers and raceways, and are sensitive to vibrations and shocks. Moreover, users usually have to use hardened shafts, as soft ones run the risk of shrinkage, due to high edge pressure. With polymer plain bearings, on the other hand, the risk of shaft run-in is lower, even with high edge loads, so that users can use soft shafts. Furthermore, they are suitable for applications with vibrations and heavy shock loads. They are also corrosion free and are resistant to inorganic media, as well as acids, alkalis and salt solutions, due to their organic nature.

Polymer plain bearings also do away with the disadvantages of sintered bearings. These absorb oil impregnation in the porous material, which provides a lubricating effect at high rotation speeds.

The problem: with slow or pivoting movements, the lubricating wedge often cannot build up optimally. “In this case, the homogeneous structure of the polymer plain bearings with solid lubricants ensures that lubricant is always available – regardless of the type of movement and speed,” Dean Aylott concludes.

Test laboratory results enable risk-free changeover

In many cases, it is economical and sustainable to replace classic metal bearings with variants made of highperformance polymers. Whether a changeover is worth considering is answered by igus with an online service life calculator. Interested parties can specify the parameters of their application and have the service life of polymer plain bearings calculated. The calculation is based on results of realistic tests obtained from the in-house laboratory, which evaluates several billion movements annually.

www.igus.co.uk/spherical-insert-bearing

Polymer spherical balls are wear resistant, durable and insensitive to dirt. (Source: igus)

ABB robots help deliver fast palletising solution for soft drinks maker

RMGroup has installed three end-of-line robotic palletisers for the soft drinks business, Radnor Hills. Enabling the fast palletising of multi-packs in a variety of combinations, the move has enabled the manufacturer to benefit from improved process efficiencies throughout its production.

Manufacturing a wide range of spring waters, flavoured waters, functional waters, school-compliant drinks, premium sparkling pressés, fruit juices and own-label brands, Radnor Hills first approached RMGroup in 2018 to investigate automating an end-ofline palletising operation with a robot arm.

On the line, packs of bottles needed to be palletised at a rate of 14 packs per minute. Given the throughput and pallet stack formats, RMGroup needed to ensure that the

second was installed on Radnor’s Tetra Pak line to palletise cardboard cartons from dual production lines at a rate of six cases per minute. A third was installed on Radnor’s canning line, involving a much higher output of 24 packs, 12 of which needed to be palletised on euro pallets, at a rate of 20 cases per minute.

“One of the key benefits of working with RMGroup is that they listen to us,” said David Pope, Radnor Hills’s General Manager. “They take on board our requirements and come back to us with solutions to make it happen. The whole team has been a pleasure to work with, especially the engineers, who have been extremely knowledgeable and helpful throughout the whole process.”

“The glowing praise from the customer for

our robotic palletising solutions,” says Steve Banton, Channel Partner Manager for ABB Robotics UK & Ireland. “It also highlights the value that our RobotStudio offline programming software can deliver in helping to develop and refine solutions that can start delivering benefits as soon as they are installed on the factory floor.”

For more information about ABB’s Value Providers, visit http://bit.ly/ABB_VPs.

For other information about ABB’s robots and RobotStudio programming software, visit www.abb.com/robotics

For more information on RMGroup’s end-of-line robotic palletisers, visit

Can DC motors be used at high temperatures?

Those familiar with the maxon catalogue and technical specification will have noticed that there are specified maximum ambient and winding temperatures for its motors. The majority of DC motors have a maximum ambient temperature of between 85ºC and 100ºC, and a maximum winding temperature of between 100ºC and 125ºC.

Why is this?

First, the difference between the ambient temperature and maximum winding temperature. Input supply is divided into voltage (V) and current (A). The voltage determines the speed, and the current determines the torque. When in

use, the current will generate heat in the winding, so when a motor is specified for operation at high ambient temperatures, it cannot be worked as hard as if it were at regular workshop temperatures – otherwise, it will burn out.

What are the problems associated with heat?

Inside the motor is a magnetic circuit generated by the permanent magnet and the electromagnet, the motor winding. Both the permanent magnet and the winding are affected by heat. The neodymium magnets start to demagnetise at around 160ºC. Unfortunately, cooling the motor does not reverse the effect; it is a permanent degradation. The winding is encased in an insulating varnish, which provides stability as well as insulation. As the temperature

increases above 160ºC, the varnish softens and the winding can deform, resulting in rubbing, which wears away the insulation and causes a short circuit and motor failure. Very high-temperature increases can cause the varnish and insulation to melt, again resulting in a short circuit. The results are always the same: the motor is ruined.

maxon high-temperature motors

Not surprisingly, there are projects where motors need to operate in environments with higher temperatures; for example, drilling into the Earth’s core for oil, gas or geothermal energy, or valve actuators in aircraft engines. maxon has a range of DC motors designed for these environments. The brushless HD (heavy-duty) range can operate in ambient tempera-

tures of up to 200ºC, with a maximum winding temperature of 240ºC.

How do these motors operate in such high temperatures?

The magnets in maxon HD motors are manufactured from samarium cobalt (SmCo). Samarium cobalt rare earth magnets can reach much higher temperatures before they start to demagnetise. The copper wire used in the winding also has a higher temperature-rated insulation. Finally, the impregnation varnish is rated to a much higher temperature, which ensures that the winding remains stable throughout the operating temperature range.

Why not make all motors capable of reaching higher temperatures?

It is not an easy process to manufacture a high-temperature motor: the enhanced insulation on the copper wire is very rigid, which makes it much more difficult to wind. It also doesn’t work with all winding patterns. Another reason is cost, more specialist materials

cost more and why would people want a more specialist, higher price motor for an application where it isn’t needed?

In high-volume applications, maxon can upgrade standard motors for projects where higher temperatures are needed and, due to the limited HD range, there isn’t a motor to suit. maxon will investigate the feasibility of producing the winding and create a production size batch of windings to ensure there is a high enough yield from the wire. Finally, if the yield is sufficient, sample motors will be manufactured, and the technical specification validated.

What do you do when your application is pushing the ambient temperature boundaries?

Contact your maxon technical sales engineer, who is trained to specify the right product for the right application, in the right environment.

First, the sales engineer will ask a series of questions about the application,

what the speed and torque are at the output, what duty cycle the motor will see, and what your input supply is. They will then look at the environment, temperature, shock/vibration, as well as other restrictions, such as space envelope, mass, etc. Once they have collected all the data, they will start examining the possible options to provide a solution.

When there are high temperatures, maxon must carry out a thermal analysis to ensure the motor is not going to burn out in service. maxon analyses the speed and torque profile over the duty cycle, based on the specific ambient temperature. The maxon-developed software gives crucial information, including the winding temperature.

maxon will only specify a solution that it is confident will meet the requirements of your application.

Contact Andrew on andrew.gibson@ maxongroup.com or +44 01189 733 337 to discuss your application.

Improving standards sustainability of electric motors

Theinternational focus on minimising our carbon footprint aims to reduce the effects of global warming and stabilise our weather patterns. At the same time, there is a realisation that we need to improve our sustainability and preserve the world’s resources for the next generation and beyond. For those operating in industrial sectors, there is an opportunity to contribute to these efforts by looking at the most effective solution for motor repairs.

Source: Houghton International

for motors

Thomas Marks, Secretary, AEMT, looks at the importance of considering all the options when an electric motor needs to be repaired.

Many service centres for electric motors belong to the Association of Electrical and Mechanical Trades (AEMT) which encourages members to assess and deliver the most appropriate repair or replacement of a motor. This ensures that its customers have the opportunity to reduce their energy usage by upgrading to a more efficient option, or repair the asset using the latest international standards, and extend the service life of the motor cost effectively.

Improved performance

Making the best choice relies on having all the relevant information for a certain situation. The decision to replace a motor with one of a higher efficiency classification is usually governed by the initial cost against the additional savings that will be made during its service life. Depending on

the application, upgrading from an IE2 to an IE3 motor may not be justified by the improvements in efficiency.

However, some operators have concerns about the efficiency of a repaired motor, compared to the original factory build specification. These questions can be answered by a recent study jointly carried out by the AEMT and the Electrical Apparatus Service Association (EASA) in the USA. It concluded that the energy efficiency of a motor is retained after a repair that follows international standards and guides of good practice.

Furthermore, the repair or remanufacturing of a motor effectively doubles the service life of the machine, especially in modern, clean environments. The reliability of the motor is similarly extended and, in many cases, it will carry the same warranty period as a new machine.

For those with specialist environments that require repairs to hazardous area motors, suitably qualified and certified repair centres will follow international standards (IEC 60079-19) to ensure the continued safety of the intrinsic protection concepts. It is worth noting that only suitably trained staff should undertake such repairs, otherwise the asset record for the motor may be compromised and, with it, the assurances of the manufacturer’s design.

Circular economy

The decision to repair a motor, rather than replacing it, is not only a cost-effective solution, but also minimises the number of resources that need to be used. This is summarised in IEC 60034-23, the international standard for rotating electrical machines: repair, overhaul and reclamation. It highlights the fact that replacing the bearings in a 110kW machine effectively doubles the life of the asset, while retaining 99 percent of the original machine. Furthermore, the old bearings can be recycled as high-quality ‘green’ steel scrap.

For a refurbishment that involves a motor rewind, 90.5 percent of the motor is reused and the parts that are replaced consist mainly of high-grade copper and steel scrap that can be recycled. In fact, just 0.9 percent of the original machine – made up of varnish, grease, insulation and paint – will not be reused or recycled.

In every case, maintenance and repair centres that are members of AEMT will always consider all the options for each case and ensure that the operator is aware of both the financial and environmental costs. With all the available information, it is the responsibility of those working with electric motors to decide on the best course of action.

https://www.theaemt.com/

About the author:

Thomas Marks is the General Manager and Secretary at AEMT. As Secretary, Thomas works directly with the council and executes the direction of the association. He joined the AEMT in 2013, taking responsibility for marketing and events until 2017. After many years in events and marketing in London, Thomas brought his experience to the AEMT, giving the association the rejuvenation and energy required to take it to where it is now.

Use sensorless vector control with BLDC and PMS motors to deliver precise motion control

The need for precise motion control is growing across applications such as robotics, drones, medical devices, and industrial systems. Brushless DC motors (BLDCs) and AC-driven permanent magnet synchronous motors (PMSMs) can deliver the required precision, while also meeting the need for high efficiency in a compact form factor. However, unlike brushed DC motors and AC induction motors, which are easy to connect up and run, BLDCs and PMSMs are much more complex.

Examples of precision motion control applications

Drones are complex motion control systems and typically employ four or more motors. Precise and coordinated motion control is needed to enable a drone to hover, climb, or descend.

To hover, the net thrust of the rotors pushing up the drone must be balanced and equal to the gravitational force pulling it down. By equally increasing the thrust (speed) of the rotors, the drone can climb straight up. Conversely, decreasing the rotor thrust causes the drone to descend. In addition, there’s yaw (spinning the drone), pitch (flying the drone forward or backwards) and roll (flying the drone to the left or right).

Precise and repetitive motion is one of the features of many robotics applications. A stationary multi-axis industrial robot has to deliver different amounts of force in three dimensions in order to move objects of varying weights (Figure 1). Motors inside the robot supply variable speed and torque (rotational force) at precise points, which the robot’s controller uses to coordinate motion along different axes for exact speed and positioning.

In the case of wheeled mobile robots, a precise differential drive system can be used to control both the speed and direction of motion. Two motors are used to provide motion along with one or two caster wheel(s) to balance the load. The two motors are driven at different speeds to achieve rotation and changes in direction, while the same speed for both motors results in straight-line motion, either forward or backwards.

Motor choice

A BLDC eliminates the commutator and brushes of brushed DC motors, and depending on how the stators are wound, it can also be a PMSM. The stator coils are wound in a trapezoidal manner in a BLDC motor, and the back electromotive force (EMF) produced has a trapezoidal waveform, while PMSM stators are wound sinusoidally and produce a sinusoidal back EMF (Ebemf) (Figure 2).

Figure 1: A stationary multi-axis industrial robot has to deliver different amounts of force in three dimensions in order to move objects of varying weights and coordinate its activities with other robots on the assembly line. (Image source: Texas Instruments)

Torque in BLDC and PMSM motors is a function of current and back EMF. BLDC motors are driven with square wave current, while PMSM motors are driven with sinusoidal current.

BLDC motor features:

• Easier to control with six-step square wave DC currents

• Produces significant torque ripple

• Has lower cost and performance than PMSMs

• Can be implemented with Hall effect sensors or with sensorless control

PMSM features:

• More complex control using three-phase sinusoidal pulsewidth modulation (PWM)

• No torque ripple

• Higher efficiency, torque and cost than BLDC

• Can be implemented with a shaft encoder or with sensorless control

What is vector control?

Vector control is a variable-frequency motor drive control method in which the stator currents of a three-phase electric motor are identified as two orthogonal components that can be visualised with a vector. One component defines the magnetic flux of the motor, the other the torque. At the core of the vector control algorithm are two mathematical transforms: the Clarke transform modifies a three-phase system to a two-coordinate system, while the Park transform converts two-phase stationary system vectors to rotating system vectors and their inverse.

Using the Clarke and Park transforms brings the stator currents that can be controlled into the rotor domain. Doing this allows a motor control system to determine the voltages that should be supplied to the stator to maximise the torque under dynamically changing loads.

Driving three-phase PMSM and BLDC motors for industrial and consumer robotics

To get around the complexity of vector control, designers can use readymade evaluation boards. For example, the DRV8301-69M-KIT from Texas Instruments is a DIMM100 controlCARD-based motherboard evaluation module that designers can use to develop three-phase PMSM/BLDC motor drive solutions (Figure 3). It includes the DRV8301 three-phase gate driver with dual-current shunt amplifiers and a buck regulator, and an InstaSPIN-enabled Piccolo TMS320F28069M microcontroller (MCU) board.

The DRV8301-69M-KIT is an InstaSPIN-FOC and InstaSPIN-MOTION

Texas Instruments technology-based motor control evaluation kit for spinning three-phase PMSM and BLDC motors. With InstaSPIN, the DRV830169M-KIT allows developers quickly to identify, automatically tune, and control a three-phase motor, providing an “instantly” stable and functional motor control system.

The DRV8301-69M-KIT hardware features:

• A three-phase inverter baseboard with an interface to accept

DIMM100 controlCARDs

• A DRV8301 three-phase inverter integrated power module (with integrated 1.5A buck converter) baseboard, supporting up to 60V and 40A continuous

• The TMDSCNCD28069MISO InstaSPIN-FOC and InstaSPIN-MOTION cards

• The ability to work with MotorWare supported TMDXCNCD28054MISO (sold separately) and TMDSCNCD28027F + External Emulator (sold separately)

Figure 2: A PMSM motor generates a sinusoidal Ebemf, while a BLDC generates a trapezoidal Ebemf wave. (Image source: Texas Instruments)

Figure 3: Designers can develop three-phase PMSM/BLDC motor drive solutions using the DRV8301-69M-KIT motor kit. (Image source: Texas Instruments)

Feature: Motion control

High-performance, highefficiency PMSM and BLDC motor drives

About the author: Rolf Horn, Applications Engineer at Digi-Key Electronics, has been in the European Technical Support group since 2014 with primary responsibility for answering any development- and engineering-related questions from final customers in EMEA, as well as writing and proofreading German articles and blogs on DK’s TechForum and maker.io platforms. Prior to Digi-Key, he worked at several manufacturers in the semiconductor area, with a focus on embedded FPGA, microcontroller and processor systems for industrial and automotive applications. Rolf holds a degree in electrical and electronics engineering from the University of Applied Sciences in Munich, Bavaria and started his professional career at a local electronics products distributor as a System-Solutions Architect to share his steadily growing knowledge and expertise as a Trusted Advisor.

The EVAL-IMM101T from Infineon Technologies is a full-featured starter kit that includes an IMM101T Smart IPM (integrated power module) that provides a fully integrated, turnkey, high-voltage motor drive solution that designers can use with high-performance, high-efficiency PMSM/BLDC motors (Figure 4).

The EVAL-IMM101T also includes other necessary circuitry required for “out-ofthe-box” evaluation of IMM101T Smart IPMs, such as a rectifier and an EMI filter stage, as well as an isolated debugger section with a USB connection to a PC.

The EVAL-IMM101T was developed to support designers during their first steps in developing applications with an IMM101T Smart IPM. The eval board is equipped with all assembly groups for sensorless field-oriented control (FOC). It contains a single-phase AC connector, EMI filter, rectifier and three-phase output, for connecting the motor. The power stage also contains a source shunt for current sensing and a voltage divider for DC-link voltage measurement.

Infineon’s IMM101T offers different control configuration options for PMSM/ BLDC drive systems in a compact 12 x 12 mm surface-mount package, minimising the external component count and printed circuit board area. The package is thermally enhanced such that it can perform well with or without a heatsink.

The IMM100 series integrates either a 500V FredFET or a 650V CoolMOS MOSFET. Depending on the power MOSFETs employed in the package, the IMM100 series covers applications with a rated output power from 25 watts (W) to 80W, with 500V/600V maximum DC voltage. In the 600V versions, the Power MOS technology is rated at 650V, while the gate driver is rated at 600V, which determines the maximum allowable DC voltage of the system.

24-volt motor control eval system

Designers of 24V PMSM/BLDC motor drives can turn to Renesas’s RTK0EM0006S01212BJ motor control

evaluation system for the RX23T microcontrollers (Figure 5). The RX23T devices are 32-bit microcontrollers suited for single inverter control with a built-in floating-point unit (FPU) that enables them to be used to process complex inverter control algorithms. This helps greatly to reduce the man-hours required for software development and maintenance.

In addition, due to the core, the current consumed in software standby mode (with RAM retention) is only 0.45 microamperes (μA). RX23T microcontrollers operate over the range of 2.7 to 5.5 volts and are highly compatible with the RX62T line at the pin arrangement and software level. The kit includes:

• 24V inverter board

• PMSM control function

• Three-shunt current detection function

• Overcurrent protection function

• CPU card for RX23T microcontroller

• USB mini B cable

• PMSM

Conclusion

BLDC and PMSMs can be used to deliver precision motion control solutions that are compact and highly efficient. The use of sensorless vector control with BLDC and PMS motors adds the advantage of eliminating the sensor hardware, thereby reducing costs and improving reliability. However, sensorless vector control in these applications can be a complex and time-consuming process.

As shown, designers can turn to development platforms and evaluation boards that come with sensorless vector control software. In addition, these development environments include all of the motor controller and power management hardware integrated into a complete system, speeding the time to market.

https://www.digikey.co.uk/

Figure 4: The IMM101T eval board is a complete solution capable of driving PMSM and BLDC motors using sensorless FOC. (Image source: Infineon Technologies)

Figure 5: Renesas’ 24-volt motor control evaluation system for the RX23T microcontroller includes an inverter board to drive the included PMSM. (Image source: Renesas Electronics)

As an advanced motion control technology distributor and manufacturer, Mclennan supplies and fully supports a wide range of precision motion control components from its distribution partners - and also has the capability to combine these products with its own design and build service for bespoke and turn-key motion sub-systems - for applications across industry and research.

Mclennan is your perfect partner in your quest for the right miniature electric motor. We can help you specify and integrate the exceptional range of Portescap motors into your next project or design. Portescap offer a rapid prototype service to support new projects and at Mclennan we cover a range of Portescap products from stock, and support OEM customers with integrated solutions and Kanban delivery agreements. Talk

Driving Your Solutions

DX4 Servo Drive and MX Motor packages provide performance and dependability, optimised in every detail for high axis count motion applications. 50W - 3kW in 3 compact sizes.

DX4 is fully Integrated into Motion Perfect providing a single tool set for your entire system.

Everything you need, nothing more

Why VFDs will be integral to being ‘Fit for 55’

The clock is ticking fast for industry in the UK, Europe, and throughout the world when it comes to reducing carbon emissions in engineering and manufacturing processes.

With the European Commission having set out its European Green Deal (Fit for 55) in July to reduce net greenhouse emissions by at least 55 percent by 2030, compared to 1990 levels, it will be down to industry to meet much of the reduction in carbon emissions.

While many believe new technology is the answer, variable frequency drive (VFD) technology is already here and capable of cutting energy use by up to 50 percent in many electric motor applications.

From manufacturing to water pumping, agriculture to mining, most industries have an application involving an electric motor, resulting in high energy usage.

Eight billion electric motors consume 50 percent of electricity produced in the EU

Around eight billion electric motors consume nearly 50 percent of the electricity produced in Europe. Globally, 40 percent of electricity is used to power industry, with two-thirds of this used by electric motors. Yet, less than 20 percent of electric motors are controlled by VFDs.

“Electric motors account for a significant proportion of electricity usage globally – and it’s not just in industry. Our everyday lives are impacted by AC motors in one way or another, from HVAC building systems to retail refrigeration,” said Kes Beech, Technical Manager at Invertek Drives.

“Inefficient motors create higher energy use which, in turn, generates increased carbon emissions – and it’s not just the energy that’s contributing to these emissions. The processes themselves, such as those in manufacturing, the water industry and ventilation, can also impact emissions or have environmental ramifications if they are not accurately controlled.”

VFDs can reduce energy use by up to 50 percent

“Globally, VFD technology is already cutting energy use by between 30 and 50 percent in many applications. This is leading to reduced carbon emissions. But with less than 20 percent of electric motors controlled by drives,

significant in-roads can be made to [meet] the new EC climate ambitions.

“The EC’s green deal aims to make Europe the first climate-neutral continent by 2050. That might seem some time off, but, in terms of industry, it’s not. VFDs can be easily retrofitted onto existing electric motor processes, as well as integrated into new applications. We don’t need to look to the future and yet-to-be-developed technology. It already exists. But we, in the drives industry, governments and trade organisations, have to promote and encourage greater use of VFDs in existing and future electric motor-controlled applications.”

Nearly every process that uses a motor will benefit from speed control. Not only is the process generally improved but, in many cases, particularly with pumps and fans, there is considerable energy saving.

For example, instead of a pump operating at constant maximum flow, the rate can be altered, depending on demand. This reduces water usage, cuts energy wastage and can also reduce wear and tear, and associated costs or downtime.

In most cases, VFDs can be easily retrofitted, either replacing an existing drive or as a completely new motor control. The installation and commissioning of a drive are generally straightforward and some VFDs come with default settings and parameters for most applications, making the process quick and easy.

Cutting energy costs, emissions and downtime on an industrial shredder

An Italian industrial automation control systems supplier has significantly cut energy costs in the use of an industrial shredder, by introducing VFDs into the process.

High electrical absorption was being created on start-up by an existing Star/Delta starter. This, combined with a lack of motor speed control, was creating high energy costs and wear on the blades of the shredder.

A high-performance VFD was introduced to the process, capable of producing up to 200 percent torque from zero speed. It also allowed accurate speed control under all load conditions. The drive used was a three-phase, 250kW, 350HP, 450A VFD to control a 160kW, 300A motor.

“Straight away, we were able to accurately control the speed of the motor, resulting in reduced energy use. We shredded a range of materials and there was immediately much less wear or damage,” said Manuel Meneghelli, Area Manager at Invertek Drives Italia.

“Just as importantly, the previous high absorption resulting from Star/Delta starter was reduced, cutting energy costs for the plant.”

www.invertekdrives.com

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Running a brushed DC motor as a generator

It won’t surprise engineers with even a fundamental understanding of motor design that a brushed DC motor can be operated as a generator to produce a DC power supply. However, it is possible that they will not yet have appreciated the usefulness of the principle, considering the increasing number of intelligent, remote, powered devices.

Getting the most out of such a configuration requires a consideration of electrical and mechanical factors, when determining the operating points. Here, Sunil Kedia, Core Market New Product Development Manager at Portescap, looks at the basic relationship between speed, voltage, torque and current when using a brushed DC motor as a generator.

The rise of the Internet of Things (IoT) has seen rapid growth in the number of intelligent sensors and devices that are interconnected and exchanging data. In the industrial environment, this Industrial IoT forms the backbone for the digital transformation of an enterprise as part of its journey towards Industry 4.0. With many of these devices operating wirelessly or in remote locations, the question of how

About the author: Sunil Kedia is a New Product Development Manager for Medical Infusion Systems at Portescap, with a background in electromagnetic and mechanical system design and development. He has a proven track record in product industrialisation and providing technical assistance for customers in product design, customisation, evaluation, and value addition. He holds a master’s degree in physics, and a PhD in large electromagnetic systems design from the Institute for Plasma Research, India.

they should be powered is key. Battery power is part of the solution but, eventually, the battery has to be replaced, or recharged.

Of course, this isn’t just an industrial problem. Outdoor activities, such as camping and hiking, take people off the grid, with the risk of batteries running out of power before the next plug-in location. Then, there is the growing number of people simply wishing to lower their carbon footprint and take more advantage of sustainable resources to generate the power they need.

Against this background, the ability of a brushed DC motor to act as a generator and provide a DC supply can be very useful indeed. With the shaft mechanically coupled to and rotated by an external source, causing the coil segments in the rotor to rotate through a magnetic flux in the air gap, a back EMF is measured at the output terminals. So, attach a wind-powered vane to the shaft of the motor, for example, and even a light breeze can begin to generate a useful output voltage.

The voltage generated is a function of the back EMF constant (a characteristic parameter of the motor, given in mV/rpm) and the shaft speed. This is a key consideration in the selection of the motor

for the task: the achievable shaft speed needs to be sufficient to generate the required back EMF, yet not so high as to exceed the motor’s maximum permissible speed parameters. If it is too high, a different motor should be chosen with a higher speed rating. If it is too low, a suitable gear unit can be added to increase the speed at the motor shaft.

A further consideration is the load that will be connected across the generator’s output terminals. The maximum voltage output occurs when there is no load. With a load connected, for a fixed shaft speed, the current flowing through both the load and the motor windings increases as the load’s resistance decreases. The inherent resistance of the motor windings is the limiting factor for the maximum current in generator mode.

The back EMF constant also has a role to play here. A motor with a higher back EMF constant and lower resistance will provide stable operation. In contrast, if the resistance of the windings is high, the sensitivity of the generator system increases and the resulting voltage variation with current drawn creates an unstable system.

Torque must also be considered, with motor selection limited by the maximum amount of torque that can be applied on the shaft in generator mode. Selecting

a motor that can handle the generator torque on the shaft and manage the maximum current through its circuit is similar to the process of sizing a motor based on desired load points.

Let’s consider two real-world examples, looking at motors in Portescap’s Athlonix series of brushed DC motors. The back EMF constant of the Athlonix 17 DCT with a 209P coil is 1.17mV/rpm, while the resistance in the coil windings is 7.8Ω. If this motor is used as a generator at 5,000rpm shaft speed, the output voltage would be 5.85V. The maximum load current through the circuit under short-circuited conditions, using I=V/R, would be 0.75A. But this value exceeds the maximum continuous current of this particular motor (0.55A). One solution would be to use a series load resistance; another would be to use a different coil – in this example, the 221P coil might be a better choice.

As a second example, the Portescap 16C18 motor with a 205P coil has a 0.70mV/rpm back EMF constant and a 65Ω coil resistance. At 10,000rpm, the open circuit output voltage at the terminal is 7.0V. Under short-circuited conditions, the maximum current that can flow through the windings is 0.108A, which is less than the maximum continuous current for the motor. Therefore, using this motor as a generator at 10,000rpm shaft speed would be acceptable, without considering an external resistance load.

As a final consideration, the design engineer should look at the efficiency of the motor in generating mode. While this will be less than when functioning as a motor, reasonably high efficiency can be achieved with the proper selection of the motor, loads, and operating speed.

Taking advantage of a motor’s ability to function as a generator can provide a useful source of power in the field, but it is important to determine all the operating points. Where there is any uncertainty, it is always worth engaging with a knowledgeable supplier who can help in the selection of the appropriate motor for the application.

For more information, visit www.portescap.com

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Revolutionary underwater diver-safety monitoring system

Build

C-Tecnics, specialists in the design and development of underwater imaging and video recording systems, required a paired LCD and single-board computer solution to be integrated into a Peli Case as part of a revolutionary underwater safety monitoring system.

The new C-Vision system from C-Technics would be designed to allow the remote monitoring of both inshore and offshore divers working in dangerous environments, with up to three streams being fed to remote health and safety experts, who monitor the progress of the divers and ensure their safety while they work. Onshore applications such as pipeline inspections, where remote video monitoring is essential, would also benefit from the C-Vision system.

Challenge

With the customer’s requirement for the screen to be situated in the lid of the Peli Case, it was not possible to use a panel PC. Peli Case lids offer limited depth, so a panel-mounted panel PC would not fit. Furthermore, the volume of cabling for the I/O needed for the cutting-edge C-Vision sys-

tem would be too large to be stored in the lid. Therefore, to keep with the OEM look of the C-Vision system and IP67 rating, an embedded board would need to be in the base and paired with a separate LCD screen.

Design

To accompany the customer’s desired 15.6” LCD panel, the Impulse Embedded design specialists were tasked with identifying a suitable single-board computer that would fit their requirement of high-power components with minimal heat production. To minimise heat build-up and cost, the design engineers picked out a Mini-ITX single-board computer which provided all the I/O the project needed, enough graphic power to support up to three simultaneous video streams, along with a reduced cost of ownership.

Due to the layout of the Peli Case, it was imperative to adhere to the customer’s cabling requirements. After receiving the relevant measurements of the enclosure, the Impulse Embedded design engineers created and standardised a cabling solution, ensuring the required length and configuration of the cabling did not conflict with the electrical threshold of the technology. Screening was integrated with the cabling to stop any potential EMC noise from interfering with other components, and after thorough endurance testing, the kit of parts was signed off and prepared for mass production.

Support

As with all Impulse projects, C-Tecnics enjoys free, lifetime technical support, ensuring a fast frontline assistance and quick turnaround on RMAs. Due to Impulse’s 35,000 sq. ft. facility, the company was able to offer flexible call-off schedules, allowing C-Tecnics to benefit from purchasing economies of scale and a fast turnaround of parts, whilst maximising credit terms and product warranties.

Scott Younger, Technical Manager of C-Tecnics said, “C-Tecnics have been working closely with Impulse, spanning back seven years, in tailoring a computing solution consisting of an industrial motherboard, solid-state drives, and a custom display for several C-Tecnics ruggedised case systems. The support received from Impulse on new solutions and technical support is greatly appreciated and highly recommended.”

www.impulse-embedded.co.uk

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The benefits of using Safety over EtherCAT in your next machine design project

With the development of Safety over EtherCAT in PLCs and drive controllers, powerful new tools are available for machine builders to use in their next machine design project, which can help provide their machines with a valuable technological edge, say Mark Checkley and Mike Keefe of KEB Automation.

Modern communication systems not only realise the deterministic transfer of control data, but also enable the transfer of safety-critical control data through the same medium. EtherCAT utilises the Safety over EtherCAT (FSoE = FailSafe over EtherCAT) protocol for this purpose.

The safe operation of machines often requires safety functions to limit speeds, directions of rotation, or axis positions. With traditional safety solutions, dangerous operating states are detected and avoided using external safety modules. However, this only serves to increase the complexity of the machine’s safety concept. In contrast, drive controllers with integrated safety functions and safety PLCs, including certified function blocks, can be used today.

The benefits of using FSoE in machine design projects are numerous, but here are five key benefits to consider.

Reduced and simplified wiring

One simple yet key benefit of FSoE is the reduction of the discrete safety wiring. It is no longer necessary to wire all the discrete safety I/Os back to the safety PLC. The advantages of reduced wiring become most evident in applications that have longer cable runs or where many safety devices are required.

FSoE enables the evaluation of discrete safety inputs and even safe encoder signals (position), in the case of KEB’s COMBIVERT S6 or F6 drive controllers. This information can then be communicated from the drives to the safety PLC over the SIL3-certified FSoE protocol. Both the safety information and regular machine data can be transferred via a standard Ethernet cable, which means the wiring and terminations are quick and easy, with little chance of wiring mistakes.

About the authors: Mike Keefe graduated from the University of Wisconsin-Madison with a BS in Mechanical Engineering in 2014. He began at KEB America in July 2014 as an Applications Engineer within the high-speed applications group. Later, he transitioned into the Automation and Drive group with a focus on KEB’s next-generation S6 and F6 drives.

With this simple connection, all safety functionality on the FSoE and standard EtherCAT drive control can be achieved. This allows for a more complex machine safety design, without worrying about the cost and time involved with wiring. The time spent on wiring and testing I/ Os can be saved or put to better use with more comprehensive machine commissioning.

Flexibility of safety functions

With FSoE, there is also more flexibility in the selected ‘Safe Motion’ functions available in KEB EtherCAT drive controllers. It is no longer just about implementing the dual-channel STO (Safe Torque Off). The sixth generation of KEB Automation drives offers scalable safety functions directly in the drive controller. The device variants are Compact, Application and Pro for the COMBIVERT F6 and S6, enabling selectable functions according to the requirements. Several Safe Motion functions offer advanced functionality and handling, which carry a safety certification of up to SIL3.

For example, if an FSoE configuration is used that is dependent on encoder data, such as ‘Safe Limited Speed’ (SLS), but no encoder has been configured within the drive safety setup, a bus configuration error will display on the log. The state machine utilised by FSoE and the detailed log functionality within Combivis Studio 6 can be powerful tools in the commissioning of new machines or troubleshooting existing machines with functional safety.

Configurable process data

Safety function blocks

Mark Checkley is the Sales and Marketing Manager for KEB UK Ltd. He has over 25 years’ experience within the industrial automation industry, covering a wide breadth of its technology and applicational requirements.

For example, a robotic controller may utilise ‘Safe Acceleration Range’ to monitor the acceleration rates of the robotic arms. Detecting an abnormal acceleration can provide a faster error response than waiting to reach a limit switch or torque limit.

Another example is a machine or process that may require a motor shaft to spin in only one direction. Spinning the motor in an unintended direction could cause catastrophic damage to the machine, such as damaging a screw or special bearings. A design engineer might utilise the ‘Safe Direction’ function to ensure that the motor only rotates in the intended direction.

Detailed state machine

Each FSoE slave device is built on a state machine backbone. At start-up, the state machine must be incremented sequentially before it is possible to transmit the process data. In combination with the log in KEB’s Combivis Studio 6 programming environment, tracking EtherCAT and FSoE statuses or troubleshooting errors is much simpler.

Utilising FSoE and the wizards built into Combivis Studio 6 allows for the simple and easy setup of dozens of different configurations of process data. On the simple side, configurations with six FSoE frame elements can be used to control the safety functionality and read back the statuses. On the more complex side, configurations with 15 FSoE frame elements can be used to support additional safety functionality. This allows for more flexibility when setting up the FSoE and allows the user to select as many or as few safety functions as needed.

The actual configuration of the KEB safety drives is carried out using the certified safety editor, within COMBIVIS Studio 6. This is where the safety functionality and limits can be configured. These settings can be saved and downloaded to other drives via COMBIVIS or the controller. Current parameters and the error history can be used for system diagnosis. The export function makes it easy to create the required documentation.

With the number of safety functions available in the KEB S6 and F6 drive controllers that can be transmitted via the process data of FSoE, it could be overwhelming to start the programming of the safety PLC. However, KEB’s Combivis Studio 6 provides pre-certified safety function blocks according to the PLCopen Safety standard. These pre-prepared function blocks minimise the programming time of the safety PLC to allow for an easy start-up, while also enabling more complex programs if needed. In addition, Combivis Studio 6 clearly identifies safe and unsafe variables, making it clear which variables can and cannot be used with safety function blocks. Utilising these tools allows for almost limitless options when programming the safety functionality within FSoE and the safety PLC.

Conclusion

With the increasing desire and requirement of functional safety in new machine designs, FSoE can be a powerful tool for machine builders. Utilising KEB’s range of FSoE devices (drive controllers and safety PLCs) can save time and money in all stages of the machine life cycle, from initial design to commissioning and servicing.

For more information on KEB drive controllers or advice on how FSoE can be implemented in your application, please visit www.keb.co.uk or www.kebamerica.com

Safety constraints are driving innovation in advanced material use

Materialforms the heart of any design. It determines a component’s cost, performance, durability and reliability, and passes on those properties to the wider product. Customer expectations and environmental imperatives are therefore driving greater scrutiny into how engineers can best exploit materials.

Take, for example, the UK aviation sector’s commitment to reaching net zero emissions by 2050. To meet this ambitious target, which will require more lightweighting and design evolution than the industry has ever had to contend with, the old ways of understanding material performance will not work. Many engineers are looking to composites and reinforced thermoplastics as a way of increasing the rate of innovation while

still complying with stringent safety regulations, but this is only feasible when paired with advanced modelling that allows you to make assumptions with the same confidence (or more) as a traditional steel element in FEA.

The mixed-material internal structure of composites is what gives them desirable properties, but it’s also what makes their behaviour challenging to predict – they are not black metal. Exploiting materials to their full potential means understanding how they will behave when a product is shipped and in service, and many engineers don’t have access to that information. This renders it difficult to predict how they will affect the performance of each component and, in turn, how they will contribute (or not) to the safety and validation of a final product, such as an aircraft or vehicle.

Even worse, the team that tests or vali-

dates materials traditionally works in silos, duplicating effort and inhibiting the sharing of valuable knowledge. Without a two-way flow of information across product development and production, e-Xstream has seen customers incurring expensive and time-consuming delays in detecting and correcting flaws. This can lead to overengineering parts – treating them as black metal and not fully exploiting the material’s potential for lightweighting – or failures in the manufactured structure.

At best, this ad hoc nature of material design and testing could stifle innovation, hindering developments that could boost the industry as a whole – a crucial consideration as aerospace and automotive OEMs grapple with post-pandemic revenue recovery. The worst-case scenario is that this could lead to a critical flaw in a part having a domino effect across production. One flaw in the microstructure

of an advanced material used for a safety-critical component could jeopardise the safety and performance of the entire structure. For example, GM recently announced it is having to recall more than 130,000 of its cars because the plastic emergency jack can break under load if positioned incorrectly, which is not the case for the replacement metal versions.

The solution to this loss of knowledge is to equip material engineers and product designers with an understanding of every aspect of that material and how it could perform for their exact needs – before they even start production. They need material insight, mature computer-aided engineering (CAE) modelling, accessible computing power and a comprehensive technology ecosystem, to make sure every aspect is considered, tested and accessible to wider teams. This will ensure traceability of knowledge across the full life cycle of a product or material.

This gives an idea of the kind of progress ahead, as advanced materials are exploited more in everyday processes and products. Most material engineers will have heard a great deal about Integrated Computational Materials Engineering (ICME) over the past decade, for example. ICME is lauded as a paradigm shift in the production and application of advanced materials, but, up until very recently, it was considered an academic exercise, without available commercial options. It is an approach that allows engineers to combine analyses of the manufacturing process, material’s microstructure and engineering properties, and final part performance.

e-Xstream engineering’s Digimat composite modelling software was the first comprehensive commercial ICME software platform on the market, and the company has since seen the multi-scale modelling approach introduce widespread cost and time savings, and improvement in product safety. This is because a material life cycle management database (that documents and enables sharing of essential data on the material, design and production, combined with advanced simulation) dramatically lowers the barriers to innovation. As a single source of data, it allows engineers instantly to select the best material for their application.

This is how ICME enables largescale, high-speed virtual prototyping of high-performance parts using car-

bon-fibre composites, which involves selecting many different combinations of fibres, resins, and material layers. It enables engineers to select or design the material for the design objective, from cost to carbon efficiency, at the microstructural level. This means that stringent safety thresholds can be ‘baked in’ to every aspect of a product without sacrificing performance or cost savings. Engineers can predict how every constituent part impacts the performance of the whole product.

By identifying the right material and process at the design stage and eliminating the need for many real-world prototypes, e-Xstream engineering’s 10xICME techniques contribute to a significant reduction in the time and cost of manufacturing high-value parts. For example, through ICME, Vibracoustics (a high-quality suspension systems manufacturer) was able to reduce the cost of its design changes by 70 percent and cut the design lead time from seven days to 15 hours.

This is an exciting time for design engineers and materials engineers. While safety constraints used to be viewed by many as a barrier to innovation, the digitalisation of advanced materials data through methods like ICME and CAE modelling are actually stimulating innovation, by prompting engineers to explore these materials’ potential and develop new ways of optimising their use.

https://www.e-xstream.com/

About the author: Dr Boisot leads e-Xstream engineering, the materials & ICME (Integrated Computational Material Engineering) arm of Hexagon’s Manufacturing Intelligence division. He joined e-Xstream engineering in 2009 as a Senior Project Engineer, successfully held a variety of business-related positions, and then led the business development. Dr Boisot holds a PhD and MS in solid mechanics and materials and totals more than 15 years in the field of computational material engineering.

Machine safety: is it on or off?

Today, environmental, health and safety (EHS) and similar professionals are more likely to have their responsibilities expanded beyond programs such as Lockout/Tagout (LOTO) and Confined Space. They may now be expected to design and test functional safety devices that, historically, were the responsibility of the plant engineer or equipment manufacturer.

However, there is still confusion about when to use LOTO and when to use alternative protective measures (APM).

OSHA’s Control of Hazardous Energy regulation (1910.147) allows for alternative methodologies to be used, so long as they are “as effective as Lockout/ Tagout” for the task – and that’s where many companies run into problems. Often, companies use the exception clause to allow the employee to “create their own path” to safety if Lockout/ Tagout is impractical. But this should not increase the risk to employees.

These five steps will help you mitigate the risk associated with potential hazards:

1. Risk assessment

The risk assessment process takes away the guesswork when prescribing safety system performance and serves as documented proof of “due diligence”. It provides a method for determining equivalent levels of protection when designing safeguards that allow the safe use of OSHA’s minor servicing exception.

2. Safety functional requirements specification (SFRS)

The safety functional requirements specification reviews the initial risk-re-

duction recommendations from the risk assessment and confirms the ability to implement them. The specification contains existing and proposed safety functions and serves as a basis for the safety system design and validation plan.

3. Design and verification

Safety system design includes all aspects of the safety system, as defined in the SFRS. Documentation should include a bill of materials, drawings for safety control panel layout, wiring diagrams, hardware interface diagrams, and any safety or HMI software development. The safety system should then be documented to demonstrate compliance with the safety circuit architecture and circuit performance requirements specified in the risk assessment.

4. Installation and validation

After the safety system is designed and verified, you can install the approved safety control hardware and guarding. Validation will demonstrate the designed system is correctly installed in accordance with the SFRS. The validation plan is a step-by-step documented process, testing the normal and abnormal operation of the safety system.

5. Maintenance and improvement

Using the machine safety life cycle’s

iterative approach, changes to the equipment, process, and interaction with the machine are identified and any new risk to the employee can be mitigated appropriately.

Alternative de-energisation procedures (ADP)

Be sure to document what tasks can be done safely using ADPs and instruct the machine users on what steps to take. These tasks and instructions are documented in an alternative de-energisation procedure. These ADPs are vitally important to communicate acceptable use of the APMs put in place.

Paths to safety

Effective safety programs can reduce the risk to employees and maximise efficiency. For tasks requiring complete de-energisation of a machine, companies will benefit by having a robust Lockout/Tagout program. Risk reduction can be achieved for routine, repetitive, and integral tasks when the machine remains energised, by following a set of good engineering principles as outlined in the machine safety life cycle.

To learn more about modernising your industrial safety to maximise both safety and efficiency, contact RACSMSAFETY@ra.rockwell.com and the TÜV Rheinland-certified safety experts will be ready to assist.

W

ith the increased demand on our industrial workforce, many facilities are expanding the “do more with less” approach when it comes to machine safety.

About the authors:

Nuala Mullan is Business Development Lead for Safety Services at Rockwell Automation. She has been with the company for more than nine years, having begun as an Associate Sales Engineer and moving up the ladder to her current position.

Troy Hoffman is the Safety Manager at Rockwell Automation.

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Fastener challenges for hybrid and electric vehicles

In2021, the UK replaced France as Europe’s second-largest electric car market, after 31,800 new electric vehicles were sold in the first three months of the year. As emissions legislation tightens, government incentives increase and demand spirals, manufacturers are rapidly scaling up their electric vehicle (EV) and hybrid vehicle manufacturing.

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Here, Justin Lawrence, Applications Engineer at TFC, discusses the challenges when producing hybrid and electric vehicles, and explains how they can be overcome.

2020, almost ten billion pounds was

spent by governments globally on incentives and tax deductions for electric car purchases – a 25 percent year-onyear rise. This is just one incentive for an environmentally savvy consumer base, which purchased and registered over three million new electric cars worldwide in the same year. For the first time, Europe led over China and the US with 1.4 million registrations, while the UK more than doubled its registrations to 176,000.

With demand set to increase as the total cost of ownership lowers, manufacturers are looking for ways to mass produce EVs efficiently.

Connector challenges

Electric vehicle manufacturing will require far more connectors than the production of internal combustion engine (ICE) cars. One reason is the use of connectors in EV charging stations and other supporting infrastructure. Another is increased design complexity – the battery, for example, requires more cooling, which increases connector requirements.

There can be double the number of connectors in an EV compared with a traditional vehicle, due to the added complexities involved in regulating the temperature of batteries, electric motors, power electronics, and other subsystems. Therefore, there are challenges at the design stage – EVs require connectors that can fit in tight spaces and withstand the temperature and pressure conditions. To solve this, manufacturers,

such as ARaymond, have developed a wide range of connectors in different materials, configurations, and sizes. What this hasn’t overcome, until recently, is the manufacturing challenges.

Manufacturability of EVs

Producing a vehicle using more connectors has a knock-on impact on the production staff, who will be required to connect more fluid lines. This greatly increases the amount of force they are required to use during the day, increasing the risk of musculoskeletal conditions and injury.

To improve working conditions on the assembly line, the EV manufacturing industry can opt for more ergonomic connector technology that reduces insertion force. Specifying such components during the design phase can create a healthier, happier workforce with lower sickness rates, all while speeding up production. One exciting development is the launch of VDA LOW PUSH Quick Connectors, which reduce the insertion force required by 45 percent, compared with other industry-standard components for NW16. Consequently, only around half the daily effort is required by staff – six tonnes rather than twelve, for 1,500 connections a day.

The need for more connections and different connector types also increases the risk of misassembly. Because fluid lines perform essential functions like carrying fuel or coolant, they are safety

critical and must be connected reliably. To ensure that connections are secure, manufacturers can use connectors that offer audio/visual confirmation of this. ARaymond’s new product comes with an optional verifier tab that confirms proper connection and displays a customisable QR code that can be detected and read to prevent misassembly.

As manufacturers upscale the number of connectors they use daily, supply chain management becomes a growing consideration. Just-in-time delivery as part of a vendor-managed inventory (VMI) partnership can help manufacturers save both time and money when managing C-class component supply – a particularly compelling value proposition in a market where demand is changing so rapidly.

As well as solving inventory management problems, working with an experienced partner who assesses each connector’s suitability for the environment and application, provides an additional safety net for manufacturers and designers.

Scaling up EV production introduces several new challenges for automotive manufacturers. For help selecting, managing, and sourcing fasteners and connectors for electric or hybrid vehicles, get in touch with TFC.

For more information, visit https:// www.tfc.eu.com/ or call +44 (0) 1435 866011 to speak to TFC’s team.

Shape the engineering of

About the author:

Justin Lawrence specialises in the design and technical sales of wave springs, retaining rings and technical fasteners, designing bespoke products for a range of applications within the oil and gas, aerospace, automotive, and medical industries.

Justin has worked at TFC Ltd for 18 years and has over 20 years of experience in the mechanical and industrial engineering sector.

tomorrow.

Ease of use, strong performance: Let the new EPLAN Platform 2022 inspire you! You can look forward to a completely new user interface with a practical dark mode, a flexible new ribbon, a backstage view and much more. Furthermore, our complementary cloudbased services open up new possibilities for collaboration across teams.

Rapid-response composite wrap repairs damaged chemical tank

Theability of online repair specialist, Hydratight, to repair a chemical tank at speed with the LOCTITE Composite Repair System saved its customer from serious consequences.

The problem was spotted during a routine inspection of the operator’s processing facility. It needed to be resolved quickly, not only to restore compliance with stringent environmental legislation, but also to prevent production losses.

As the large holes and pitting marks that Hydratight discovered were in the roof of the chemical tank, some 14 metres off the ground, the first task was to construct scaffolding to provide access.

As a welded repair was unsuitable for this area, Hydratight proposed Henkel’s LOCTITE Composite Repair System. Hydratight uses this proven solution to restore vessel integrity and safeguard health and safety, especially when time is of the essence.

Central to Henkel’s LOCTITE Repair System is a resin-based composite material, reinforced with fibres. When used for steel pipelines and structures, the material reinforces and seals the damaged sections, and protects them against renewed corrosion. It allows

corroded vessels to be repaired in situ, without the need for costly steel re-

placements and the associated extended repair time.

The ISO/TS24817 and DNV GL-certified LOCTITE System is suitable for the repair of non-through-wall and throughwall defects, covering all repair classes from 1-3. When used to repair steel pipes, it can increase the structure’s service life by as much as 20 years.

For this specific application, Hydratight technicians, in collaboration with Henkel engineers, used a digital calculation and documentation tool to determine the most effective repair approach. The damaged surface was then prepared by grit blasting or wire brushing to ensure it was debris free and treated with a corrosion inhibitor. Next, LOCTITE EA 3478 Superior Metal was applied as a defect filler and held in place by multiple layers of LOCTITE composite material, topped by a sprayable ceramic coating to finish.

The project was completed in just 72 hours, with the teams working over the weekend to ensure the repair was finished in time for the customer to resume full production at the start of the next working week.

For more information, go to: www.henkel-adhesives.co.uk

After the repair

Before the repair

Investing in adhesives: Why ROI is more than just the payback period

If you’ve ever tried to source an adhesive for your application, you probably realised quickly that there is no universally perfect adhesive. Everything from the substrates you’re bonding to the operating temperature and humidity, through to the exposure of the assembly to solvents, weather and mechanical stress, will influence your choice.

It is worth understanding that the adhesive choice will only be one component of the full bonding process (which includes surface preparation, adhesive mixing, application and dispensing, curing, and QA) and it is in this entire process that you are investing. It is important to take a holistic view; for example, application and curing equipment costs, and efficiency of the method, are factors that will affect an ROI calculation and allow comparison to other options.

We think of ROI as a measure of how fast we get our money back after making an investment. For a bonding process, an investment in equipment can be justified by improvements in the method, or savings in resources like labour, energy, or space. However, there are many hidden, intangible benefits that come with suitable investment – ones that go beyond the headline ROI figure.

Determining ROI

There is always a compromise to be made in adhesive specification, and that is often between ultimate adhesive functionality and the optimal bonding process. The very best bond strength may come from an adhesive with a complicated preparation requirement and an extensive cure time, but that may not be suitable for the proposed production volumes or speed of manufacture. Sometimes, this dilemma stems from over-specifying the adhesive requirements, which limits material choice and, therefore, can add cost. Factoring in adhesive “processability” can ultimately deliver a faster ROI, without compromising on quality.

For example, while the upfront cost of UV light-curing equipment may be higher than a process using an adhesive that cures at room temperature over time, the increased throughput achieved with on-demand curing – seconds, rather than minutes or hours – may well offer a much shorter payback period.

In fact, when a UV light-curing systems technology is looked at as an integral part of a full production process –across inventory, dispensing, curing and quality assurance – it can lead to an average of 30 percent savings in overall process costs.

Precision offers payback

While not necessary for small-batch adhesive assembly operations where manual mixing and application are deemed sufficient, the accuracy and repeatability possible using robotic dispensing or automated adhesive mixing lowers process variability and can be compelling even in moderate volume applications. By reducing human error and increasing precision, you can lower scrappage rates and material waste. The labour cost element is often reduced, as operators are reallocated to more productive work (possibly with upskilling). Adhesive dispensing robots are available for surprisingly modest costs and factoring in all the advan-

One of the major considerations when specifying an adhesive is how quickly it will deliver return on investment (ROI), a metric that is affected by a variety of tangible and intangible factors. Here, Matthew Baseley, Technical Sales Executive at Intertronics, explains the considerations that determine ROI in an adhesives process.

tages of automation usually results in a quick ROI.

It’s important to note that the collective improvement in all these areas, from throughput and standardisation to quality and yield, has an impact on the business that goes well beyond the tangible measurables. It is ultimately the imperceptible improvement in your brand and reputation that leaves a lasting impact in the mind of your customer.

Thinking about the return on investment for a new bonding application, or improvement of an existing one, involves a comprehensive consideration of the entire process. A higher initial investment can lead to a faster ROI. In addition, investing in a robust, reliable and repeatable process can have a lasting, intangible impact on your brand.

To find out more about how you can generate a fast ROI in your adhesive process, visit the Intertronics website or call +44 (0) 1865 842842.

The Data Driven Solution to Spring Design & Validation

About the author: Matt Baseley consults with high-technology companies in electronics, medical devices, aerospace and other industries to help them find adhesives, protective materials and related equipment which fits their production process and product design.

How can the use of adhesives in the manufacturing process impact sustainability?

Sustainability is a big word – and a key driver for every manufacturing business. But sustainability means different things to different people. To some, it means reducing the use of potentially harmful chemicals in the manufacturing process; to others, it means reducing the manufacturing time and improving efficiency; to another group, it may mean reducing the number of parts, especially plastic, and improving their carbon footprint.

So how does the choice of adhesives affect sustainability at potentially every level?

Adhesive manufacturing

One of the key factors is how the adhesive itself is manufactured. ‘Traditional’ methods of manufacturing face a number of challenges. Typically, they consume large amounts of energy and generate high levels of waste. Controlling potentially harmful emissions is similarly an issue. New manufacturing processes have been developed that overcome these issues and more.

Latest techniques, including those used in the manufacture of MECA (methoxyethyl cyanoacrylate)-based adhesives, for example, have no such issues. The process consumes considerably less energy than conventional manufacturing techniques, while delivering a higher yield (estimated at between 95 percent and 98 percent on average) and creating less waste. It is also a much ‘cleaner’ process, allowing for far greater control of emissions.

Faster curing times

The performance of the adhesive is also important. A product with a faster curing time (but without sacrificing perfor-

mance) enables the manufacturing process to become more efficient.

When it comes to cyanoacrylate (CA) adhesives specifically, new, patented ‘light cure’ technology is certainly helping in this regard. Conventional UV technology requires at least one transparent surface to cure, which means it is not effective on non-transparent materials, limiting its application. New ‘dual-cure’ technology, however, is different: it has two curing mechanisms, combining light (UV) and contact (humidity).

These new CA dual-cure adhesives are designed for bonding applications that

About the author: Jean-François Chartrel is Technical Director, Engineering Adhesives (Global), Bostik SA. During his 26 years with Bostik, JeanFrançois has held R&D positions for product development, innovation and new business development. He has been Technical Director of the engineering adhesives department since 2018, helping support the global Born2Bond product line.

require fast fixturing, coating, or surface cure. The UV sensitivity allows rapid bonding through transparent parts, and quick curing of light-exposed bulk or surface-coated areas. The instant bonding capability of light-cure CA adhesives also ensures curing between opaque substrates, giving designers and manufacturers much greater flexibility.

To give some idea of the speed with which CA adhesives cure, without light exposure, bonding time is recorded at approximately 60 seconds, whereas, with light curing, that time is closer to five seconds. The implications on the sustainability and efficiency of the manufacturing process are obvious, not to mention the impact on cost.

The use of LED lamps is a major source of energy saving (this is true across both ‘traditional’ UV and the current dual-cure systems) and is a very penetrating source of light (so it does not just cure on the surface), making it more efficient. The dual process is quicker and uses less energy than conventional UV systems. It also negates the need for any post-curing, further improving efficiencies.

The performance of the adhesive has an impact on sustainability in other ways. The volume of the adhesive dispensed is reduced (when using manual or au-

tomated dispensing equipment) and dual-cure technology allows the assembly of multiple substrates on the same production run, which would not be possible (or as efficient) with mechanical fasteners.

Glass, metals and plastics can all now be accommodated with ease, as well as leather and even woven products, allowing the precision bonding of small parts within complex designs; for example, perfume bottles that combine metal with glass, hearing aids and speakers, luxury goods such as leather shoes and bags, expensive glass and crystal, and highclass jewellery. MRO and automotive aftermarket segments can also benefit from adhesives that allow for maintenance and repair.

Indeed, the processes that use UV curing to bond components gain a further advantage in terms of flexibility and sustainability. When these products are end of life, or in need of repair, parts can be easily dismantled through the further application of heat, allowing those components to be recycled or re-used. This is proving very popular, for example, in smartphone manufacturing and repair.

Reducing waste

A benefit of adhesives is that they help to reduce waste, since they often replace

the need for solder or screws, though, in certain processes (the assembly of an aircraft fuselage, for example), a rivet may be used to secure the bond further. A cure-on-demand, high-precision process is highly welcome in manufacturing and allows for the exclusion of non-cured adhesives from bonded substrates and parts.

As a general trend, however, the enhanced bonding characteristics and performance of a new generation of adhesives are helping to reduce the number of parts typically used in a finished product. This means that complex designs often can be further simplified and rationalised, making them lighter and, typically, requiring less energy to make. Fewer parts also equate to better use of resources and less waste, thereby supporting a manufacturer’s sustainability credentials. An accelerated production line and manufacturing process also support a higher margin in sometimes low-margin businesses.

A sustainable business must first and foremost be sustainable itself, and new thinking in adhesive product development is helping manufacturers to meet their sustainability targets, while delivering a more efficient manufacturing process.

www.bostik.com

Hybrid solutions also available at moderate cost.

Our products are widely used in industry, education and R&d markets, with some of the following as typical applications.

Robotics, laboratory equipment, surveillance cameras, slot machines, shop displays,vehicle equipment, telecoms equipment,lighting and ventilation control. Locking mechanisims, machinery activators, shop displays etc etc.

datafocus

Our products are widely used in industry, education and R&d markets, with some of the following as typical applications. Robotics, laboratory equipment, surveillance cameras, slot machines, shop displays, vehicle equipment, telecoms equipment,lighting and ventilation control. Locking mechanisims, machinery activators, shop displays etc etc.

Smiths Interconnect launches K-band waveguide components for space applications

Smiths Interconnect, a leading provider of technically differentiated electronic components, subsystems, microwave and radio frequency products, launches its broad range of K-band waveguide components for satellite communication payloads in GEO/MEO and LEO orbits.

Highly compact and ruggedised, Smiths Interconnect’s K-band waveguide components are rigorously qualified for spacecraft use in the company’s state-ofthe-art test and qualification laboratory in Dundee, Scotland.

WR51 waveguide products are tuneless and optimised to operate over broad assigned bands. They are provided with a standard clear passivation coating but can be supplied with low emissivity black paint finish if desired. Their design is optimised to maximise reliability, and to minimise cost and application risks.

For further details contact: Please visit our website www.smithsinterconnect.com

Stainless Steels & Titanium inserts with both Metric, Unified and British Standard threads

Contact details:

Tappex Thread Inserts Ltd

Tel: +44 1789 206600

Email: sales@tappex.co.uk;

New Website: www.tappex.co.uk

Downloadable catalogues and applications advice on the website.

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Compact. Modular. Flexible.

Cube67

by Murrelektronik

The perfect I/O system for decentralized installation concepts

Cube‘s flexibility creates the best solution for every application – all the way from the controls to the on-machine I/Os.

Cube solutions offer the best value for your money during the engineering phase, commissioning phase and maintenance phase. Maximizing uptime and productivity.